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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns an inner lining for the roof of a motor vehicle that has a ceiling consisting of a self-supporting fitting which is attachable to the roof frame structure of the motor vehicle via an adhesive.
2. Description of Related Art
An inner lining of this type is known from EP 88 931 B1. This known inner lining consists of a prefabricated self-supporting finished ceiling made, for example, from a heat compressed material. Strip-shaped hardening elements or sprigs, which essentially extend over the total width of the inner lining and can consist of plastic strips, are formed into the basic material. Attachment means for attaching the finished ceiling to the motor vehicle structure in the area of the roof frame are provided at the sprig ends.
SUMMARY OF THE INVENTION
The object of this invention is to provide an inner lining of the type described above which facilitates the installation of passenger support systems in the motor vehicle.
This object is attained according to the invention by an air-bag arrangement which can be premounted into the finished ceiling before being installed in the motor vehicle.
The air-bag arrangement can be premounted into a carrier arrangement which is supported by the strip-shaped hardening elements (sprigs) of the finished ceiling. The carrier arrangement can consist of strip-shaped carriers (metal strips) attached to the hardening elements (sprigs) of the finished ceiling which extend across the longitudinal direction of the motor vehicle.
In this way, an integration of the air-bag devices into the finished ceiling is obtained before the same are installed in the motor vehicle. Once installed, the air-bag arrangements lie between the roof outer layer or the roof frame and the finished ceiling.
The air-bags can be essentially anchored along the full length of the strip-shaped carrier elements. In order to allow the air-bags to unfold inside the motor vehicle during filling, desired breaking points are provided on the finished ceiling which are opened when the air-bags are filled by means of the generated filling pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail with respect to the figures, wherein:
FIG. 1 shows a finished ceiling with different air-bag arrangements;
FIG. 2 shows a cross-sectional representation along a section line 2--2 of FIG. 1;
FIG. 3 shows a cross-sectional representation along a section line 3--3 of FIG. 1; and
FIG. 4 shows a cross-sectional representation along a section line 4--4 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Two strip-shaped hardening elements or sprigs 1 are provided for hardening and pretensioning the represented finished ceiling onto the motor vehicle structure. The sprigs 1 possess protruding ends provided with attachment means 16, for example in the form of extenders, for fixing the finished ceiling 11 to the motor vehicle structure in a manner as shown, for example, in German patent application 196 04 055.8.
Attachment strips 3 are provided on the sprigs 1, which extend sideways in the longitudinal direction of the motor vehicle along the finished ceiling. An attachment strip 4 that extends diagonally relative to the motor vehicle direction is provided at the front end of the side attachment strip 3. The extension of this attachment strip 4 corresponds approximately to the extension of the roof frame of the upper edge of the windshield of the motor vehicle.
A further attachment strip 2 extends in the longitudinal direction of the motor vehicle and is displaced sideways a small distance with respect to a longitudinal middle plane 17. The attachment strip 2 is attached to the diagonally running front attachment strip 4 as well as to both sprigs 1.
Two other V-shaped attachment strips 5 are attached on the rear sprig 1. Both attachment strips 5 extend from the rear sprig 1 diagonally to the rear.
The attachment points, which like the sprig 1 can be made of metal (metal strips) or plastic, form a carrier arrangement in the form of an attachment framework for different air-bag arrangements 6 to 10. This attachment framework is supported by both sprigs of the finished ceiling 11.
In the exemplary embodiment, an air-bag arrangement 8 with an air-bag 15 which extends along the attachment strips 4 is attached to attachment strips 4. The air-bag 15 of this air-bag arrangement 8 is essentially anchored along its entire length to the attachment strip 4. When folded, the air-bag arrangement 8 adapts to the contour of the attachment strip 4 and, therefore, to the contour of the roof frame at the upper edge of the windshield of the vehicle. When the air-bag is filled, the desired break point 14 in the finished ceiling is opened due to the filling pressure that fills the air-bag 15, so that the air-bag 15 can expand downward into the inside of the motor vehicle, particularly for protecting the head against a collision. This is apparent from FIG. 2.
An air-bag arrangement 7 is attached to the attachment strip 2. The air-bag 15 of this air-bag arrangement, as shown in FIG. 3, is anchored along the total length of the attachment strip 2. The air-bag arrangement 7 extends, as shown in FIG. 1, essentially in the longitudinal direction of the motor vehicle and is located in the longitudinal middle plane 17 of the finished ceiling 11 or of the motor vehicle. When the air-bag is filled, also due to the filling pressure, a desired breaking point 14 provided in the finished ceiling 11 is broken through, so that the filled air-bag cushion can expand downward inside the motor vehicle. The filled air-bag cushion is arranged between the sitting positions at the height of the heads of passengers sitting in the front seats. A side head collision protection for two motor vehicle passengers sitting one beside the other is provided in the middle of the motor vehicle in this manner.
An air-bag arrangement 9 is also attached diagonally to the sprig 1 that runs along the motor vehicle longitudinal direction. This air-bag arrangement 9 serves as collision protection for passengers sitting in the back seats or rear bench of the motor vehicle. In a manner similar to the representation in FIG. 3, the finished ceiling 11 is equipped with a desired breaking point 14, so that an air-bag 15 of this air-bag arrangement can expand for protecting the passengers in the middle seat against a collision with the front seats of the motor vehicle.
Furthermore, a manner similar to the arrangement represented in FIG. 3, air-bag devices 10 are anchored on the attachment strips 5. These devices serve as side collision protection between the middle seat passengers sitting in the rear seat of the motor vehicle. The V-arrangement of the devices makes it possible for a third motor vehicle passenger, sitting between both air-bag arrangements 10 on the rear seat, to have side collision protection, particularly for the head area, on both sides with respect to the other motor vehicle passengers sitting next to the third passenger. The operation of the air-bag arrangement 10 is the same as the operations of the above-described air-bag arrangements.
Two side air-bag arrangements 6 are further provided. The side air-bag arrangements 6 run in the longitudinal direction of the motor vehicle and are anchored on the attachment strips 3 essentially along their total lengths. The configuration of the air-bag arrangements 6 results from the representations in section (section line A--A in FIG. 1) of FIG. 4. In this air-bag arrangement, an air-bag 15 corresponding thereto, extending essentially along the total length of the motor vehicle, that is, from column A to column C, is attached to the metal strips 3 that also extend along the total length of the motor vehicle (from column A to column B). The air-bag arrangement 6 is located below the attachment elements 16, which are constructed as described in German patent application 196 04 055.8. In this way, the air-bag arrangement 6 is arranged below the height of the handles of the attachment means 16. The air-bag arrangements 6, which extend particularly between the sitting positions of the front seat and the motor vehicle door, provide a side collision protection, particularly at the height of the head.
The air-bags 15 in the represented embodiments of the air-bag arrangements are positioned around the corresponding attachment strips 2 to 5 and are eventually glued to the same. Filling tubes 18 (FIG. 2, FIG. 4) extending along a longitudinal direction are provided for filling the air-bags as is known, for example, from the air-bag arrangement of EP 694 444 A2. These filling tubes can be connected to corresponding gas generators. In the normal or folded condition, the air-bag 15 is located between the finished ceiling 11 and the roof outer layer 12 or the roof frame 13, as can be seen in FIGS. 2 to 4. When there is a crash, as already explained, the desired breaking point 14, which extends also essentially along the total length of the air-bag arrangement in the finished ceiling, is broken through by the filling pressure. Each air-bag can unfold in the motor vehicle and can expand downward. The different air-bag arrangements are preferably built so that they can offer a side or front collision protection for the area of the head and, if needed, also the thorax region in the corresponding direction.
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An inner lining for a motor vehicle with a finished ceiling made of a self-supporting form piece attachable to the edge of the motor vehicle structure includes at least one air-bag which is premounted on the self-supporting form piece before the ceiling is installed in the motor vehicle.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a National Phase application claiming priority to PCT/GB2011/051689 filed Sep. 9, 2011 which claims priority to GB1015032.4 filed Sep. 10, 2010, all of which are herein incorporated by reference in their entireties.
FIELD OF INVENTION
The invention to which this application relates is to improvements to a valve assembly and particularly, although not necessarily exclusively, to a valve assembly in the form of a block and bleed valve assembly in which there is provided first and first and second, or more, valve balls located along a fluid passage formed in the body of the valve.
BACKGROUND OF THE INVENTION
Conventionally, the manufacture of the block and bleed valve, is well known however there is always pressure with regard to the design of the same to ensure that the dimensions of the valve, and in particular, the length of the same, meet International standards.
The applicant has a series of granted patents and co pending patent applications which address this issue and further prior art documents are known such as, EP1322886, which also attempt to address the dimensional challenges, with varying degrees of success.
The applicant has identified that for certain requirements the prior art valve assemblies do not provide a satisfactory solution.
The aim of the present invention is therefore to provide a new form of valve assembly which allows the same to fulfil the requirements for International standards while, at the same time, take into account commercial and manufacturing considerations.
SUMMARY OF THE INVENTION
In a first aspect of the invention, there is provided a valve assembly, said valve assembly including at least one passage along which fluid can be selectively allowed to pass, said assembly including a valve body in which the passage is formed and at least one ball located in the passage so as to be moveable between a first position in which a channel in the ball forms part of the passage and a second position in which the ball prevents fluid passing along the passage and wherein at at least one end of the body and depending inwardly towards one side of the at least one ball there is provided a retention assembly, said assembly comprising a first annular member to contact with the ball, a second annular member receiving and locating at least one biasing means, said first and second annular members located within an annular housing, said annular housing retained within the valve body, and an annular securing member which is engaged with the valve body and which has an outer face which forms or receives an external sealing face for the valve assembly to a pipeline or pipeline flange.
In one embodiment the annular housing and annular securing member are independently retained with the valve body.
In an alternative embodiment the annular housing is retained in the valve body by the annular securing member.
Typically, the external sealing face, is adapted in a suitable manner so as to allow the same to be engaged and sealed with a pipeline or a pipeline flange in conjunction with which the valve is to be used.
In one embodiment, a retaining assembly as described is provided at each end of the valve body.
In one embodiment, the valve assembly includes at least first and second balls provided at spaced locations along the fluid passage formed in the valve body and a first retaining assembly is provided at the first end of the valve body to contact with one side of the first ball. In one embodiment a second retaining assembly is provided at the other end of the valve body to locate with a side of the second ball.
Typically, a sealing assembly is provided between the first and second balls so as to locate with the respective opposing sides of the balls which are not in contact with a retaining assembly.
In one embodiment there is provided a first annular seat for contact with a face of a first ball and a second annular seat for contact with a face of the second ball and said first and second seats are provided with at least one biasing means depending between the same.
In one embodiment a plurality of biasing means are provided spaced apart around a circular path at the periphery of the said passage.
In one embodiment the biasing means pass through a channel formed in a portion of the body or another member which depends partially inwardly so as to locate the biasing means with respect to the longitudinal axis of the same.
In one embodiment the first annular member is formed as a valve seat for sealing contact with the ball side. In this embodiment the valve seat and hence first annular member is formed of a metal or metal alloy. In an alternative embodiment the first annular member supports and receives thereon a valve seat. In this embodiment the valve seat is formed of a rubber or equivalent material.
In one embodiment, the biasing means provided in the second annular member are a series of springs provided at spaced locations around a circular path. In one embodiment first ends of the springs are located in the second annular member. In one embodiment the said spring ends are received and located in a part of the second annular member which is received in a recessed portion in the first annular member so as to locate the second annular member. In whichever embodiment the springs are provided within the retention assembly so that the same are held in compression so as to act on the first annular member to bias the first annular member towards contact with the ball.
In one embodiment, the opposing ends of the biasing means springs are located with the face of the annular housing which in turn is retained in position within the valve body by the threaded engagement of the annular securing member with the valve body. Thus, it can be ensured that at all times, the biasing means springs exert sufficient force on the first annular member so as to provide a sufficient seal with the ball.
Typically, sealing means are provided between the first annular member and the annular housing and the second annular member with the annular housing.
Typically, at least one sealing means is provided between the annular housing and the valve body.
Typically, at least one sealing means is provided between the annular ring and the valve body.
In a further embodiment of the invention, the biasing means are provided to act on the second annular member and are located within the annular housing such that the biasing means springs act on the second annular member to move the same towards the first annular member and in turn, to move the first annular member into engagement with the ball.
In one embodiment the components which are located within and along the valve body are moved into position from one, common, end of the valve body and the components are retained in position by the engagement of the annular housing and/or annular securing member in position at or adjacent to the end of the body from which the components are moved into position, once the components are in position.
In one embodiment the components include, in order of insertion into the valve body, a first sealing ring for a first valve ball, the first valve ball, a spigot for the first valve ball, a sealing assembly for the first valve ball and a second valve ball, the second valve ball, a spigot for the second valve ball, the annular housing with first and second sealing members located therein, and an annular securing member.
In a further aspect of the invention there is provided a retaining assembly for use in a valve assembly to retain the components of the valve passage therein, said retaining assembly including an annular housing having first and second annular members located therein and an annular securing means wherein one or both of the annular housing and/or annular securing means, are provided in engagement with the valve assembly body so as to retain the retaining assembly in position and provide the first and second annular members in the required position within the valve body.
Further aspects of the invention which can be used separately to, or in conjunction with, the valve assembly features described above, are now described.
In the further aspect of the invention, there is provided a valve assembly, said valve assembly including a valve body having a fluid passage therein and at least one ball mounted in the passage, said ball moveable between a first position in which a channel in the ball is provided in line with the passage so as to allow fluid to flow there through and a second, closed position in which the ball prevents fluid from passing along the passage, said ball mounted on first and second trunnions so as to be rotatable and wherein at least one of said trunnions is mounted and located internally of the valve body.
This is in contrast to the conventional fixed trunnion arrangement in which there is typically provided first and second trunnions locating with opposing sides of the ball and each of said trunnions is located to the exterior of the valve, one having a stem which can be operated to turn the valve ball and the other trunnion having a flange which is located externally of the valve body and which is bolted in position to secure it to the valve body.
Typically, the location of the flange and the bolting of the same on the valve body means that the valve body has to be of a relatively large size to receive the bolts and to provide the strength for securing the flange and hence lower trunnion to the valve body. This problem is overcome by the current invention in that the lower trunnion is located within a recess depending into the valve body from the fluid passage such that the lower trunnion does not have to pass through the valve body and does not have to be located externally of the valve body.
By locating the trunnion within the valve body, there is no need to bolt the same externally to the valve body and hence the dimensions of the valve body can be reduced significantly.
In one embodiment, the lower trunnion is formed as a solid cylinder or peg, with a first end received within the recess of the valve body and a second end received within a recess of the ball.
In one embodiment the said cylinder or peg is introduced into position within the valve body by first placing the ball into position in the valve body and then passing the peg or cylinder into the channel in the ball and then through a locating aperture in the ball and into the receiving recess of the valve body so that the peg or cylinder is received in the recess and the locating aperture.
In one embodiment a securing means is then put into position to secure the peg or cylinder in position with the ball and/or valve body.
Typically, the movement of the ball with respect to the peg and valve body is achieved by movement of the first trunnion opposing the said peg and which can be provided in a conventional manner.
Typically the second trunnion is located on the opposite side of the ball from the first trunnion and the longitudinal axes of the first and second trunnions define the axis of rotation of the ball between first and second positions.
In a further aspect of the invention there is provided a valve assembly including at least one passage along which fluid can be selectively allowed to pass, said assembly including a valve body in which the passage is formed and at least first and second balls located in the passage, each selectively movable between a first position in which a channel in the ball forms part of the passage and a second position in which the ball prevents fluid passing along the passage and wherein a sealing assembly is provided in the space in the valve body between said balls, said sealing assembly including a sealing ring for location with a face of a first ball and a sealing ring for location with a face of the other of said balls and wherein biasing means are provided with a first end of each of the biasing means located to act on the first sealing ring and a second end located to act on the second sealing ring.
In one embodiment the first and second sealing rings are separate components.
In one embodiment at any given time the biasing means act to bias one of the sealing rings into contact with the respective ball surface.
In one embodiment a plurality of biasing means are provided spaced along a circular path.
In one embodiment the biasing means are located in position by the location of the ends with the respective sealing rings.
Typically at least a portion of the biasing means intermediate the ends of the same are located in a channel for each respective biasing means. Preferably the said channels are formed in a portion of the valve body. The provision of the locating channels acts to prevent the possibility of the springs being twisted along their longitudinal axes by the rotational movement of the sealing rings which may occur during use of the valve. Typically the said portion protrudes into the passage of the valve body and is located intermediate the first and second sealing rings.
In an alternative embodiment the said channels are provided in a member located between the first and second sealing rings.
In a yet further aspect of the invention there is provided a valve assembly including at least one passage along which fluid can be selectively allowed to pass, said assembly including a valve body in which the passage is formed and at least one ball located in the passage so as to be moveable between a first position in which a channel in the ball forms part of the passage and a second position in which the ball prevents fluid passing along the passage and at at least one end of the body and depending inwardly towards one side of the at least one ball there is provided a retention assembly and wherein the components to be located along the passage of the valve body are introduced into the valve body from the same common end and then retained in position by the movement of the said retention assembly into position at said end of the valve body.
In one embodiment the retention assembly is an annular securing member provided to be engaged with the valve body.
In one embodiment the retention assembly includes a first annular member to contact with the ball, a second annular member receiving and locating at least one biasing means, said first and second annular members located within an annular housing, said annular housing retained within the valve body, and the annular securing member which is engaged with the valve body and which has an outer face which forms or receives an external sealing face for the valve assembly to a pipeline or pipeline flange.
In one embodiment, for a single ball valve the components which are moved into position and located within the passage from the common end include a first sealing ring for a first ball, a first ball, a trunnion for the first ball a sealing assembly for sealing against the opposing surface of the first ball from the first sealing ring and the annular securing member.
In one embodiment, for a double ball valve the components located within the passage from the common end include a first sealing ring for a first ball, a first ball, a trunnion for locating the first ball, a sealing assembly for sealing against the opposing surface of the first ball from the first sealing ring, and a surface of a second ball, the second ball, a trunnion for locating the second ball, means for sealing against the opposing surface of the second ball from the sealing assembly and the annular securing member.
Typically the sealing assembly includes biasing means which are located in position by respective sealing rings for the first and second balls.
Typically the valve assembly formed is what is commonly referred to as a double block and bleed valve assembly.
In a yet further aspect of the invention there is provided a method of positioning and locating the components required within a body of a valve assembly to form the same, said valve assembly including first and second balls located along a passage within a valve body and along which passage fluid can be selectively allowed to flow by selectively positioning the said first and second balls by rotating the same, said method comprising the steps of introducing from one open end of the valve body and into the same so as to be positioned along said passage, a first sealing ring for a first ball, a first ball, a trunnion for locating the first ball, a sealing assembly for sealing against the opposing surface of the first ball from the first sealing ring, and a surface of a second ball, the second ball, a trunnion for locating the second ball, means for sealing against the opposing surface of the second ball from the sealing assembly and an annular securing member.
Typically at least the annular securing member is engaged with the valve body so as to close the passage at the open end to a sufficient extent to retain the components in position within the valve body.
Specific embodiments of the invention are now described with reference to the accompanying drawings; wherein
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a - c illustrate a first embodiment of a valve in accordance with the invention;
FIG. 1 d illustrates an alternative embodiment to part of the assembly shown in FIGS. 1 a - c
FIGS. 2 a and b illustrate a second embodiment of a valve in accordance with the invention;
FIGS. 3 a and b illustrate, respectively, a conventional ball and trunnion arrangement and an embodiment of a ball and trunnion arrangement in accordance with the invention;
FIGS. 4 a - c illustrate two embodiments of a sealing assembly in accordance with the invention; and
FIG. 5 illustrates a further embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring firstly to FIGS. 1 a - d , there is illustrated a valve 2 in accordance with one embodiment of the invention. The valve 2 includes a valve body 4 in which there is formed a passage 6 along which fluid can pass from a first pipeline end located at a first end 8 of the valve body and towards a second pipeline located at the opposing end 10 of the valve body.
In this embodiment, located within the passage within the valve body, are first and second balls 12 . The balls are shown in FIG. 1 b , in an open position inasmuch that channels 16 formed in each of the balls are provided in line with the passage 6 so as to allow fluid to pass along the passage of the valve body. However, the balls can be individually rotated about the respective axes 20 , 22 to a closed position in which the ball channel is no longer in line with the passage and prevents the passage of fluid along the passage 6 . Operating means for the respective balls are provided in the form of rotatable handles 24 , 26 and the balls are mounted in respect of the valve body via trunnions in the form of upper trunnions 28 to which the handles are connected and lower trunnions 30 , which trunnions are located with opposing sides, typically top and bottom, of the respective ball.
It is necessary for the ball to be located within the valve body in a sealed manner and in accordance with this embodiment of the invention at each end of the valve body there is provided a retaining assembly 32 , 34 . In each of the retaining assemblies, there is provided a first annular member 36 which is provided to contact in a sealing manner with a side of the ball. The first annular member can be formed as a valve seat in it's entirety or can be provided to secure and support a valve seat material therewith. The first annular member is acted upon by biasing means in the form of springs 38 which are provided at spaced locations along a circular path in a second annular member 40 . One end of the springs contact with the second annular member as shown and the opposing end of the biasing means springs 38 contact with a face of an annular housing 42 which has a recess 49 in which the first and second annular members are located.
The biasing means are provided as compression springs of a size and strength such that when the components of the retaining assembly are in position the springs act to bias the first annular member towards sealing engagement with the ball as indicated by arrow 51 in FIG. 1 c . In FIG. 1 c the annular housing is located with respect to the valve body by the provision of an annular securing member 44 which is provided in threaded engagement with the valve body and which can be screwed in to the open end of the valve body to a position so as to locate the annular housing and hence first and second annular members in the required sealing locations with the ball. In FIG. 1 d which is a preferred embodiment the annular housing 42 is provided in threaded engagement with the valve body as shown by threads 47 so that the annular housing is independently located and retained in position with the valve body. In this embodiment the annular securing member is again provided and in this case is again threadedly secured to the valve body but does not act on the annular housing and indeed need not be in contact with the same as it is not required to exert any retaining force on the annular housing 42 .
In either embodiment the external face 46 of the annular securing member can be adapted to have a pipeline sealing form which meets International requirements so as to allow the same to be sealed to a flange of a pipeline. This therefore means that the remainder of the retaining assembly components can be provided in a common manner and only the annular securing member need be provided to include a particular form of pipeline sealing means on the external sealing face. Thus common valve assemblies can be formed under factory conditions and tested with the appropriate securing member provided at the factory or at the location of connection to the pipeline to suit the particular pipeline sealing arrangement requirements and pipeline sealing formation for that particular job. This therefore greatly simplifies the manufacturing operation where conventionally the entire retaining assembly, as it is typically a one piece construction, has to be provided with the required pipeline sealing formation at the factory and at the time of manufacture and tested with the appropriate pipeline sealing formation already provided.
Thus, in accordance with the invention, there is provided a retaining assembly which has a plurality of components which ensure that the appropriate sealing arrangement is provided with the ball and that the ball is appropriately located and retained within the valve body. However, at the same time, the retaining assembly is provided in a form and configuration such that the overall valve assembly which is formed can be formed of a length which falls within the International specification.
Preferably, in the spacing between the respective balls 12 and 14 there is provided a sealing assembly 43 which comprises first and second sealing rings 48 , 50 located with a central assembly 52 which includes a plurality of springs located around a circular path, said springs acting on both the first and second sealing members 48 , 50 to bias the same towards contact with the respective balls 12 . Once again, provision of this central sealing assembly, allows the overall length of the valve to be reduced in comparison to the conventional sealing assembly. Two possible embodiments of this sealing assembly are described with reference to FIGS. 4 a - c , which both show sectional views along the central axis of the sealing assembly located intermediate the balls of the valve assembly. In FIG. 4 a there is illustrated a first embodiment in which first and second sealing members 48 , 50 are provided to act on surfaces of respective balls 12 a and 12 b . In this case the opposing ends 49 , 57 of each of the plurality of springs 51 which are spaced around the passage along a circular path are located in and act on the first and second members 48 , 50 respectively. It is found that at any given time only one of the sealing members needs to be biased to act on one of the valve balls, depending on the flow of fluid at that time and hence the particular sealing member which is required to apply sufficient pressure to create the seal with the appropriate ball. This therefore means that the springs are able to apply the biasing force on one of the sealing members at any given time as required rather than applying a biasing force against both sealing members simultaneously, although this could be achieved by the sealing assembly if required. Particularly, although not necessarily exclusively, in smaller valve assemblies the springs may be susceptible to deformation by twisting or bending about their longitudinal axis if, for example, there is relative rotational movement between the first and second sealing members during use of the valve. This bending could cause the biasing effect to be adversely affected and therefore in accordance with the embodiment shown in FIGS. 4 b and c each of the springs is located to pass through a channel 53 so that the springs are each located by their respective channel intermediate the ends of the spring. As the channels are typically provided in a member which is provided in a fixed position in the valve body or more typically provided in a portion 55 which is formed as an integral part of the valve body 4 as shown in FIGS. 4 b and c , the intermediate portions of the springs are provided in a fixed location and therefore cannot be bent by any relative rotational forces from the first or second sealing members with which the spring ends are located and so the biasing force of the springs can be maintained.
Referring to FIGS. 2 a and b , there is provided a further embodiment of a valve assembly in accordance with the invention and, where appropriate, the same reference numerals have been used for the same components as used in FIGS. 1 a - c.
In this case, the retaining assemblies 32 , 34 are of a different design to that shown in the embodiment of FIGS. 1 a - c . In this case, the retaining assembly 34 , details of which are shown in FIG. 2 b , comprises a first annular member 54 which is provided to engage sealingly with the ball 14 and which is acted upon by second annular member 56 . The second annular member receives an end 58 of each of a plurality of biasing springs 60 which are provided at locations along a circular path with the ends 58 being received within a recess 62 in the second annular member 56 . The opposing end 64 of each of the springs 60 is received in a recess 68 in an annular housing 66 . In turn, the annular housing 66 is located with respect to the valve body 4 by annular securing member 70 . In this case, both the annular securing member 70 and the annular housing 66 can be threadedly engaged with the valve body 4 so as to secure the retaining assembly in position as is also illustrated in FIG. 1 d.
In both embodiments, sealing means in the form of o-rings can be selected to be located at positions between respective components of the retaining assembly, and the retaining assembly and the valve body so as to ensure that fluid seepage through the retaining assembly and through the interface between the assembly and the valve body is prevented.
The embodiments shown herein and the inventive aspect provide several key advantages over the prior art. In particular the invention allows greater flexibility in the use of the retention assembly and maintenance of the same with respect to the prior art arrangements. For example, in the current invention by removing the annular securing member the first annular member, second annular member and annular housing as well as the springs can be removed and replaced or maintained without the need to loosen the ball and trunnion stems or corrupting the major body seal, which would affect the factory set geometry of those components and potentially invalidate warranty if the primary pressure seal was broken.
Furthermore by having the arrangement shown there is less susceptibility to loosening of the retention of the valve seat position in service due to vibration. This is in contrast to a single retaining component as shown in the prior art which is more susceptible to loosening and which is why this conventional design typically requires an external (tangential) retaining bolt to be fitted which corrupts the body integrity because this retaining bolt, for it to connect to the inner insert, requires a hole to be drilled through the pressure retaining outer body wall to the inner body wall to make contact with the insert it intends to retain.
The provision of the annular housing and annular securing member allows the removal of one without corrupting the valve's body pressure integrity, which means that the outer insert with say an RTJ pipeline seal formation groove machined upon it can be removed and replaced with another outer insert of the same dimensions with a raised face finish to provide a different form of external sealing face. As a result the valve assembly in accordance with the invention has an element of universal interchangability between pipeline seal standards rather than being a dedicated size/pressure class/sealing face type product as is conventionally the case.
The ability to provide the annular securing member as a separate component allows the same to be manufactured of alloy steels at a lower cost. Alloy inserts are required to comply with client required hardness values to make positive pipeline seals when using a soft material intermediate sealing ring, such as RTJ flange standards. The alternative to alloy inserts can be welded inlay, which is expensive and requires additional testing including radiography; all are not required with the current invention. Furthermore the annular securing member can be considered as sacrificial. For example should a prior art design valve be dropped on its end or bumped the end flange seal may become damaged the valve will require stripping down, the part replacing, and the valve re-testing and even returning to the factory.
Whereas, in the current invention if the annular securing member suffers the same damage the same can be replaced on site without the need to strip down the valve or re-test.
Turning now to FIGS. 3 a and b , there is illustrated, in FIG. 3 a a conventional ball and trunnion arrangement in a schematic manner. In a conventional arrangement, there is provided a ball 100 located in the valve passageway 102 so as to be rotatable about axis 104 between the valve open position which is shown and the valve closed position in which the channel 106 of the ball is located so as to prevent the fluid flow along passage 102 . In this conventional arrangement, the ball is located with respect to the valve body 108 by first and second trunnions, an upper trunnion 110 and a lower trunnion 112 . The upper trunnion 110 is typically connected to a handle or other actuation means which allows rotation of the same and hence rotation of the ball between the open and closed positions. The lower trunnion 112 is typically provided with a flange 114 mounted externally of the valve body 108 and the flange 114 receives a plurality of bolts 116 , one of which is shown, which passes through an aperture 118 in the flange 114 and into the valve body 108 so as to secure the trunnion in position.
The requirements shown in the conventional design of FIG. 3 a for the lower trunnion 112 to be located with the valve body via the external engagement means of the flange and bolts, means that the wall of the valve body 108 , and in turn, the outer dimensions of the valve body as a whole, have to be sufficiently large so as to receive and locate the bolts. This therefore means that the overall size of the valve body can be greater than desired.
FIG. 3 b illustrates a new embodiment of a trunnion and ball assembly in accordance with the invention. In this case, there is provided ball 100 which again is movable about axis 104 between the respective open and closed positions. The upper trunnion 110 can be provided in a conventional form but the lower trunnion of FIG. 3 a is no longer used and instead a cylinder or peg 120 is provided. This peg is received in a locating aperture 122 in the ball 100 and the opposing end of the peg is received in a recess 124 formed in the valve body 108 . Thus, the peg 120 is entirely located within the valve body and therefore no engagement flange or bolts are required externally of the valve body. Because the external engagement means are not required, thus the overall dimensions of the valve can be significantly reduced. For example, a reduction of up to 40% in the thickness of the valve body at the location of the peg 120 in comparison to that which would be required if a conventional, externally located trunnion was to be used. Furthermore the use of the internally mounted trunnion avoids problems which can be experienced in the required accuracy of the externally mounted trunnions, especially with relatively large valves. A further and very important advantage which is obtained is that as the trunnion or peg 120 is mounted wholly internally of the valve body no leak path is provided to the external face of the valve assembly. It will be appreciated that with conventional externally mounted trunnions as they pass from the interior of the valve body to the outside this creates a possible leakage path for fluid from the internal passage in the valve which, in turn, means that relatively complex sealing arrangements are required to be provided in the conventional arrangements. This is not required in the current invention.
Although it may not always be required it is envisaged that suitable mechanical location means can be provided as required to allow the trunnion to be located with the ball and/or valve body.
Typically, the retaining peg is introduced into the passage of the valve body once the ball is in position. The peg is then placed into the channel in the ball and then moved downwardly as indicated by arrow 101 to pass into and through the locating aperture 122 and into the recess 124 and it is then held in position such that the valve body can rotate around the peg and about axis 104 . A retention means (not shown) may be introduced so as to secure the peg or cylinder to the ball and/or valve body.
Referring now to FIG. 5 there is illustrated a further embodiment of the invention which incorporates the aspects of the invention described herein and the same reference numerals are used herein as appropriate. FIG. 5 also illustrates the manner in which a further aspect of the invention can be achieved, namely the insertion of the components which are to be positioned along the passage 6 from one common end 130 of the valve body 4 in the direction of arrow 132 . This is achievable by the use of the aspects of the invention as herein described and importantly allows the valve assembly to be created with the required components in the required location and with a greatly reduced number of leak paths between the passage 6 and the external face of the valve body as the number of interfaces between the passage and the external face of the body is greatly reduced in comparison to conventional valve assemblies in which the components are typically inserted from both ends of the valve body, which therefore doubles the number of leak paths and requires the external mounting of trunnions which again doubles the number of leak paths in comparison the to assembly shown in FIG. 5 . This in accordance with the arrangement shown in FIG. 5 the order of insertion of components into position in the valve body through the initially open end 130 of the valve body would be as follows. First insert the sealing ring 133 and any biasing means 134 to the opposing end 136 of the passage and abut the same against locating wall 138 as shown, move the first ball 12 a into position as shown, locate the first internally mounted trunnion 120 a into position through the channel in the ball and into the recess 124 a . Move the sealing assembly 43 of the type shown in FIG. 4 a into position to contact with the first ball 12 a on one side and, following the insertion of the second ball 12 b into position, contact with that ball, move the trunnion 120 b into the location recess 124 b to locate with the ball 12 b and then move the retaining assembly with the first and second annular members and annular housing 36 , 40 , 42 and biasing means 38 into position with the annular housing 42 in threaded engagement with the valve body. With these components in position the annular securing member 44 can be engaged with the valve body to retain the other components in position and close the opening 130 and also, as required provided the appropriate external sealing face formation 46 to allow engagement with the pipeline. Thus, the valve components can be inserted from only one end and reduce the number of potential leak paths which, in turn reduces the number of sealing components required to be provided. The trunnions 110 can be introduced and located in a conventional manner.
There is therefore provided an improved version of a valve assembly which ensures the efficient and correct operation of the same whilst ensuring that the same complies with applicable International standards and at the same time provide further advantages over conventional valve assemblies as set out herein. It should be appreciated that while it is preferred that the various aspects described herein be used in combination it is possible and, it is intended to provided protection for, the possible uses of all combinations of the different aspects described hereonin and/or the use of each of the aspects independently of the others to advantageous effect.
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A valve assembly, including a valve body, at least one passage along which fluid can be selectively allowed to pass, and at least one ball located in the passage so as to be movable between a first position in which a channel in the ball forms part of the passage and a second position in which the ball prevents fluid passing and wherein at least one end of the body and depending inwardly towards one side of the at last one ball there is provided is retention assembly.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is filed under 35 U.S.C. §120 and §365(c) as a continuation of International Patent Application PCT/EP2013/059150, filed on May 2, 2013, which application claims priority from German Patent Application No. 10 2012 103 938.0, filed on May 4, 2012, which applications are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The invention relates to a plasma generating device for generating a plasma with at least two plasma modules. Each of these plasma modules includes at least a gas inlet for a process gas, a discharge device for the generation of plasma from the process gas and a plasma outlet.
BACKGROUND OF THE INVENTION
[0003] Plasma treatments are widely used, for example to activate surfaces for a better adhesion, for the sterilization of food, wounds or surgical cutlery, for coating or even to the in situ production of ozone from precursor gases. Especially the industrial field of application of plasma treatment extends to new special applications. Increasingly, non-plasma-based standard processes are replaced by plasma processes. The requirements on the plasma may vary from application to application regarding the plasma properties (such as plasma pressure, plasma power, plasma density, plasma temperature or degree of ionization) or the design of the plasma generator. Cost efficiency and at the same time variable applicable concepts are drivers for standardized plasma generators. Desirable properties are in particular a compact, flexible design of the plasma generator, low voltage operation to atmospheric pressure and a lower excess heat during the plasma generation. Plasma sources with a nozzle shaped structure can produce plasma beams with a relatively high ion density. However, as a wide surface machining of components is only possible by scanning the plasma beam across the surface. At a given power density of plasma generator the processing time increases with the area to be treated. In case an increased number of plasma generators is simultaneously used the overhead for the electrical wiring and supplies with process gas increases as well.
[0004] The German patent application DE 37 33 492 A1 discloses a device with an electrically powered plasma generator. Two electrodes form an air gap, through which a gas stream is conducted. With the help of a corona discharge the streaming gas is ionized.
[0005] The UK patent application GB 1 412 300 A reveals an arc generator with a plurality of electrodes to which an at least three-phase AC voltage is applied in order to ignite plasma beam from a gas and to direct the plasma beam onto a work piece which is at ground potential. In accordance with one embodiment, the three electrodes reach into a gas flowed trough housing with a nozzle and are connected individually via a control line to a current regulator. In accordance with another embodiment, groups of three electrodes are connected with a current regulator, which are in turn connected to a voltage source.
[0006] The German patent application DE 10 2007 024 090 A1 suggests a device for plasma treatment that includes several plasma generators. In housing of each plasma generator, acting as an external electrode, a nozzle opening is trained which houses an inner electrode. About a branch of a common gas supply of the device, a gas stream is fed into each plasma source.
[0007] Piezoelectric high-voltage generators are used in plasma sources as electrodes and are suitable for light the plasma from gases near atmospheric pressure, see for example, DE 10 2005 032 890 A1. However, they are limited in their performance by the thermal losses and its electromechanical limit. The power limit by the thermal losses can be overcome by an efficient transfer of heat to the environment, but their overall performance limited remains. This is accompanied by a reduced plasma power when compared to other types of plasma generators. A cluster of several such plasma generators is also possible, with which a sufficiently high plasma density over larger areas can be achieved.
[0008] With a nozzle like structure, the plasma density can be increased locally by a secondary plasma beam, which is produced with relatively high ion density. However, a large-scale treatment of a surface is possible a grid like scanning of the surface with the plasma beam. Apart from the mechanically complex additional scanning device the time to treat surfaces is thus significantly extended. The clusters described DE 10 2005 032 890 A1 allow a little variable and limited configurability of the system. Also, the electrical wiring and supply of process gas of the individual plasma generators and is time-consuming and expensive.
SUMMARY OF THE INVENTION
[0009] It is an object of the invention to provide a plasma generating device, which is easy to assemble, to upgrade, to maintain and to operate. This problem is solved by a plasma generating device which includes at least two plasma modules, a module housing provided to each plasma module, wherein the plasma module has at least one gas inlet for supplying a process gas, a discharge means provided in the module housing for generating the plasma from the process gas, a plasma outlet, and at least one gas outlet for a portion of the process gas is provided with each plasma module, wherein the at least one gas outlet of at least one plasma module opens in each case into the gas inlet of another plasma module; and the plasma modules are pluggable connected with each other in a form-fit and/or force-fit manner.
[0010] The inventive plasma generating device for generating a plasma comprises at least two plasma modules. This can be operated independently or in conjunction with other identical or similar plasma modules. In a module housing of each plasma module at least one gas inlet for supplying a process gas and at least a gas outlet for a portion of the process gas, which is not in the plasma state, is provided. The gas inlets and gas outlets are in fluid communication via a gas supply channel, trained in the module housing. A discharge means is provided in the module housing for generating the plasma from the process gas.
[0011] Preferably the discharge means of the plasma module has a controllable, via a control line, electric driver module and a piezoelectric transformer. The driver module is connected to the primary side of the piezoelectric transformer via at least two electrical cables. A piezoelectric transformer can be designed in compact design and can generate with a relatively low primary side input voltages (e.g. 24 V AC) a sufficiently high voltage at his secondary side in order to ignite a plasma from the gas in the normal pressure range (ambient pressure). The plasma outlet of the plasma module can be trained as a nozzle to create a targeted plasma beam. In particular, the secondary side of the piezoelectric transformer can be arranged in the nozzle.
[0012] According to an embodiment of the invention a control module of the plasma module is assigned to the module housing. The control module can be an integral part of the module housing. It is also conceivable that the control module is a releasable connected component of the module housing. The control module is electrically connected via a control line and at least one voltage line with the discharge means. The control module supports at least an output interface and at least an input interface for the at least one voltage supply line and the control line.
[0013] The control module has a control line and at least one voltage supply line, which are electrically connected to the driver module. Furthermore, the control module has at least one output interface and one at least one input interface.
[0014] The invention plasma generating device for generating a plasma consists of at least two plasma modules. Each plasma module has a module housing with at least one gas inlet to the supply of a process gas and a plasma outlet. A discharge means for the generation of plasma from the process gas is provided in the module housing. In addition, at least a gas outlet for a portion of the process gas is formed with each plasma module. The plasma generation means is designed in such a way that the at least a gas outlet of the at least one plasma module enters into a gas inlet of another plasma module. This creates a superordinate gas supply channel via which all plasma modules of the plasma generating device are in fluid communication. For example, the entire plasma generation device is supplied with a single external gas supply pipe with process gas.
[0015] The discharge means of the plasma generating device can have in particular a controllable electric driver module, which is electrically connected to a piezoelectric transformer for the production of plasma by means of discharge in the normal pressure range.
[0016] In a particular embodiment of the invention of the plasma generating device, each plasma module can include a control module. Each control module is electrically connected via a control line and at least one voltage supply line with the discharge means of the respective plasma module. For each of its voltage supply lines and for its control line, the control module carries at least an input interface and at least one output interface. The plasma modules are connected with each other, such that at least one output interface of the control module of each first plasma module is electrically connected with at least an input interface of the control module of a connected plasma module. The control lines are connected such that as common control bus is formed to the control all and each of the coupled plasma modules, respectively.
[0017] The plasma modules of the plasma generating device are preferably connected electrically via their control modules with each other. Consequently, at least a gas inlet of a plasma module is in fluid communication with a gas outlet of a connected plasma module.
[0018] The plasma modules can be connected directly or indirectly through an arrangement of spacing bridges. A spacing bridge according to the invention has a connector and a gas supply channel with at least a gas inlet and a gas outlet. A single spacing bridge connects at least two successive plasma modules, so that the connector of the spacing bridge electrically connects the plasma control modules, and that at least a gas outlet of one plasma module is in fluid communication with a gas inlet of a further module.
[0019] The coupling of plasma modules with each other can be in particular designed releasable and based on force or form closure. So the plasma modules or the plasma module and the spacing bridge can be pluggable connected with each other, so that a force or form closure is created. According to a preferred embodiment of the invention, the connection is based on a connection assembly. The connection can additionally be secured by engagement hooks, screws, bolts or ears with cable straps. For example, the gas inlets and gas outlets can be designed as positive interlocking counterpart of a couple of plugs, resulting in a gas-tight coupling. Sealant such as seals or sealing grease can be provided for additional sealing of the plug connector. Similarly, the input interface and output interface of the control modules can be trained as positive interlocking counterparts of a couple of plugs.
[0020] The plasma generating device can be designed such, that at least one plasma inlet and/or a plasma outlet of a plasma module is not connected with a gas outlet and a gas inlet of another plasma module or a spacing bridge, respectively.
[0021] In accordance with one embodiment of the invention, this free gas inlets and gas outlets can remain open, so that the plasma generation device can, if required be cooled with gas. In accordance with another embodiment of the invention, the free gas inlets and gas outlets are sealed gas-tight with closure elements. Closure elements are, for example, blind flanges with sealing elements. The free gas inlets and gas outlets can also by a housing of a plasma generation device, which encloses the plasma modules. In particular, all free gas inlets or gas outlets can be sealed with closure elements so that gas can exit only through the plasma outlets of the housing module of the plasma modules.
[0022] The plasma modules can be connected directly or via spacing bridges with each other. According to the Invention to each spacing bridge is a connector, so that the control modules of the plasma modules are electrically connected. In addition or alternatively any spacing bridge can have at least a gas inlet and a gas outlet. According the invention to at least one gas inlet and at least one gas outlet of each spacing bridge leads to a gas outlet or a gas inlet of connected plasma modules or further connected spacing bridges.
[0023] The connected plasma modules of the plasma generating device can be arranged in a one, two- or three-dimensional way. For example, the plasma modules and/or spacing bridges of the plasma generating device are connected in a one-dimensional arrangement, such as a linear row or a closed contour like a circle. A further possibility is a two-dimensional matrix arrangement. For example, if a work piece with a depth profile, like with a groove, needs to be plasma treated, the plasma modules are connected at a side and from below with a spacing bridge. The advantage of the invention is, that any one-, two- or three-dimensional contour can be depicted by a matrix of plasma modules, so that the plasma generating device needs only to be positioned above a work-piece to be plasma treated. This is often faster, easier and more cost effective than a scan a contour or surface of the work-piece by a robot or a user. The processing time increases with fixed power density of the area to be treated with the plasma generator. Portions of areas of a contour or a surface can be left open by the plasma treatment by using appropriately positioned spacing bridges or by a selective activation of the plasma modules.
[0024] According to a particular embodiment of the invention, the plasma modules and spacing the bridges of the plasma generating device can be attached on a common mounting batten. Advantageous, the attachment is releasable, e.g. a plug-in. The mounting batten can be designed, for example, as a terminal strip, pneumatic strip or top hat rail.
[0025] According to a particular embodiment of the invention plasma generating device all plasma modules are surrounded by a common housing. In particular the plasma outlet of the plasma modules from the common housing can lead out via a common plasma outlet. The plasma outlet can as well enter into a connected plasma module.
[0026] The proposed plasma generating device has the advantage that it can be modularly extended and converted easily. The supply voltage is in the range of low voltage (e.g. 24V bus). Still, the cooling of the components can be achieved by the process gas because the plasma modules have a large total surface area across which the process gas flows. Furthermore, a simple installation, maintenance, and a simple exchange of individual components are possible. In addition, individual control of plasma modules is achieved via a control bus.
[0027] Thus the power of plasma generating device can be expanded in a modular way, while at the same time an uneconomic diversity in the parts of the basic construction elements is largely avoided.
[0028] Peripheral devices, like voltage sources, gas supplies (e.g. blowers or gas tanks with pressure regulators, mass flow, controllers for controlling the plasma sources via control cables, carrying scaffolds or work-piece holders, are assigned to the plasma generating device. The peripheral devices are connectable via appropriate cables with the plasma generating device. These cables are provided advantageously inventive control modules, input interfaces, output interfaces and gas inlets and gas outlets respectively. An inventive plasma generating device can in turn be a module in a system of plasma generating devices.
[0029] Controlled and homogeneous plasma conditions must prevail in all plasma modules of plasma generating device, therefore the dynamic and static pressure conditions in the plasma modules must be homogeneous, where the plasma is ignited from the process gas. This requires a homogeneous pressure or back pressure in the superior channel of gas supply. The back pressure is sufficiently homogeneous, if the total of the free cross sectional areas of plasma outlets of all plasma modules is small against the free cross sectional area of the superior channel of the gas supply. This condition limits the number of e.g. in series connectable plasma modules. The “free” cross sectional area, referred here, stand for the area, through which gas can flow and from which flow impedance are ruled out. A flow impedance represents, for example, an electrode arranged in the plasma outlet opening. To achieve homogeneous plasma conditions in the plasma modules, it is also beneficial to supply the plasma modules with a minimal gas flow velocity (e.g. with Reynolds number under 1000) and laminar flow. Furthermore, flow impedance or elements causing turbulences should be avoided by the design of the module housing or the housing of plasma generating device.
[0030] The control line can act as a data line to log the plasma treatment process through an electronic data set and to secure the electronic data for example in a connected nonvolatile storage medium. This increases the comprehensibility, e.g. which work piece was subjected when and to what plasma treatment, and thus contributes to the security of the process.
[0031] A further advantageous embodiment of the plasma generating device for generating a plasma, includes at least two plasma modules, a module housing provided to each plasma module, wherein the plasma module has at least one gas inlet for supplying a process gas, a discharge means provided in the module housing for generating the plasma from the process gas, a plasma outlet, at least one gas outlet for a portion of the process gas is provided with each plasma module, wherein the at least one gas outlet of at least one plasma module opens in each case into the gas inlet of another plasma module; and the plasma modules are pluggable connected with each other in a form-fit and/or force-fit manner, and a control module is associated with the plasma modules of the plasma generating device, wherein the control module has a control line and at least one voltage supply line, which are electrically connected to a electric driver module of the discharge means.
[0032] Still another advantageous embodiment of the plasma generating device for generating a plasma, comprises, at least two plasma modules, a common housing houses the plasma modules, wherein each plasma module has at least one gas inlet for supplying a process gas, a discharge means for generating the plasma from the process gas, a plasma outlet and at least one gas outlet for a portion of the process gas, wherein the at least one gas outlet of the at least one plasma module opens in each case into the gas inlet of another plasma module, a common gas supply is formed by the common housing via which the process gas is directed into the common housing, and separating walls are provided inside the common housing to separate the plasma modules, wherein the separating walls define an upper section and a lower section, the gas outlet and the gas inlet are provided at the upper section of the separating walls and plasma outlets are provided the lower sections of the separating walls.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Further advantages and advantageous embodiments of the invention are subject of the following figures and the corresponding parts of the description. Same and equal-functioning features are marked with the same reference numeral.
[0000] It shows in detail:
[0034] FIG. 1 is a schematic representation of an inventive plasma module;
[0035] FIG. 2 is a schematic representation of a plasma generating device, formed by serially coupled inventive plasma modules according to FIG. 1 ;
[0036] FIG. 3A is a schematic representation of an embodiment of the inventive spacing bridge;
[0037] FIG. 3B is a schematic representation of a further embodiment of the invention spacing bridge;
[0038] FIG. 4 is a schematic representation of a plasma generating device with a spacing bridge of FIG. 3A and plasma modules according to FIG. 1 ;
[0039] FIG. 5 is a schematic representation of a plasma generating device with spacing bridge of FIG. 3B and plasma modules according to FIG. 1 ;
[0040] FIG. 6 is a schematic representation of a plasma generating device with the inventive design of a common housing:
[0041] FIG. 7A is a schematic representation of an inventive plasma module with triangular cross-section profile;
[0042] FIG. 7B is a schematic representation of an inventive plasma module with square cross-section profile;
[0043] FIG. 7C is a schematic representation of an inventive plasma module with hexagonal cross-section profile;
[0044] FIG. 8A is a schematic representation of an inventive embodiment plasma generation device with mounting batten;
[0045] FIG. 8B is a schematic side view of a further embodiment of the inventive plasma generating device which is a three-dimensional matrix of plasma modules;
[0046] FIG. 8C is a schematic top view of a further embodiment of the inventive plasma generating device as a two dimensional matrix of plasma modules; and
[0047] FIG. 8D is a schematic top view of a further embodiment of the inventive plasma generating device, wherein the plasma modules are arranged in form of a closed contour.
DETAILED DESCRIPTION OF THE INVENTION
[0048] An inventive plasma module 1 , which is a component of a plasma generating device 100 is schematically shown in FIG. 1 . Plasma module 1 has module housing 5 , in which piezoelectric transformer 2 and electronic driver module 4 are housed. Piezoelectric transformer 2 is basically a piezoelectric crystal rod with two primary-side power-electrodes 21 , 22 and secondary side electrode 23 . By applying an AC voltage on the primary side electrodes 21 , 22 mechanical vibrations are induced in the piezoelectric crystal rod. The frequency of the mechanical vibrations is dependent from the geometry of the piezoelectric crystal rod, which acts as a resonator, and the mechanical construction of piezoelectric transformer 2 . The mechanical vibrations produce, due to the piezoelectric effect, an output voltage on secondary side 23 of the piezoelectric crystal rod. Depending on the geometry of the piezoelectric crystal rod and the position of electrodes 21 , 22 , the output voltage is higher or lower than the input voltage. As a result of the high transformation ratio, low input voltages can be transformed power-efficient into high output voltages. The performance range of a single piezoelectric transformer 2 is relatively low and is up to some 10 Watts, at resonance frequencies around some 10 kHz up to several 100 kHz. Thus high sinusoidal AC voltages can be generated easily, which are suitable for the generation of plasma 60 .
[0049] Through gas inlet 17 , process gas 18 G can flow in module housing 5 . A portion of process gas 18 G flows out again over gas supply channel 18 from gas outlet 19 from module housing 5 . Another portion flows out through plasma outlet 3 as directed beam of plasma 60 . On secondary side 23 of piezoelectric transformer 2 , process gas 18 G is transferred into plasma 60 prior to the flow out. Plasma outlet 3 can be structured as a nozzle or a nozzle with a variable geometry can be attached to plasma outlet 3 .
[0050] Module housing 5 is equipped with control module 20 . Two voltage supply lines 6 , 7 and control line 8 of control module 20 are electrically connected with electric driver module 4 . Electric driver module 4 is electrically connected to the two primary-side electrodes 21 , 22 of piezoelectric transformer 2 . The electrical power, effective on piezoelectric transformer 2 , is controlled according to the control signals transmitted via control line 8 . On the side of gas inlet 17 , control module 20 has individual input interfaces 6 e , 7 e and 8 e for voltage supply lines 6 , 7 and control line 8 . On the side of gas outlet 19 , individual and corresponding output interfaces 6 a , 7 a and 8 a are formed. The input interface 6 e , 7 e , 8 e and output interfaces 6 a , 7 a , 8 a are formed on the module housing, such that input interfaces 6 e , 7 e , 8 e of plasma module 1 is connectable with output interfaces 6 a , 7 a , 8 a of a further plasma module 1 . Likewise, gas outlets 19 and gas inlets 17 are formed such on module housing 5 of plasma module 1 that gas inlet 17 of one plasma module 1 is connectable with gas outlet 19 of a further plasma module 1 .
[0051] Plasma module 1 should be constructed in such a way, that cross section 18 D of gas supply channel 18 is greater than cross section 3 D of plasma outlet 3 . Plasma generating devices 100 (see FIG. 2 or FIG. 4 ), which are made from several plasma modules 1 , should have a gas supply channel 18 wherein its cross section 18 D exceeds the sum of cross sections 3 D of all plasma modules. This condition ensures that the back pressure of process gas 18 G in each plasma module 1 is essentially equal, so that in each plasma module 1 , uniform and controlled plasma conditions are present.
[0052] FIG. 2 illustrates schematically a plasma generating device 100 according to a first embodiment, which is formed by several plasma modules 1 which are coupled together and assembled in a horizontal row. Control modules 20 and gas channels 18 of all neighboring and in the series connected plasma modules 1 are directly connected by the plug connector. Therefore, voltage supply lines 6 , 7 of each plasma module 1 are connected to superior power supply lines 6 , 7 , control lines 8 of each plasma module 1 are connected to superior control line 8 and gas channels 18 of the individual plasma modules 1 are connected to superior gas channel 18 . Connected control lines 8 of the control modules form control bus 24 , so that each plasma module 1 can be controlled individually.
[0053] One preferred embodiment of the invention provides that gas inlet 17 and gas outlet 19 are interlocking counterparts of the plug connector. To increase the gas tightness of this plug connector, suitable sealing elements (not shown) can be provided between gas inlet 17 and gas outlet 19 .
[0054] FIGS. 3A and 3B show two embodiments of inventive spacing bridges 11 . Spacing bridge 11 , shown in FIG. 3A , carries, according to the invention, connector 20 A, voltage supply lines 6 , 7 and control line 8 . Voltage supply lines 6 , 7 and control line 8 carry input interfaces 6 e , 7 e and 8 e and output interface 6 a , 7 a , 8 a arranged on connector 20 A. Additionally, spacing bridge 11 has gas inlet 17 and gas outlet 19 , which are in fluid communication via gas supply channel 18 .
[0055] According to the embodiment shown in FIG. 3A , all gas inlets 17 and gas outlets 19 as well as all input interfaces 6 e , 7 e , 8 e and output interfaces 6 a , 7 a , 8 a of spacing bridge 11 of plasma modules 1 are formed “male” and “female” respectively. Thus, spacing bridge 11 , according to this embodiment, can be coupled with one or more plasma modules 1 . Spacing bridges 11 of this embodiment can be connected with each other and/or with plasma modules 1 .
[0056] In accordance with the further embodiment, shown in FIG. 3B , of spacing bridges 11 all gas inlets 17 and gas outlets 19 on and all input interfaces 6 e , 7 e , 8 e and output interfaces 6 a , 7 a , 8 a of spacing bridges 11 are “male” and that plasma module 1 are “female” (see FIG. 5 ).
[0057] FIG. 4 shows a schematic representation of a further embodiment of inventive plasma generating device 100 . Plasma generating device 100 is formed of spacing bridges 11 according to FIG. 3A and plasma modules 1 according to FIG. 1 . While according to the example shown in FIG. 2 , plasma generating device 100 is defined by a direct coupling of several plasma modules 1 , plasma modules 1 , as shown in FIG. 4 , are indirectly connected through spacing bridges 11 . Within inventive plasma generating device 100 , plasma modules 1 are basically coupled directly or indirectly by spacing bridges 11 . To bridge larger distances between plasma modules 1 , two or more spacing bridges 11 are coupled in between.
[0058] FIG. 5 illustrates a further embodiment inventive plasma generating device 100 . It includes spacing bridges 11 according to FIG. 3B and plasma modules 1 , whose gas inlets 17 , gas outlets 19 , input interfaces 6 e , 7 e , 8 e and output interfaces 6 a , 7 a , 8 a are formed as a “female” part of the connector. This allows indeed that plasma modules 1 and spacing bridges 11 are assembled to plasma generating devices 100 of variable geometry. However, plasma modules 1 or the spacing bridges 11 of this embodiment cannot be connected with each other. According to the invention, plasma generating devices 100 can be formed as well from combinations of spacing bridges 11 and/or plasma modules 1 of the embodiments according to FIGS. 4 and 5 .
[0059] In FIG. 6 is another embodiment of plasma generating device 100 is shown schematically. In this embodiment, plasma modules 1 are housed in common housing 105 . Housing 105 has common gas supply 117 via which process gas 18 G is directed into the housing 105 , so that it enters into gas inlet 17 of first plasma module 1 . Module housing 5 of plasma module 1 is formed in this embodiment of the walls of housing 105 and of separating walls 106 inside housing 105 . Between upper section 106 U of separating walls 106 and housing 105 , apertures are provided, which each are gas outlet 19 and gas inlet 17 of consecutive plasma modules 1 , respectively. Also between lower section 106 L of separating walls 106 and housing 105 openings are provided, which act as laterally arranged plasma outlets 3 which enter into adjacent plasma module 1 . Plasma outlet 3 of at least one plasma module 1 joins at least a common plasma outlet 103 of housing 105 . From this common plasma outlet 103 , a beam of plasma 60 exits housing 105 , which consequently has a higher intensity, ion density or power density as plasma 60 generated with single plasma module 1 only. Plasma modules 1 are connected via their respective control modules (not shown).
[0060] FIGS. 7A , 7 B and 7 C show schematically possible polygonal cross section profiles of inventive plasma modules 1 . Inventive spacing bridges 11 can be formed appropriately. In the sense of a flexible modularity, the cross section is designed preferably as an equilateral polygon. Each side area of plasma module 1 can carry a gas inlet 17 or a gas outlet 19 . It is also possible that some side areas of plasma modules 1 do not have a gas inlet 17 or gas outlet 19 . As each side of plasma module 1 can have input interface 6 e , 7 e , 8 e or output interface 6 a , 7 a , 8 a of control module 20 and connector 20 A respectively (not shown here). The smaller the cross sectional area of plasma module 1 is, the more compact they can be arranged to plasma generating device 100 , and higher areal plasma power densities can be achieved with plasma modules 1 of a given power limit. Plasma modules 1 and spacing bridges 11 of different cross sectional profiles can be combined in inventive plasma generating device 100 .
[0061] FIG. 7A shows a triangular cross section profile, where plasma module 1 carries two plasma inlets 17 and one plasma outlet 19 . FIG. 7B shows a square cross section profile, which carries on each adjacent side faces two plasma inlets 17 and two plasma outlets 19 . FIG. 7C shows three plasma modules 1 coupled with each other with a hexagonal cross section profile, which carries three plasma inlets 17 and three plasma outlets 19 on each of three adjacent side faces.
[0062] FIG. 8A to 8D illustrate schematically on some simple examples, how invention plasma modules 1 can be coupled to inventive plasma generating devices 100 . For the sake of clarity, only plasma modules 1 are shown. In principle at least one inventive spacing bridge 11 can be used between each plasma module 1 . The embodiments shown in the FIGS. 8A to 8D can be combined according to the invention in order to form more complex plasma generating devices 100 and/or fit to create special-application plasma generating devices 100 .
[0063] FIG. 8A shows a schematic top view of an embodiment of inventive plasma generating device 100 with mounting batten 101 , to which three plasma modules 1 are coupled serially to each other. Plasma modules 1 and also spacing bridges 11 can be pushed or clicked easily on mounting batten 101 . It is also possible that a defective plasma module 1 can be exchanged quickly and easily. In this way, the down time of a system which uses plasma modules 1 is restricted to a minimum. Similarly, plasma generating device 100 can be adapted to the various configurations of the work piece to be treated with the plasma.
[0064] FIG. 8B is a schematic side view of an embodiment of inventive plasma generating device 100 in a three-dimensional set-up. Two plasma modules 1 are coupled with each other by spacing bridge 11 . A third plasma module 1 is coupled to a lower side of spacing bridge 11 , so that third plasma module 1 is, compared to the two other plasma modules 1 , deposed to bottom. With this example, work piece 30 with cut-out 31 can be treated in one process step and anywhere with the same working distance 6 D (typically about 1-5 cm) to plasma outlet 3 . The dimensions of plasma modules 1 can be different from the dimensions of spacing bridge 11 . Spacing bridge 11 can have, according to the invention, a triangular side profile, so that plasma module 1 , connected to spacing bridge 11 from below, is directed at a different angle to work piece 30 as two spacing bridges 11 connected to the sides of plasma modules 1 , in order to provide a more homogeneous plasma treatment of the vertical surfaces of recess 31 .
[0065] FIG. 8C shows a schematic top view of a further embodiment of inventive plasma generating device 100 , which has two rows with three identical plasma modules 1 . In order to connect the top row and bottom row in the inventive manner, the third plasma module 1 from left is rotated 90° counter clockwise. Generally, inventive plasma module 1 with polygonal cross section can be coupled at an angle orientation with other plasma modules 1 or spacing bridges 11 , which represents a multiple of 360° divided by the number of corners of its cross section. In this exemplary embodiment, all unconnected gas inlets 17 and gas outlets 19 are sealed with closure elements 15 and all adjacent plasma modules 1 are in direct fluid communication with each other.
[0066] FIG. 8D shows a schematic top view of a further embodiment of inventive plasma generating device 100 . The identical and identical angle oriented plasma modules 1 are each connected to two other plasma modules 1 along a closed contour. Gas inlet 17 is connected to external gas supply 40 . All unconnected gas inlets 17 and gas outlets 19 are sealed with sealing elements 15 , so that process gas 18 G can flow only as plasma 60 from plasma outlets 3 of plasma module 1 .
[0067] The invention has been described with reference to exemplary and preferred embodiments. It is obvious to a skilled person that in the light of the disclosure of the invention, various forms of execution or aspects of the invention can be combined without leaving the scope of protection the following claims.
LIST OF REFERENCE NUMERALS
[0000]
1 plasma module
2 piezoelectric transformer
3 plasma outlet
3 D cross section
4 electric driver module
5 module housing
6 voltage supply line
6 e input interface
6 a output interface
6 D working distance
7 voltage supply line
7 e input interface
7 a output interface
8 control line
8 e input interface
8 a output interface
11 spacing bridge
15 closure element
17 gas inlet
18 gas supply channel
18 D cross section
18 G process gas
19 gas outlet
20 control module
20 A connector
21 , 22 primary side electrodes
23 secondary side electrodes
24 control bus
30 work piece
31 cut out
40 external gas supply
60 plasma
100 plasma generation device
101 mounting batten
103 common plasma outlet
105 housing
106 separating wall
106 U upper section
106 L lower section
117 common gas supply
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The invention relates to a plasma generation device comprising a plurality of plasma modules for generating a plasma. Each plasma module has a module housing with at least one gas inlet for supplying a process gas. Furthermore, a discharge device for generating the plasma from the process gas and a plasma outlet are provided. The plasma generation device has at least two plasma modules for generating a plasma. Each plasma module has at least one gas outlet for some of the process gas, wherein the at least one gas outlet of at least one plasma module issues into a respective gas inlet of another plasma module.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application No. 62/171,426, filed Jun. 5, 2015, the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure relates generally to providing user assistance in a user's daily routine.
BACKGROUND
[0003] Some modern mobile devices can record a series of locations the mobile device has visited upon user request. Based on the recorded location, the mobile device can predict where a user of the device will likely visit at given time. The mobile device can then provide various predictive user assistance services for the user who elects to receive the services. For example, upon user request, a mobile device can determine a location that a user visits daily at a given hour and predict that the user will visit the same location at the same hour on a given day. In response, the mobile device can provide user assistance ahead of the hour on that day, e.g., by providing an alert to the user prompting the user to leave for that location earlier than usual upon determining that, on that given day the traffic conditions on a path to that location are worse than usual. Conventionally, the predictive user assistance services can be based on an estimation of whether a user will visit the location and at what time.
SUMMARY
[0004] Techniques for data-driven context determination are disclosed below. A mobile device can provide predictive user assistance based on various sensor readings, independently of, or in addition to, locations previously recorded by the mobile device. The mobile device can determine a context of an event. The event can be an action performed by a user using the mobile device or using an external system other than the mobile device. The mobile device can record readings of multiple sensors of the mobile device at time of the event and designate the recorded sensor readings as the context of the event. The mobile device can store the context and a label of the event on a storage device. The label can be associated with the event. At a later time, the mobile device can match new sensor readings with the stored context. If a match is found, the mobile device can predict that the user is about to perform the action or recognize that the user has performed the action again. The mobile device can respond by performing various operations, including, for example, providing user assistance based on the prediction or recognition.
[0005] The features described in this specification can achieve one or more advantages. For example, a mobile device implementing the techniques described in this specification can provide predictive user assistance for users who perform routine tasks at multiple locations. The mobile device can provide assistance when location information is unavailable, for example, when the mobile device is located in a home inside a multi-story building. The information collection can be data driven and unsupervised without requiring a user to perform a survey of a venue or requiring a user to enter various labels manually. In some example applications, the mobile device can recognize various rooms in a house even though a respective geographic location of each room cannot be determined. Accordingly, for example, the mobile device can remind a user that a light or a stove remains on in a kitchen when the user enters a bedroom. The mobile device can configure itself to match users with different habits, and categorize various entities, events and venues accordingly. The mobile device can achieve each of the advantages without knowing geographic locations of the mobile device.
[0006] The details of one or more implementations of the subject matter are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a diagram illustrating an exemplary mobile device determining context data for an event.
[0008] FIG. 2 is a diagram illustrating an exemplary mobile device predicting or recognizing a user action using sensor measurements and stored context data.
[0009] FIG. 3 is a diagram illustrating an exemplary mobile device detecting a transition of states of the mobile device based on context data.
[0010] FIG. 4 is a diagram illustrating an exemplary mobile device determining a context of a user action using a map service.
[0011] FIG. 5 is a diagram illustrating multiple contexts associated with a user by an exemplary mobile device.
[0012] FIG. 6 is a block diagram illustrating components of an exemplary mobile device determining and using context data.
[0013] FIG. 7 is a block diagram illustrating an exemplary structure of a context vector.
[0014] FIG. 8 is a flowchart of an exemplary process of determining and using context data.
[0015] FIG. 9 is a block diagram illustrating an exemplary device architecture of a mobile device implementing the features and operations described in reference to FIGS. 1-8 .
[0016] FIG. 10 is a block diagram of an exemplary network operating environment for the mobile devices of FIGS. 1-8 .
[0017] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
Exemplary Context Data
[0018] FIG. 1 is a diagram illustrating exemplary mobile device 102 determining context data for an event. Mobile device 102 can interact with external system 104 to perform action 106 , or detect a user interaction with external system 104 to perform action 106 . Mobile device 102 can be a device that has received user authorization to determine and use event context data. External system 104 can be a smart home controlling system controlling one or more appliances of a home or office. The appliances can include, for example, a light 108 , a garage door or a kitchen stove. Action 106 can be a user act of controlling an appliance, e.g., turning on light 108 or opening a garage door using external system 104 . For example, the user can turn on light 108 using a user interface of external system 104 displayed on mobile device 102 . Alternatively, the user can turn on a light using a user interface of external system 104 displayed on a television or a desktop, laptop, or tablet computer.
[0019] External system 104 can provide label 110 to mobile device 102 . Label 110 can be a text or binary information item characterizing, describing, or identifying action 106 . For example, label 110 can be a message broadcast to nearby devices by external system 104 through a wireless channel for near-field communication after a user turns on light 108 using external system 104 . The message can include a text snippet “turning on living room light” previously associated with action 106 by a user or by external system 104 . In some implementations, label 110 can be a text string previously stored on mobile device 102 associated with a user interface item for interacting with external system 104 .
[0020] Mobile device 102 can obtain various sensor readings of an environment in which action 106 is performed. For example, mobile device 102 can record readings of a wireless receiver of mobile device 102 . The readings can include received signal strength indicators (RSSIs) of one or more wireless signal sources 112 . The one or more signal sources 112 can include, for example, wireless access points, near-field communication (NFC) beacons, or cellular towers. Likewise, mobile device 102 can record readings of a microphone of mobile device 102 measuring ambient sounds from one or more sound sources 114 . Mobile device 102 can record readings of a thermometer of mobile device measuring ambient temperature generated by one or more heat sources 116 . Obtaining the sensor readings can be continuous or can be triggered by action 106 .
[0021] Mobile device 102 can store the sensor readings obtained in context database 118 . Mobile device 102 can store the sensor readings as one or more sensor vectors 120 and 122 . Each of the sensor vectors 120 and 122 can correspond to one set of sensor readings and be associated with a same or different label, for example, label 110 , or a value (e.g., hash value) representing label 110 . The sensor vectors 120 and 122 and associated label 110 can be designated as context vector 124 of action 106 . Mobile device 102 can store multiple context vectors in context database 118 , each context vector corresponding to a different action or a different type of action. Mobile device 102 can create and store the context vectors without user intervention, other than the initial user input authorizing mobile device to create and store the context vectors. Exemplary ways of how mobile device 102 may use the stored context vectors are described in additional detail in reference to FIG. 2 .
[0022] FIG. 2 is a diagram illustrating exemplary mobile device 102 predicting or recognizing a user action using sensor measurements and stored context data. Mobile device 102 can obtain, from various sensors of mobile device 102 , readings on an environment in which mobile device 102 is located. The readings can include, for example, temperature readings, sound level readings and readings on wireless signals received by mobile device 102 . These readings can be affected by one or more signal sources 202 , sound sources 204 , and heat sources 206 . The signal sources 202 , sound sources 204 and heat sources 206 may be the same as, or different from, the signal sources 112 , sound sources 114 , and heat sources 116 of FIG. 1 .
[0023] Mobile device 102 can determine sensor vector 208 representing the readings. Sensor vector 208 can be a collection of sensor readings arranged in a pre-defined format that maps to a format of context vectors stored in context database 118 . Mobile device 102 can search the context database 118 for a context vector that matches sensor vector 208 . Searching context database 118 can include performing a statistical match between stored context vectors and sensor vector 208 . Mobile device 102 can perform the match by modeling observation noise and evaluating a likelihood function. In some implementations, the search can be based on categories, where the stored context vectors are organized in multiple categories and subcategories. Mobile device 102 can determine a category and subcategory of sensor vector 208 , e.g., based on whether sensor vector 208 is predominated by motion readings, sound readings, or temperature readings to be categorized as a motion vector, sound vector or heat vector. Mobile device 102 can then compare sensor vector 208 with context vectors in a corresponding category. In various implementations, the search can be a linear or binary search, comparing sensor vector 208 with one or more context vectors in a category or subcategory.
[0024] In the example shown, mobile device 102 identifies a match between sensor vector 208 and context vector 124 associated with label 110 and corresponding to action 106 of FIG. 1 . As a result, mobile device 102 can make determination 210 that a user of the mobile device will perform action 106 or has performed action 106 at time mobile device 102 took the readings in sensor vector 208 . Determination 210 can trigger various functions of mobile device 102 , including, for example, displaying a user interface for interacting with external system 104 , displaying an alert or reminder or executing a user-specified application.
[0025] FIG. 3 is a diagram illustrating exemplary mobile device 102 detecting a transition of states of mobile device 102 based on context data. The transition of states can be changing locations, changing environments or both. In certain situations, determining a precise location of mobile device 102 can be difficult or impossible. For example, mobile device 102 can be in a home or office where GPS signals are weak and no Wi-Fi™ access points are available for location determination. Using technology described below, mobile device 102 can determine transitions of states of mobile device 102 , e.g., moving from one room to another, without knowing where mobile device 102 is physically located.
[0026] At a given time T0, mobile device 102 may be located in a particular room, e.g., living room 302 of a home. Mobile device 102 can record a set of sensor readings and store the sensor readings in context database 118 as context vector 304 . Mobile device 102 can assign to context vector 304 a label that is generated by a device (e.g., a Bluetooth™ receiver of a sound system) located in living room 302 . The label can be an identifier (e.g., a media access control (MAC) address), a user provided or default name (e.g., “Room 1”) of a Bluetooth or NFC device or a string generated by mobile device 102 . Mobile device 102 can store multiple context vectors associated with the label. The context vectors can include sensor readings taken at different time (e.g., daytime or nighttime, weekday or weekend) and having different characteristics (e.g., when lights are on or off). Mobile device 102 can aggregate the context vectors into a category related to living room 302 or aggregate the context vector into a single master context vector associated with living room 302 .
[0027] Likewise, at a later time T1, mobile device 102 may be located in another room, e.g., bedroom 306 . Mobile device 102 can take sensor readings and associate the sensor readings with a second label, e.g., “Room 2.” Mobile device 102 can store the sensor readings and the associated label as context vector 308 in context database 118 .
[0028] At a given later time Tx, mobile device 102 can determine that mobile device 102 is in a context that matches context vector 304 associated with label “Room 1.” Mobile device 102 can make the determination by comparing sensor readings taken at or near time Tx with context vectors including context vector 304 stored in context database 118 and determining that the sensor readings match the readings of context vector 304 . At a yet later time Ty, mobile device 102 can determine that mobile device 102 is in a context that matches context vector 308 having an associated label “Room 2.” Accordingly, mobile device 102 can determine that mobile device 102 transitioned from “Room 1” to “Room 2” at a time between Tx and Ty.
[0029] Determining the transition can trigger mobile device 102 to perform various tasks. For example, mobile device 102 can determine that while mobile device 102 is in a context corresponding to label “Room 1” a light was turned on. Mobile device 102 can make the determination by determining that mobile device 102 was temporarily in a context that matches a label indicating a context that a light was turned on, or, in some implementations, by recording an action that mobile device 102 interacted with an external system (e.g., system 104 of FIG. 1 ) to turn on a light. Upon determining that mobile device 102 has made the transition mobile device 102 can display user interface 310 . User interface 310 can include one or more options to turn off the light through interaction between mobile device 102 and the external system.
[0030] FIG. 4 is a diagram illustrating exemplary mobile device 102 determining a context of a user action using a map service. Mobile device 102 may be carried by a user jogging along path 402 . Many users may carry mobile devices while jogging, each in a different and unique way. Some users may customarily carry mobile devices in a pocket, running pouch or backpack. Some users may customarily fasten mobile devices to arms, legs or waists using elastic bands. Accordingly, movement patterns of mobile devices, while being carried jogging, may be very different for different users.
[0031] Mobile device 102 , while being carried by a jogging user, may access map service 404 . Through map service 404 , mobile device 102 may determine that, for a given period of time, mobile device 102 travels along path 402 , which is classified in map service 404 as a jogging path. Accordingly, mobile device 102 can associate a vector of sensor readings, e.g., motion sensor readings 406 , with a label, e.g., “jogging,” as provided by map service 404 , and store the sensor vector and label as context vector 408 .
[0032] Mobile device 102 may record an event associated with context vector 408 . For example, mobile device 102 may record that when mobile device is on jogging path 402 , a user of mobile device 102 has turned on a given feature of mobile device 102 one or more times, e.g., a heart rate monitoring application program. Accordingly, when mobile device 102 obtains sensor readings that match sensor readings 406 in context vector 408 mobile device 102 may provide a prompt that includes the label obtained from map service 404 (e.g., “jogging”) and a user interface item asking a user whether the user wishes to turn on the feature, e.g., launch the heart rate monitoring application program. Providing the prompt can be triggered by the sensor reading match rather than location. Accordingly, mobile device 102 may provide the prompt upon detecting the motion pattern, even when mobile device 102 is not located on jogging path 402 .
[0033] Recording the context vector 408 can be data driven and independent of a user's individual habit. For example, mobile device 102 may be carried by a second user along path 402 . The second user may have a unique way of carrying mobile device 102 and a unique stride while jogging. Accordingly, mobile device 102 may associate sensor vector 410 with the label “jogging” and store them as context vector 412 . Sensor vector 410 may have a pattern that is different from a pattern of sensor readings 406 . Different context vectors 408 and 412 allow mobile device 102 to customize mobile device 102 to different users without being trained or manually configured by different users.
[0034] FIG. 5 is a diagram illustrating multiple contexts associated with a user by exemplary mobile device 102 . Context database 118 hosted on or coupled to mobile device 102 can store multiple context vectors for each of one or more users. For example, context database 118 can store context vectors 502 , 504 , 506 , and 508 for user 510 identified by user identifier, e.g., a user name or a user's cloud identity. Each of context vectors 502 , 504 , 506 , and 508 can include one or more representations of sensor readings associated with a label, e.g., “jogging,” “driving,” “bedroom,” or “turn on light.” Each representation can be actual sensor readings or a statistical representation of sensor readings, e.g., one or more of a mean, median, mode or deviation that is derived from a set of the sensor readings.
[0035] Mobile device 102 can determine the statistical representations using aggregation 512 . Aggregation 512 can include determining the statistical representations using multiple sensor vectors, e.g., sensor vectors 514 , 516 , and 518 taken at various times. For example, for a number of X weekdays, mobile device 102 can determine that mobile device 102 is on jogging path 402 (of FIG. 4 ). Each time mobile device 102 is on jogging path 402 , mobile device 102 can record a set of motion sensor readings. Mobile device 102 can determine that these motion sensor readings are sufficiently similar to one another by determining that differences between magnitude or frequency (e.g., computed by a Fast Fourier Transform (FFT)) of linear or angular accelerations in readings on day one and readings on day two are smaller than a threshold. Upon this determination, mobile device 102 can aggregate the readings of day one and day two, e.g., by calculating a mean and deviation of the magnitude or frequency, associate the aggregated readings with the label “jogging” to create context vector 502 and associate context vector 502 with user 510 who may be the registered user of mobile device 102 .
Exemplary Device Components
[0036] FIG. 6 is a block diagram illustrating components of exemplary mobile device 102 determining and using context data. Each component of exemplary mobile device 102 can include hardware and software, firmware, or cloudware components.
[0037] Mobile device 102 can include context determination subsystem 602 . Context determination subsystem 602 is a component of mobile device 102 configured to determine one or more context vectors for a user. Context determination subsystem 602 can receive a user input enabling context determination functions of mobile device 102 . Upon receiving the input, context determination subsystem 602 can enable context determining functions by recording readings from one or more sensors 604 of mobile device 102 as sensor vectors.
[0038] Recording readings from one or more sensors 604 of mobile device 102 can be triggered by the user input or be triggered by interactions between mobile device 102 and external system 606 . External system 606 can include a system that can provide a label of a user action or information for constructing a label of a user action. For example, external system 606 can include a smart home controlling system, a Bluetooth device or a map service as described above.
[0039] Context determining subsystem 602 can include sampling subsystem 608 . Sampling subsystem 608 is a component of context determining subsystem 602 configured to interact with sensors 604 , including turning on or off each of the sensors 604 and receiving the readings from the sensors 604 . Sampling subsystem 608 can provide the readings to labeling subsystem 610 as sensor vectors.
[0040] Labeling subsystem 610 is a component of context determination subsystem 602 configured to associate a label with the sensor vectors provided by sampling subsystem 608 . Labeling subsystem 610 can receive the label from external subsystem 606 or determine the label from information provided by external subsystem 606 , for example, by hashing an identifier provided by external subsystem 606 . Labeling subsystem 610 can provide the sensor-reading vectors associated with the label to aggregation subsystem 612 .
[0041] Aggregation subsystem 612 is a component of context determination subsystem 602 configured to perform aggregation 512 on multiple sensor vectors as described above in reference to FIG. 5 . Result of the operations of aggregation subsystem 612 can include one or more context vectors. Aggregation subsystem 612 can store the context vectors in context database 118 . Context database 118 can be a subsystem of mobile device 102 including one or more storage devices or a database located remotely from mobile device 102 and connected to mobile device 102 through a communications network.
[0042] Mobile device 102 can include context recognition subsystem 620 . Context recognition subsystem 620 is a component of mobile device 102 configured to receive readings from sensors 604 , compare the received readings with context vectors stored in context database 118 and determine if mobile device 102 is in a particular context if the comparison results in a match. Upon determining that mobile device 102 is in a particular context, context recognition subsystem can call a system function or launch an application program that is previously associated with the context by user input or by learning by mobile device 102 from past user actions. In some implementations, calling the system function or launching the application program can trigger user interface subsystem 622 to present a visual, audio or tactile output. In some implementations, calling the system function or launching the application program can trigger communication between mobile device 102 and external system 606 to cause external system 606 to perform an action, e.g., turning on or off a light or an electric appliance.
[0043] FIG. 7 is a block diagram illustrating an exemplary structure 700 of a context vector. The context vector can be stored in a context database 118 of FIG. 1 .
[0044] The context vector can include, or otherwise be associated with label 702 . Label 702 can be a text string, a markup language tag or a binary identifier. The context vector can include one or more sensor vectors 703 . Sensor readings 703 can include actual readings from sensors of a mobile device, e.g., mobile device 102 of FIG. 1 or statistical representations of the actual sensor readings.
[0045] Sensor vector 703 can include wireless signal readings 704 . Wireless signal readings 704 can include RSSI values of one or more signal sources as measured by a wireless receiver of the mobile device. The RSSI values can be associated with identifiers, e.g., media access control (MAC) addresses of the corresponding signal sources. The RSSI values can include RSSI values of signals from, for example, wireless access points (APs), NFC beacons, cellular towers, Bluetooth™ devices or Bluetooth low energy (BLE) beacons.
[0046] Sensor vector 703 can include sound readings 706 . Sound readings 706 can include measurements of ambient sound taken by a microphone of the mobile device. The measurements can include particular patterns of sounds from various activities. For example, a user activity of turning on a stove can include a click of lighter, which can generate a particular sound. The mobile device can record the particular sound, or a frequency, an amplitude, and a duration of the particular sound and store the recorded values or a statistical representation (e.g., a mean and variance) of the values as sound readings 706 .
[0047] Sensor vector 703 can include motion readings 708 . Motion readings 708 can include lateral or angular accelerations taken by one or more motion sensors of the mobile device. Motion readings 708 can include a direction vector in a three-dimensional space, amplitude, duration, and frequency of the accelerations.
[0048] Sensor vector 703 can include light readings 710 . Light readings 710 can include measurements taken from a light sensor of the mobile device. The measurements can include measurements of intensity and color readings of the light sensor.
[0049] Sensor vector 703 can include proximity readings 712 . Proximity readings 712 can include measurements taken from a proximity sensor of the mobile device. The measurement can indicate a duration that the mobile device is located within a threshold distance to an object such that the proximity sensor can detect the object, a distance between the mobile device and the object and an angle at which the mobile device is facing the object.
[0050] Sensor vector 703 can include magnetometer readings 714 . Magnetometer readings 714 can include measurements of a magnetometer of the mobile device. The measurements can include measurements on magnitude, direction, and rate of change of a magnetic field in which the mobile device is located.
[0051] Sensor vector 703 can include thermometer readings 716 . Thermometer readings 716 can include temperature measurements taken by a thermometer of the mobile device. Sensor readings 703 can include barometer readings 718 . Barometer readings 718 can include measurements of atmospheric pressure taken by a barometer of the mobile device. Sensor vector 703 can include moisture sensor readings 720 . Moisture sensor readings 720 can include measurement of humidity in the air taken by a moisture sensor, e.g., a hygrometer, of the mobile device.
[0052] Sensor vector 703 can include additional sensor readings 722 . Additional sensor readings can include measurement of various environment variables taken by sensors of the mobile device or sensors connected to the mobile device. These sensors can include, for example, a heart rate monitor, a multimeter probe, a blood pressure sensor, a GPS receiver or a breath analyzer. The mobile device can designate various combinations of the sensor vector 703 as a context. In some implementations, the absence of some readings, like the presence of some readings, can form part of the context. For example, the mobile device can determine that the absence of GPS signals indicates a context in which the mobile device is located indoors.
[0053] Context vector 700 can include user input history 724 . User input history 724 can include a set of records each representing a user action. The user action can include, for example, a search request including a search term, turning on or off an appliance, selecting a channel on a television, shutting down the mobile device or setting the mobile device to airplane mode where a wireless transceiver of the mobile device is turned off. The mobile device can associate user input history 724 with label 702 and sensor vector 703 to estimate what the user will do when the mobile device is in a same context, e.g., when the mobile device encounters sensor readings that are similar to those of sensor vector 703 .
Exemplary Procedures
[0054] FIG. 8 is a flowchart of an exemplary process of determining and using context data. A mobile device, e.g., mobile device 102 of FIG. 1 can perform process 800 . In some implementations, process 800 can be performed by one or more server computers connected to the mobile device.
[0055] The mobile device can interact with a system external to the mobile device. The mobile device can determine ( 802 ) that a user of the mobile device performed an act, the act being associated with a label describing or identifying the act. The label can be supplied by the system external to the mobile device at time the user performs the act. The external system can be configured to control one or more electric appliances of a home or an office. The act can include an act of turning on or off an electric appliance of the home or office, or an act of adjusting an electric appliance of the home or office.
[0056] In some implementations, the label can be obtained by the mobile device from an external map information system upon determining, by the mobile device, that the mobile device has transitioned from a first geographic area represented in the map to a second geographic area represented in the map. The label describing or identifying the act can include information on the first geographic area or information on the second geographic area. For example, the mobile device can determine that the mobile device transitioned from a home to an office through a jogging path or biking path. The map information system can provide a name of the path or a description (e.g., jogging or biking) of the path. The label can include the name or description.
[0057] In response to determining that the user performed the act, the mobile device can determine ( 804 ) a vector of environmental readings obtained by one or more sensors of the mobile device at time the act is performed. The vector can be exemplary context vector 700 described in reference to FIG. 7 . Determining the vector of environmental readings can include aggregating the environmental readings with previously recorded environmental readings associated with a same label. In some implementations, determining the vector of environmental readings can be triggered upon determining that the user performed the act. Determining the vector of environmental readings can occur without prompting the user to enter the label.
[0058] The mobile device can store ( 806 ) the vector of environmental readings in association with the label on a storage device. The vector can include at least one of the following: readings from a wireless receiver of the mobile device measuring received signal strength, readings of ambient sound from a microphone of the mobile device, readings of linear or angular accelerations of the mobile device from a motion sensor of the mobile device, readings from a light sensor of the mobile device, readings from a proximity sensor of the mobile device or readings from a magnetometer of the mobile device.
[0059] The mobile device can match ( 808 ) a set of sensor readings with the stored vector. The mobile device can obtain the set of sensor readings at time after the act is performed. Matching the set of sensor readings obtained at time after the act is performed with the stored vector can include performing a statistical match and determining a probability that the set of sensor readings obtained at a time after the act is performed corresponds to the act satisfies a pre-specified threshold value.
[0060] The mobile device can determine ( 810 ), based on the matching, that the user of the mobile device will perform the act that is described or identified by the label associated with the stored vector. Upon determining that the user of the mobile device will perform the act, the mobile device can present a user interface item to the user prompting the user to turn on, turn off, or adjust an electronic appliance or execute a user-specified application program.
Exemplary Mobile Device Architecture
[0061] FIG. 9 is a block diagram of an exemplary architecture 900 for the mobile devices of FIGS. 1-8 . A mobile device (e.g., mobile device 102 ) can include memory interface 902 , one or more data processors, image processors and/or processors 904 , and peripherals interface 906 . Memory interface 902 , one or more processors 904 and/or peripherals interface 906 can be separate components or can be integrated in one or more integrated circuits. Processors 904 can include application processors, baseband processors, and wireless processors. The various components in mobile device 102 , for example, can be coupled by one or more communication buses or signal lines.
[0062] Sensors, devices, and subsystems can be coupled to peripherals interface 906 to facilitate multiple functionalities. For example, motion sensor 910 , light sensor 912 , and proximity sensor 914 can be coupled to peripherals interface 906 to facilitate orientation, lighting, and proximity functions of the mobile device. Location processor 915 (e.g., GPS receiver) can be connected to peripherals interface 906 to provide geopositioning. Electronic magnetometer 916 (e.g., an integrated circuit chip) can also be connected to peripherals interface 906 to provide data that can be used to determine the direction of magnetic North. Thus, electronic magnetometer 916 can be used as an electronic compass. Motion sensor 910 can include one or more accelerometers configured to determine change of speed and direction of movement of the mobile device. Barometer 917 can include one or more devices connected to peripherals interface 906 and configured to measure pressure of atmosphere around the mobile device.
[0063] Camera subsystem 920 and an optical sensor 922 , e.g., a charged coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS) optical sensor, can be utilized to facilitate camera functions, such as recording photographs and video clips.
[0064] Communication functions can be facilitated through one or more wireless communication subsystems 924 , which can include radio frequency receivers and transmitters and/or optical (e.g., infrared) receivers and transmitters. The specific design and implementation of the communication subsystem 924 can depend on the communication network(s) over which a mobile device is intended to operate. For example, a mobile device can include communication subsystems 924 designed to operate over a GSM network, a GPRS network, an EDGE network, a Wi-Fi™ or WiMax™ network, and a Bluetooth™ network. In particular, the wireless communication subsystems 924 can include hosting protocols such that the mobile device can be configured as a base station for other wireless devices.
[0065] Audio subsystem 926 can be coupled to a speaker 928 and a microphone 930 to facilitate voice-enabled functions, such as voice recognition, voice replication, digital recording, and telephony functions. Audio subsystem 926 can be configured to receive voice commands from the user.
[0066] I/O subsystem 940 can include touch surface controller 942 and/or other input controller(s) 944 . Touch surface controller 942 can be coupled to a touch surface 946 or pad. Touch surface 946 and touch surface controller 942 can, for example, detect contact and movement or break thereof using any of a plurality of touch sensitivity technologies, including but not limited to capacitive, resistive, infrared, and surface acoustic wave technologies, as well as other proximity sensor arrays or other elements for determining one or more points of contact with touch surface 946 . Touch surface 946 can include, for example, a touch screen.
[0067] Other input controller(s) 944 can be coupled to other input/control devices 948 , such as one or more buttons, rocker switches, thumb-wheel, infrared port, USB port, and/or a pointer device such as a stylus. The one or more buttons (not shown) can include an up/down button for volume control of speaker 928 and/or microphone 930 .
[0068] In one implementation, a pressing of the button for a first duration may disengage a lock of the touch surface 946 ; and a pressing of the button for a second duration that is longer than the first duration may turn power to mobile device 102 on or off. The user may be able to customize a functionality of one or more of the buttons. The touch surface 946 can, for example, also be used to implement virtual or soft buttons and/or a keyboard.
[0069] In some implementations, mobile device 102 can present recorded audio and/or video files, such as MP3, AAC, and MPEG files. In some implementations, mobile device 102 can include the functionality of an MP3 player. Other input/output and control devices can also be used.
[0070] Memory interface 902 can be coupled to memory 950 . Memory 950 can include high-speed random access memory and/or non-volatile memory, such as one or more magnetic disk storage devices, one or more optical storage devices, and/or flash memory (e.g., NAND, NOR). Memory 950 can store operating system 952 , such as iOS, Darwin, RTXC, LINUX, UNIX, OS X, WINDOWS, or an embedded operating system such as VxWorks. Operating system 952 may include instructions for handling basic system services and for performing hardware dependent tasks. In some implementations, operating system 952 can include a kernel (e.g., UNIX kernel).
[0071] Memory 950 may also store communication instructions 954 to facilitate communicating with one or more additional devices, one or more computers and/or one or more servers. Memory 950 may include graphical user interface instructions 956 to facilitate graphic user interface processing; sensor processing instructions 958 to facilitate sensor-related processing and functions; phone instructions 960 to facilitate phone-related processes and functions; electronic messaging instructions 962 to facilitate electronic-messaging related processes and functions; web browsing instructions 964 to facilitate web browsing-related processes and functions; media processing instructions 966 to facilitate media processing-related processes and functions; GPS/Navigation instructions 968 to facilitate GPS and navigation-related processes and instructions; camera instructions 970 to facilitate camera-related processes and functions; magnetometer data 972 and calibration instructions 974 to facilitate magnetometer calibration. The memory 950 may also store other software instructions (not shown), such as security instructions, web video instructions to facilitate web video-related processes and functions, and/or web-shopping instructions to facilitate web shopping-related processes and functions. In some implementations, the media processing instructions 966 are divided into audio processing instructions and video processing instructions to facilitate audio processing-related processes and functions and video processing-related processes and functions, respectively. An activation record and International Mobile Equipment Identity (IMEI) or similar hardware identifier can also be stored in memory 950 . Memory 950 can store context instructions 976 that, when executed, can cause processor 904 to perform operations of determining a context of a mobile device and matching sensor readings with the context, including the operations described in FIGS. 1-8 .
[0072] Each of the above identified instructions and applications can correspond to a set of instructions for performing one or more functions described above. These instructions need not be implemented as separate software programs, procedures, or modules. Memory 950 can include additional instructions or fewer instructions. Furthermore, various functions of the mobile device may be implemented in hardware and/or in software, including in one or more signal processing and/or application specific integrated circuits.
Exemplary Operating Environment
[0073] FIG. 10 is a block diagram of an exemplary network operating environment 1000 for the mobile devices of FIGS. 1-8 . Mobile devices 1002 a and 1002 b can, for example, communicate over one or more wired and/or wireless networks 1010 in data communication. For example, a wireless network 1012 , e.g., a cellular network, can communicate with a wide area network (WAN) 1014 , such as the Internet, by use of a gateway 1016 . Likewise, an access device 1018 , such as an 802.11g or 802.11n wireless access point, can provide communication access to the wide area network 1014 . Each of mobile devices 1002 a and 1002 b can be mobile device 102 as described above in reference to FIGS. 1-8 .
[0074] In some implementations, both voice and data communications can be established over wireless network 1012 and the access device 1018 . For example, mobile device 1002 a can place and receive phone calls (e.g., using voice over Internet Protocol (VoIP) protocols), send and receive e-mail messages (e.g., using Post Office Protocol 3 (POP3)), and retrieve electronic documents and/or streams, such as web pages, photographs, and videos, over wireless network 1012 , gateway 1016 , and wide area network 1014 (e.g., using Transmission Control Protocol/Internet Protocol (TCP/IP) or User Datagram Protocol (UDP)). Likewise, in some implementations, the mobile device 1002 b can place and receive phone calls, send and receive e-mail messages, and retrieve electronic documents over the access device 1018 and the wide area network 1014 . In some implementations, mobile device 1002 a or 1002 b can be physically connected to the access device 1018 using one or more cables and the access device 1018 can be a personal computer. In this configuration, mobile device 1002 a or 1002 b can be referred to as a “tethered” device.
[0075] Mobile devices 1002 a and 1002 b can also establish communications by other means. For example, wireless device 1002 a can communicate with other wireless devices, e.g., other mobile devices, cell phones, etc., over the wireless network 1012 . Likewise, mobile devices 1002 a and 1002 b can establish peer-to-peer communications 1020 , e.g., a personal area network, by use of one or more communication subsystems, such as the Bluetooth™ communication devices. Other communication protocols and topologies can also be implemented.
[0076] The mobile device 1002 a or 1002 b can, for example, communicate with one or more services 1030 and 1040 over the one or more wired and/or wireless networks. For example, one or more smart home services 1030 can allow mobile devices 1002 a and 1002 b to control a home appliance remotely. Map service 1040 can provide information, e.g., a name or a classification that can be used as a label, of a location visited by the mobile devices 1002 a and 1002 b.
[0077] Mobile device 1002 a or 1002 b can also access other data and content over the one or more wired and/or wireless networks. For example, content publishers, such as news sites, Really Simple Syndication (RSS) feeds, web sites, blogs, social networking sites, developer networks, etc., can be accessed by mobile device 1002 a or 1002 b. Such access can be provided by invocation of a web browsing function or application (e.g., a browser) in response to a user touching, for example, a Web object.
[0078] As described above, some aspects of the subject matter of this specification include gathering and use of data available from various sources to improve services a mobile device can provide to a user. The present disclosure contemplates that in some instances, this gathered data may identify a particular location or an address based on device usage. Such personal information data can include location based data, addresses, subscriber account identifiers, or other identifying information.
[0079] The present disclosure further contemplates that the entities responsible for the collection, analysis, disclosure, transfer, storage, or other use of such personal information data will comply with well-established privacy policies and/or privacy practices. In particular, such entities should implement and consistently use privacy policies and practices that are generally recognized as meeting or exceeding industry or governmental requirements for maintaining personal information data private and secure. For example, personal information from users should be collected for legitimate and reasonable uses of the entity and not shared or sold outside of those legitimate uses. Further, such collection should occur only after receiving the informed consent of the users. Additionally, such entities would take any needed steps for safeguarding and securing access to such personal information data and ensuring that others with access to the personal information data adhere to their privacy policies and procedures. Further, such entities can subject themselves to evaluation by third parties to certify their adherence to widely accepted privacy policies and practices.
[0080] In the case of advertisement delivery services, the present disclosure also contemplates embodiments in which users selectively block the use of, or access to, personal information data. That is, the present disclosure contemplates that hardware and/or software elements can be provided to prevent or block access to such personal information data. For example, in the case of advertisement delivery services, the present technology can be configured to allow users to select to “opt in” or “opt out” of participation in the collection of personal information data during registration for services.
[0081] Therefore, although the present disclosure broadly covers use of personal information data to implement one or more various disclosed embodiments, the present disclosure also contemplates that the various embodiments can also be implemented without the need for accessing such personal information data. That is, the various embodiments of the present technology are not rendered inoperable due to the lack of all or a portion of such personal information data. For example, content can be selected and delivered to users by inferring preferences based on non-personal information data or a bare minimum amount of personal information, such as the content being requested by the device associated with a user, other non-personal information available to the content delivery services, or publically available information.
[0082] A number of implementations of the invention have been described. Nevertheless, it will be understood that various modifications can be made without departing from the spirit and scope of the invention.
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A mobile device can provide predictive user assistance based on various sensor readings, independently of or in addition to a location of the mobile device. The mobile device can determine a context of an event. The mobile device can store the context and a label of the event on a storage device. The label can be provided automatically by the mobile device or by the external system without user input. At a later time, the mobile device can match new sensor readings with the stored context. If a match is found, the mobile device can predict that the user is about to perform the action or recognize that the user has performed the action again. The mobile device can perform various operations, including, for example, providing user assistance, based on the prediction or recognition.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of Application Ser. No. 229,884 filed Aug. 8, 1988, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the destruction of waste material and, more particularly, it pertains to apparatus for disposing of toxic and hazardous materials by pyroplasmic decomposition.
2. Description of the Prior Art
The disposal of waste material is a growing problem due primarily to the fact that the volume of waste material is growing faster than existing disposal equipment and methods can handle it economically. Most attempts to dispose of waste materials by combustion have included furnaces or rotary kilns. More recently, apparatus and methods for waste destruction have included plasma pyrolysis, such as disclosed in U.S. Pat. No. 4,644,877, by which waste materials are fed into a plasma arc burner where they are atomized, ionized, and subsequently discharged into a reaction chamber to be cooled and recombined into product gases and particulate matter. The method of this patent involves the use of a solvent that is miscible with the waste materials, such as methyl ethyl ketone with PCBS.
While the disposal of waste materials with systems of the type described have been satisfactory, it is desirable to increase the feed throughput and reduce the formation of carbon particulate without the use of expensive solvents such as methyl ethyl ketone (MEK).
SUMMARY OF THE INVENTION
This invention involves a method for the pyrolytic destruction of waste material including the steps of mixing the waste material, water, and/or methanol into a plasma arc having a temperature in excess of 5000° C. to form a mixture of product gases and solid particulate, separating the gases and the particulate mixture in a recombination chamber into separate phases of gases and solid particulate; transferring the solid particulate to a separate compartment and subjecting the particulate to a partial vacuum to separate any carry-over gases from the particulate which carry-over gases are combined with the gases from the recombination chamber; transferring the gas from the recombination chamber to a scrubber and subjecting the gas to a water spray to eliminate any carry-over solid particulate from the gases; and removing the scrubbed gases from the product gas stream.
The invention also comprises apparatus for pyrolytically decomposing waste material which comprises a plasma torch productive of an electric arc having an operating temperature of at least 5000° C. for incinerating a solution of waste material to form a mixture of gases and solid particulate; a recombination chamber for receiving and separating the mixture of gases and solid particulate; a solid separator for providing a partial vacuum for removing any carry-over gases from the solid particulate; a transfer chamber for receiving gases from the recombination chamber; a scrubber for cleaning the gas from the transfer chamber by passing the gas through a water spray; and storage means for gases from the scrubber. In the alternative the transfer chamber is a combustion chamber for the gases and the burned gases are directed to a draft means, such as a stack, for delivery of the burned gases into the atmosphere.
The major advantage of this method and apparatus is that there is at least a threehold increase in the feed throughput with a reduction of the flue gas volume compared with prior art procedures. This process removes the free carbon directly from the recombination chamber and flares the product gases in the combustion chamber. Alternatively, as in the first design the high heating values of the product gases can bypass the combustion process for other use by closing the combustion air stream.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram of a pyroplasma unit of prior art structure.
FIG. 2 is a sectional view through a pyroplasma unit of prior art construction.
FIG. 3 is a flow diagram of the pyroplasma system of this invention.
FIG. 4 is a sectional view through a pyroplasma unit of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A system for pyrolytically decomposing waste material of an existing, or prior art, method is shown diagrammatically in FIG. 1. It comprises a plasma torch 5, a recombination chamber 7, a scrubber 9, a draft fan 11, an inertial trap 13, and a stack 15.
The application of plasma technology to high temperature processes in the organic and inorganic material areas is recognized. The plasma torch by which the process of this invention is preferably performed includes a so-called arc heater which is similar in construction and operation to that disclosed in U.S. Pat. Nos. 3,765,870; 3,791,949; and 4,644,877 in which an electric arc extends between spaced electrodes with the generation of heat for the destruction of hazardous and toxic wastes.
Waste material is fed into the torch 15 at inlet 17 together with a solvent at an inlet 19. A typical waste material is hazardous and toxic and contains a mixture of about 60% polychlorinated biphenyls (PCB) and of about 40% trichlorobenzene (TCB) which is derived from the operation of electric transformers and is commonly referred to as Askarel. Liquid waste material is introduced into the torch feed inlet 17 which together with a solvent comprising a mixture of methyl ethyl ketone (MEK) (50% by weight) and methanol (50%) is introduced (FIG. 1) to supply the hydrogen source to produce hydrogen chloride (HCl). The solvent is miscible with Askarel. The mixture of the feed and solvent is processed at the high temperatures of operation of the plasma arc, typically ranging from 5000° C. to 15,000° C., forming a mixture of product gases and solid particulate, which is directed into the recombination chamber 7, where in the presence of air introduced at inlet 21, produces a gaseous mixture consisting of H 2 O, H 2 , CO, CO 2 , N 2 , and HCl. The gaseous mixture is then directed into the scrubber 9 where a caustic solution of water (NaOH+H 2 O) sprays at 22 the gaseous mixture to eliminate solid particulates and to convert the HCl to NaCl mixed with water. The resulting blow-down water containing NaCl and carbon particulate is drained from the scrubber at outlet 23.
The draft fan 11 transfers the gas from the scrubber 9 to the inertial trap 13 where it is subjected to additional water spray 25 to further eliminate carbon particulate. Blow-down water is drained at 26. From the inertial trap 13 the gas products are flared and vented into the atmosphere through the stack 27. The foregoing comprises the prior art procedure as shown in the flow diagram of FIG. 1.
The torch 15 (FIG. 2) provides a high temperature ionized, conductive gas that is created within the torch. As shown in the above mentioned patents regarding "arc heaters", the torch comprises a pair of cylindrical electrodes 28, 29 that are longitudinally spaced by a gap 31, into which a pressurized gas, such as air, is injected to blow an electric arc 33 into the interior of the torch. The upstream and downstream ends of the arc are located on the electrodes 28, 29. An annular nozzle 35 is located between the electrode 29 and a burner chamber 37 that is contained within a cylindrical insulation 39 through which the plasma plume 41 extends. The nozzle 35 includes a plurality of peripherally spaced, radially extending inlets 43.
Primarily, the prior art procedure involves the use of a mixture of a solvent of MEK and methanol with the waste material (Askarel) which mixture is introduced into the torch 15 through the inlets 43 of the nozzle 35. This prior art procedure processes about 0.1 gallons of PCB per minute. It is noted that the solvent mixture of MEK and methanol is miscible with the PCB and air is used as torch gas to create plasma.
In accordance with this invention the solution is water, which is immiscible with non-polar type waste material, such as PCB and TCB. The water which is mixed with the waste material before introduction into the plasma torch. Pure oxygen (not air) is used as the torch gas. Water supplies hydrogen and oxygen that allows for an increased throughput of waste at a rate of up to twelve times that which is possible in the prior art system of FIG. 1. The waste material or feed is the Askarel fluid. An alternate method to preliminarily mixing the feed and water is to inject the feed and water separately through an air atomizing nozzle into the torch.
The use of the water instead of the MEK-methanol solvent is conducive to higher output of up to one gallon per minute when used in the torch 15 of the prior art FIG. 2.
As was set forth above water provide satisfactory results for the success of this invention. The amount of water mixed with waste is from about 30% to 200% by wt. The preferred amount of water is about 50% that of waste.
The system for pyrolytically decomposing waste material of this invention preferably involves the use of the flow diagram of FIG. 3. The apparatus includes a plasma torch 43, a recombination chamber 45, a combustion chamber 47, a scrubber 49, a draft fan 51, a stack 53, and a storage tank 55. The torch 43 (FIG. 4) provides a high temperature ionized, conductive gas which is created within the torch by the interaction of a gas with an electric or plasma arc 57 produced by the torch 43 in a manner similar to that set forth in the above-mentioned U.S. patents. The interaction within the torch 43 disassociates the gas into electrons and ions which cause the gas to become both thermally and electrically conductive. The conductive properties of the ionized gas in the arc region provides a means to transfer energy from the arc to the incoming process gas. This state is called a "plasma" and exists within the immediate confines of the arc in the torch and is superheated to an extremely high temperature having a typical range of from 5000° C. to 15,000° C.
The extremely high temperatures and the ultraviolet radiation associated with the ionized superheated gases provides sufficient bond breaking energy to destroy the hazardous and toxic wastes. This pyrolytic process is designed to destroy pumpable liquid/solid mixtures with the pyroplasma arc torch 43.
To expedite movement of the material through the system, the feed is injected through a plurality of air atomizing nozzles 59 (FIG. 4) into a manifold 61 where it is mixed with air before it encountered with the plasma plume 57 at temperatures in excess of 5000° C. The compounds in the feed are reformed into compounds which are more stable at reactor temperatures according to basic thermodynamic equilibrium principles. According to the preferred embodiment of this invention the water (without methanol) and feed are mixed homogeneously and introduced through a feed inlet 63 and air enters through an air inlet 65.
Alternatively, the air atomizing nozzle 59 (FIG. 4) receives the waste feed that is mixed with water and/or methanol (up to 25%) and conducted through a static mixer 67, after which it is combined with compressed air at 69. From the nozzle 59 the waste feed 63 is introduced into the manifold 61 which is secured to the recombination chamber 45 by a mounting flange 71. The manifold 61 is annular and is disposed between an outer housing 72 and a sleeve 73 which is comprised of refractory or silicon carbide coated graphite. Within the manifold 61 the waste feed 63 is mixed with the air 65 and is emitted through outlets 75 to form a flame zone 77 with the plasma 79 which zone is the result of partial combustion of waste feed mixtures. As described in the above-mentioned U.S. patents the plasma 79 results from the combination of the electric arc 57 and torch gas 81 introduced through a gap 83 between cylindrical electrodes 85, 87 of the plasma torch 43. The resulting products are projected into the recombination chamber 45.
These products can be controlled by choosing different torch gases, such as pure oxygen, by adding solvent to adjust the elements input to the system, or by choosing the reactor temperature to optimize, or minimize, the formation of certain compounds. In the combustion process, the chlorine will compete with oxygen to form HCL over H 2 O. According to the thermo-equilibrium formula, some of the initial chlorine will become Cl 2 , while the rest of the chlorine converts to HCl. With this relatively high concentration of chlorine and oxygen, coupled with the locally high carbon loading, the formations of chlorinated dioxins and furans are highly possible in a conventional incinerator. It is known that flyash and flue gases from municipal incinerators contain dioxins and furans.
The plasma system of this invention usually operates in a slightly reduced atmosphere and the resulting flue gases are mostly H 2 , CO, CO 2 , C, N 2 , H 2 O, and HCl. From a thermodynamic standpoint all of the chlorine forms HCl because of the high concentrations of H 2 and low concentrations of O 2 . Therefore, there are no free or very low Cl 2 , O 2 , Cl, and OH radicals to form dioxins and furans.
From the torch 43 the product gases together with solid particulate, such as carbon, enter the recombination chamber 45 which is an air filter such as a cyclone separator. The product gases and solid particulate entering the recombination chamber 45 have temperatures ranging from 1000° to 1500° C. with a preferred temperature of 1200° C. In the chamber 45 the product gases exit through an outlet 89 and through a valve 91 to the combustion chamber 47. The dominant portion of the solid particulate 93 settles at the bottom of the chamber 45. There it accumulates until it is dumped.
For that purpose a high temperature dump valve 95 is provided in the bottom wall of the chamber 45 which valve comprises an elongated tube 97 in which a sliding stopper rod 99 is slidably mounted. A rod actuator 101 is provided for lowering the rod in order to open the tube 97 to enable the accumulated solid particulate 93 to drop through the tube and through a conduit 103 into a separator 105. The purpose of the separator is to remove any carry-over gases which are mixed with the particulate in the recombination chamber 45. For that purpose the separator 105 is a cyclone separator into which the solid particulate enters from the conduit 103 with sufficient centrifugal force to throw the solid particulate out against the wall and drop into the lower portion of the separator tank. The separated gas exits from the separator 105 through a filter 107 and through a conduit 109 and a valve 111 from where it is conducted to the combustion chamber 47. To cool the accumulated gas-free solid particulate 93 a heat exchanger having a coolant inlet 113 and a coolant outlet 115 is provided. Ultimately, the solid particulate 93 is discharged from the separator 105 through a discharge valve. The purpose of the filter 107 is to filter out any remaining solid particulate that may be carried by the gas as it exits from the separator 105.
During normal operation of the system with product gases from the torch entering the recombination chamber 45 under centrifugal force and with the particulate 93 accumulating in the lower portion of the chamber, the gases exit from the chamber through a filter 119 and into the outlet 89. Manifestly, the filter 119 like the filter 107 eliminates most of the particulate that may be carried by the gas into the outlet 89 and therefrom into the combustion chamber 47. During that operation the valve 91 is open and the valve 111 in the conduit 109 is closed. Inasmuch as the entire system is closed, the draft fan 51 sustains a partial vacuum through the several parts 45, 47, 49, and the interconnecting conduits therebetween. Accordingly, the gas moves from the recombination chamber 45 through the conduit 119 when valve 91 is opened.
Conversely, when the dump valve 95 is opened, valve 91 is closed and valve 111 is opened, whereby the gas leaving the separator 105 is carried through the conduit 109 to the combustion chamber 47 in response to the partial vacuum created by the draft fan 51.
The combustion chamber 47 has a primary function of burning the process gases (H 2 , CO, CO 2 , N 2 , H 2 O, HCl) which enter the chamber. For that purpose an air inlet 123 is provided to convert those gases to a gas mixture comprising CO 2 , H 2 O, N 2 , and HCl. Thereafter the gas mixture moves through the scrubber 49.
A secondary function of the combustion chamber 47 is to act as a conduit for the product gases leaving the recombination chamber 45. The gas leaves the combustion chamber 47 through a conduit 125 into the scrubber where it is subjected to a water spray having an inlet 127 in order to eliminate any solid particulate which lingers in the gas. The resulting blow-down water 129 containing particulate accumulates in the lower portion of the scrubber 49 from where it is periodically drained through an outlet 131.
In addition to the water entering through the inlet 127, a caustic solution is introduced into the water at 133 for the purpose of converting the HCl in the gas to a chloride compound. A preferred caustic solution is sodium hydroxide (NaOH) which reacts with the HCl in accordance with the following formula:
NaOH+HCl→NaCl+H.sub.2 O.
The resulting compound (NaCl) is drained from the scrubber with the blow-down water 129. The resulting gas mixture includes CO 2 , H 2 O, and N 2 which move through a conduit 135 through the draft fan and through a conduit 137 to the stack 53 where it is dissipated into the atmosphere as a non-toxic gas and devoid of solid particulate.
In the alternative, where the combustion chamber 47 serves as a mere conduit for the product gases entering through the conduit 109, without being burned, the gases pass through the scrubber 49. Again the gases are subjected to the caustic solution to eliminate the HCl and exit from the scrubber via the conduit 135 as combustable fuel consisting of H 2 , CO, CO 2 , N 2 , and H 2 O. From the draft fan 51 the fuel is diverted by a valve 139 and through a conduit 141 to the storage tank 55 from which the fuel is withdrawn as required.
In order to conserve water the foregoing system includes a recycle means for reintroducing the water into the scrubber at 127. For that purpose some of the blow-down water is eliminated at outlet 143 with the remaining blow-down water moving through a liquid solid separator 143 and a heat exchanger 145. The liquid solid separator 143 functions to eliminate any lingering solid particulate. The heat exchanger 145 functions to adjust the water to the desired temperature. Manifestly, any caustic solution remaining in the blow-down water in the scrubber tank is recirculated to the scrubber tank for the purpose intended.
The system of this invention, as shown in FIG. 3 increases the feed throughput at least three gallons/minute and dramatically reduces the fuel gas volume over the system shown in FIG. 1. The system of this invention also removes the free carbon directly from the recombination chamber and flares the product gas in the combustion chamber. The high heating values of the production gases can bypass the combustion process for other usage by closing the combustion air inlet 123. The principle of the solid removal system is initially based on high temperature dump valve 95 which is opened at designated intervals. When the dump valve is closed, valve 91 is opened while valve 111 is closed. Conversely, when the dump valve 95 is opened, valve 91 is closed and valve 111 is opened. In this manner the free carbon (solid particulate) is sucked out of the recombination chamber 45 into the solid separator 105. The quenched free carbons then are removed by lock valve 117. The scrubber effluent is recycled back without the carbon overloading the problem existent in the system of FIG. 1.
The primary differences between the system of this invention (FIG. 4) and that of the prior art (FIG. 1) is that in accordance with this invention water or methanol is used to mix with the feed or waste material to supply hydrogen and oxygen couples with the modified new feed system as shown in FIG. 4 which enables the increase of the throughput of waste approximately 10 times faster than that of the prior art. Moreover, water and methanol is a cheaper solvent than the methyl ethyl ketone/methanol solvent used in the prior art system. Additionally, the method of this invention employs the use of an air atomization nozzle to spray the feed into the plasma stream which improves on the single feed ring of the prior art structure.
The feed system of prior art (FIG. 1) injects the waste feed solution directly into the plasma arc to produce a lot of undesirable carbon especially when processing the chlorinated aromatic compounds. The feed system of the system of FIG. 4 alleviates the carbon formation by mixing air or oxygen before it contacts with the plasma plume.
Further, the recombination chamber 45 of this method removes most of the solid before entering the combustion chamber. Because the recombination chamber separates most of the particulate, a higher feed throughout the plasma torch is possible compared to the prior art. At the same time larger particles of particulate can be fed because it is readily eliminated through the solid separator.
Furthermore, the combustion chamber may be used as a conduit for the product gases from the recombustion chamber without burning the gases so that the gases may be used as a fuel instead of being flared and discarded through the stack.
Additionally, a water consumption can be reduced by recycling the blowdown water from the scrubber.
Finally, alternate torch gases, such as oxygen, may be employed instead of air to increase the throughput and to reduce the formation of cyanide (HCN) which results from nitrogen in the air. Thus, the problem of the formation of cyanide in the prior art system is virtually eliminated.
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A method and apparatus for pyrolytically decomposing waste material characterized by injecting a mixture of waste and water into a plasma torch having an operation temperature of in excess of 5000° C. to form a mixture of product gases and solid particulate; separating the gases and particulate in a first cyclone separator into separate phases; transferring the particulate to a second cyclone separator and subjecting the particulate to a partial vacuum to separate any carryover gases from the particulate; subjecting the combined reaction chamber and carry over gases in a scrubber to a spray consisting of a caustic solution and water to eliminate any carryover particulate from the gases and to neutralize and HCl in the gases; and removing the gases from the scrubber.
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FIELD OF THE INVENTION
The invention relates generally to self-inflating tires and, more specifically, to a pump mechanism for such tires.
BACKGROUND OF THE INVENTION
Normal air diffusion reduces tire pressure over time. The natural state of tires is under inflated. Accordingly, drivers must repeatedly act to maintain tire pressures or they will see reduced fuel economy, tire life and reduced vehicle braking and handling performance. Tire Pressure Monitoring Systems have been proposed to warn drivers when tire pressure is significantly low. Such systems, however, remain dependant upon the driver taking remedial action when warned to re-inflate a tire to recommended pressure. It is a desirable, therefore, to incorporate a self-inflating feature within a tire that will self-inflate the tire in order to compensate for any reduction in tire pressure over time without the need for driver intervention.
DEFINITIONS
“Aspect ratio” of the tire means the ratio of its section height (SH) to its section width (SW) multiplied by 100 percent for expression as a percentage.
“Asymmetric tread” means a tread that has a tread pattern not symmetrical about the center plane or equatorial plane EP of the tire.
“Axial” and “axially” means lines or directions that are parallel to the axis of rotation of the tire.
“Buffer volume” means the pump minimum volume.
“Chafer” is a narrow strip of material placed around the outside of a tire bead to protect the cord plies from wearing and cutting against the rim and distribute the flexing above the rim.
“Circumferential” means lines or directions extending along the perimeter of the surface of the annular tread perpendicular to the axial direction.
“Equatorial Centerplane (CP)” means the plane perpendicular to the tire's axis of rotation and passing through the center of the tread.
“Footprint” means the contact patch or area of contact of the tire tread with a flat surface at zero speed and under normal load and pressure.
“Inboard side” means the side of the tire nearest the vehicle when the tire is mounted on a wheel and the wheel is mounted on the vehicle.
“Lateral” means an axial direction.
“Lateral edges” means a line tangent to the axially outermost tread contact patch or footprint as measured under normal load and tire inflation, the lines being parallel to the equatorial centerplane.
“Net contact area” means the total area of ground contacting tread elements between the lateral edges around the entire circumference of the tread divided by the gross area of the entire tread between the lateral edges.
“Non-directional tread” means a tread that has no preferred direction of forward travel and is not required to be positioned on a vehicle in a specific wheel position or positions to ensure that the tread pattern is aligned with the preferred direction of travel. Conversely, a directional tread pattern has a preferred direction of travel requiring specific wheel positioning.
“Outboard side” means the side of the tire farthest away from the vehicle when the tire is mounted on a wheel and the wheel is mounted on the vehicle.
“Peristaltic” means operating by means of wave-like contractions that propel contained matter, such as air, along tubular pathways.
“Peristaltic pump tube” means a tube formed or molded in a tire or an embedded tube which may be inserted post cure or pre-cure.
“Pump minimum volume” or “buffer volume” means the smallest value of the pump variable volume.
“Pump maximum volume” means the volume of fluid located between the peristaltic pump tube inlet and the outlet valve.
“Pump variable volume” means the volume of fluid located between the pinched tube path and the entry of the outlet valve.
“Radial” and “radially” means directions radially toward or away from the axis of rotation of the tire.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of example and with reference to the accompanying drawings in which:
FIG. 1 is an isometric view of the valve, tube and filter for a peristaltic pump assembly.
FIG. 2 is a side view of the assembly of FIG. 1 shown mounted in a tire.
FIG. 3 is an enlarged partial cross sectional view of the tire and rim assembly with the pump valve mechanism shown mounted in the tire.
FIG. 3A is an enlarged perspective view of the pump valve mechanism of FIG. 3 .
FIG. 4 is a perspective view of a first embodiment of a regulator mechanism of the present invention.
FIG. 5 is a partial section view through the regulator mechanism of FIG. 4 in the direction 5 - 5 .
FIGS. 6 and 7 are cross-sectional views of the regulator mechanism in operation, in the closed position and the open position, respectively.
FIG. 8 is a perspective view of a second embodiment of a regulator mechanism of the present invention shown in a first position.
FIG. 9 is perspective view of the regulator mechanism of FIG. 8 shown in a second position.
FIG. 10 is a perspective view of the adjustable cap of the regulator mechanism of FIG. 8 .
FIG. 11 is a perspective view of a second embodiment of a pump system of the present invention.
FIGS. 12A and 12B illustrate front views of an interchangeable valve body.
FIGS. 13A , 13 B and 13 C represent an illustration of the pump maximum volume, the pump variable volume, and the buffer or pump minimum value.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 through 3 , a tire assembly 10 includes a tire 12 , a peristaltic pump assembly 14 , and a tire rim 16 . The tire mounts in a conventional fashion to a pair of rim mounting surfaces 18 located adjacent outer rim flanges 20 . The outer rim flanges 20 have an outer rim surface 22 that engages the bead area of the tire. The tire is of conventional construction, having a pair of sidewalls 30 extending from opposite bead areas 34 to a crown or tire tread region 38 . The tire and rim enclose a tire cavity 40 .
As shown in FIGS. 1-2 , the peristaltic pump assembly 14 includes a pump tube 42 that is mounted in a tire passageway 44 , which is preferably located in the sidewall area of the tire, preferably near the bead region. The tire passageway is preferably molded into the sidewall of the tire during vulcanization and is preferably annular in shape. The pump tube 42 has a first end 42 a joined together by an inlet device 46 and a second end 42 b joined together with an outlet device 50 . The pump tube 42 is comprised of a tube formed of a resilient, flexible material such as plastic, silicone, elastomer or rubber compounds, and is capable of withstanding repeated deformation cycles when the tube is deformed into a flattened condition subject to external force and, upon removal of such force, returns to an original condition generally circular in cross-section. The tube is of a diameter sufficient to operatively pass a volume of air sufficient for the purposes described herein and allowing a positioning of the tube in an operable location within the tire assembly as will be described. Preferably, the tube has a circular cross-sectional shape, although other shapes such as elliptical or lens shape may be utilized. Alternatively, the passageway 44 molded or formed into the tire sidewall may serve as the pump tube 42 .
As shown in FIG. 2 , the inlet device 46 and the outlet device 50 are spaced apart a desired distance typically in the range of approximately 90 degrees or more, typically about 180 degrees to 360 degrees. If 180 degrees is selected, two 180 degree pumps may be used. The inlet and outlet device may be located adjacent each other, thus forming a single 360 degree pump. Other variations may be utilized, such as 270 degrees, etc.
The inlet device 46 in its simplest form may be the inlet tube end exposed to the atmosphere. The inlet device may optionally comprise a check valve and/or an optional filter. The outlet device 50 is a pressure and flow regulating device, and regulates the tire cavity maximum pressure. The outlet device 50 also functions to regulate the flow into and out of the tire cavity. The outlet device is described in more detail, below.
As will be appreciated from FIG. 2 , the inlet device 46 and the outlet device 50 are in fluid communication with the circular air tube 42 . As the tire rotates in a direction of rotation 88 , a footprint 100 is formed against the ground surface 98 . A compressive force 104 is directed into the tire from the footprint 100 and acts to flatten a segment 110 of the pump 42 . Flattening of the segment 110 of the pump 42 forces a portion of air located between the flattened segment 110 and the outlet device 50 , in the direction shown by arrow 84 towards the outlet device 50 . The portion of air will then regulated through the outlet device 50 . If the pressure at the inlet of the outlet device is sufficiently high, the internal valve will open and fill the tire cavity, as described in more detail, below.
As the tire continues to rotate in direction 88 , the previously flattened tube segments 110 , 110 ′, 110 ″ will be sequentially refilled by atmospheric air flowing into the inlet device 46 along the pump tube 42 . The inflow of air from the inlet device 46 continues until the outlet device 50 rotating counterclockwise as shown with the tire rotation 88 , passes the tire footprint 100 .
The location of the peristaltic pump assembly will be understood from FIGS. 2-4 . In one embodiment, the peristaltic pump assembly 14 is positioned in the tire sidewall, radially outward of the rim flange surface 26 in the chafer 120 . So positioned, the air tube 42 is radially inward from the tire footprint 100 and is thus positioned to be flattened by forces directed from the tire footprint as described above. The segment 110 that is opposite the footprint 100 will flatten from the compressive force 114 from the footprint 100 pressing the tube segment against the rim flange surface 26 . Although the positioning of the tube 42 is specifically shown as between a chafer 120 of the tire at the bead region 34 and the rim surface 26 , it is not limited to same, and may be located at any region of the tire such as anywhere in the sidewall or tread. The diametric sizing of the peristaltic pump air tube 42 is selected to span the circumference of the rim flange surface 26 .
Pressure Regulating Outlet Device
The regulator device 50 is a pressure and flow regulating device, and regulates the tire cavity maximum pressure. The regulator device 50 also functions to regulate the flow into and out of the tire cavity. The regulator device has a valve body 52 having a first end 53 that has a valve passageway 54 that extends from the first end to a second end 56 . The first end of the valve body 52 is mounted through the tire sidewall as shown in FIGS. 3 , 3 A so that the valve passageway 54 is in fluid communication with the tire cavity 40 . The valve passageway 54 has an expanded portion 58 and a narrow portion 60 . A large ball 62 is received in the expanded portion 58 and positioned for engagement with the narrow portion 60 . A spring 64 is positioned within the valve passageway for engagement with the ball 62 . The spring 64 biases the ball into engagement with the narrow portion 60 , so that flow is blocked in the interior passageway 54 .
The second end 56 of the valve body has an outer threaded portion 57 that is received within a first threaded end 70 of an adjustable housing 72 . The adjustable housing has an internal cavity 74 that extends from the first threaded end 70 to the second threaded end 76 . The internal cavity 74 has a fixed buffer volume portion and an adjustable buffer volume portion. The fixed volume portion is defined by the non-threaded inner wall of the internal cavity having a length C. The fixed volume is equal to the cross-sectional area of the internal cavity times the length C. The adjustable volume portion is defined by the amount of the threaded length that is exposed within the internal cavity and is indicated as distance B. The adjustable volume is determined from the distance B times the cavity cross-sectional area. The distance B may be zero if the valve body is fully received within the adjustable housing. The adjustable housing and respective internal buffer volumes may be modified by substituting the adjustable housing as shown in FIG. 12 A in order to increase the fixed buffer volume or by substituting the adjustable housing as shown in FIG. 12 b in order to decrease the fixed buffer volume.
The regulator device 50 further comprises an elbow fitting 80 having a first end 82 connected to the adjustable housing inlet end 76 and a second end 84 connected to the pump tube outlet 42 b . The second end of the elbow fitting 80 may comprise a flared fitting 86 .
The maximum air pressure delivered by the peristaltic pump can be fixed by setting the volume of the pump tube and the buffer volume located between the end of the tube and the check valve and the adjustable buffer chamber. The pump tube volume is selected by design with the tube dimensions and the tube length. As shown in FIG. 11 , multiple pump tubes may be used, with the selection of the tube length and inner tube dimensions to tune the system. The buffer or dead volume can also be set by design. The air in the buffer volume chamber is not compressed, but functions to tune or adjust the maximum air pressure of the pump system. The buffer volume acts as a storage chamber for accumulating air mass for transfer to the tire cavity. Increasing the buffer volume will decrease the tire pressure, while decreasing the buffer volume will increase the tire cavity pressure. Thus, by adjusting the buffer volume, one can adjust the desired tire final pressure.
The operation of the system and the outlet device 50 can now be described. As shown in FIG. 2 , the tire rotates in a direction of rotation 88 , and a footprint 100 is formed against the ground surface 98 . A compressive force 104 is directed into the tire from the footprint 100 and acts to flatten a segment 110 of the pump 42 . Flattening of the segment 110 of the pump 42 forces a portion of air located between the flattened segment 110 and the regulator device 50 , in the direction shown by arrow 84 towards the outlet device 50 . The portion of air will then be regulated through the outlet device 50 . If the pressure at the inlet 86 of the regulator device is sufficiently high, the fluid pressure will overcome the spring pressure 54 (cracking pressure), thus opening the internal check valve. Thus fluid from the pump outlet 42 b will flow into the elbow fitting 80 and into the adjustable housing 72 .
If the pressure in the pump tube 42 b is less than the tire pressure, the ball 62 will engage the narrow portion 60 and block flow from either direction. The check valve 62 when closed, blocks flow from communicating from the pump 42 b into the tire cavity 40 , and also prevents back flow from the tire cavity into the pump 42 . When the check valve is closed, the pump compresses the air in the pump tube 42 . Air from the pump tube enters the elbow fitting 80 of the regulator device, and then enters the buffer volume chamber 74 . The buffer volume chamber will fill while the check valve remains closed. When the pressure in the inlet 56 of the regulator device exceeds the cracking pressure, the check valve opens and will allow air from the pump to fill the tire cavity. The check valve will close when the inlet pressure P T falls below the cracking pressure. The cycle of opening and closing the check valve will allow the tire cavity to be filled as the tire rotates a specified distance. A maximum tire cavity will be reached based upon the pump volume and the buffer volume. The buffer volume may be adjusted by turning the valve body 52 relative to the adjustable housing. Increasing the buffer volume results in a decrease of tire final pressure, while decreasing the buffer volume results in an increase of the tire final pressure. The advantage of having an adjustable buffer volume allows the maximum system pressure of the tire cavity to be tuned for a specific tire.
FIGS. 8-10 illustrate a second embodiment of a pressure regulator 200 . The pressure regulator 200 comprises a valve body 202 having an internal passageway 204 that extends through the valve body 202 . The internal passageway 204 includes a movable check valve assembly 206 . The movable check valve assembly includes a ball 208 , a spring 210 housed within a receptacle 212 . The receptacle has a retainer 214 which retains the ball 208 within the check valve assembly. The outer edge of the receptacle may have external threads like a screw, so that the receptacle may be screwed into or out of the internal passageway 204 . A variable buffer volume 220 is located adjacent the movable check valve assembly, so that when the movable check valve assembly is rotated clockwise, the variable buffer volume decreases. The outer receptacle of the check valve may have notations on it to indicate to a user to indicate the relationship of the number of turns to the volume adjustment. Alternatively, the movable check valve may slide within the passageway 204 , with retaining means located within the passageway which allow the position of the movable check valve to be repeatedly adjusted and then fixed in position.
The valve body 202 of the pressure regulator 200 further comprises a second portion 222 which is at right angles to the first portion 224 of the valve body. The second portion has an interior fixed dead volume 230 which is in fluid communication with the variable volume 220 . Located adjacent the interior fixed dead volume 230 is an outlet 240 . The outlet 240 is connected to the pump tube outlet 42 b . The second portion 222 is mounted in the tire, typically in the sidewall and connected to the pump tube outlet 42 b . The first portion 224 of the valve body is mounted through the sidewall and into the tire cavity 40 .
The operation of the system and the outlet device 200 can now be described. As shown in FIG. 2 , the tire rotates in a direction of rotation 88 , and a footprint 100 is formed against the ground surface 98 . A compressive force 104 is directed into the tire from the footprint 100 and acts to flatten a segment 110 of the pump 42 . Flattening of the segment 110 of the pump 42 forces a portion of air located between the flattened segment 110 and the regulator device 200 , in the direction shown by arrow 84 towards the outlet device 200 . The portion of air will then be regulated through the outlet device 200 . If the pressure at the inlet of the regulator device is sufficiently high, the fluid pressure will overcome the spring pressure (cracking pressure), thus opening the internal check valve. Thus fluid from the pump outlet 42 b will flow into the regulator and out into the tire cavity through a hole in the adjustable check valve assembly.
If the pressure in the pump tube 42 b is less than the tire pressure, the ball 208 will engage the narrow portion 214 and block flow from either direction. The check valve when closed, blocks flow from communicating from the pump 42 b into the tire cavity 40 , and also prevents back flow from the tire cavity into the pump 42 . When the check valve is closed, the pump compresses the air in the pump tube 42 . Air from the pump tube enters the regulator device, and fills the buffer volume chambers 220 , 230 . When the pressure to the inlet of the regulator device exceeds the cracking pressure, the check valve opens and will allow air from the pump to fill the tire cavity. The check valve will close when the inlet pressure P T falls below the cracking pressure. The cycle of opening and closing the check valve will allow the tire cavity to be filled as the tire rotates a specified distance. A maximum tire cavity will be reached based upon the pump volume and the buffer volume. The buffer volume may be adjusted by turning the adjustable check valve relative to the housing. Increasing the buffer volume results in a decrease of tire final pressure, while decreasing the buffer volume results in an increase of the tire final pressure. The advantage of having an adjustable buffer volume allows the maximum system pressure of the tire cavity to be tuned for a specific tire.
The table below indicates exemplary tires, all having the same internal tire volume of 38 L and initial tire pressure of 1.8 Bar. All of the exemplary pumps have a circumferential length of 180 degrees. Examples 1 and 2 have a pump size of 2×1 with a pump volume of 1036 mm3. For example 1 the buffer volume is selected to be 459 mm3, resulting in a desired final tire pressure of 2.2 bar. A distance of 241 km is needed to achieve the final tire pressure. If the buffer volume is decreased to 351 mm3, with all other variables being equal, the final tire pressure will be 2.9 bar (Ex. 2) as compared to 2.2 bar for Ex. 1. A longer distance of 490 km will be needed to achieve a higher final tire pressure of 2.9 bar.
Examples 3 and 4 illustrate a smaller tube size resulting in a smaller pump volume of 700 mm3. For a buffer volume of 310 mm3 (Ex 3) results in a final tire pressure of 2.2 bar and a needed distance of 355 km to achieve the final tire pressure. Ex 4 illustrates all the properties of Ex. 3, except for a smaller buffer volume of 237 mm3, resulting in a higher final tire pressure of 2.9 bar achieved in 727 km.
Examples 5-8 have the same properties as examples 1-4, with example 5 corresponding with example 1, etc. the cracking pressure of the valve is higher for examples 5-8 as compared to 1-4. A slightly lower buffer volume is needed in examples 5-8 to achieve the same final tire pressure as examples 1-4. The higher cracking pressure also results in a significantly shorter distance to be traveled by the pump/tire in order to result in the final tire pressure. The volume ratios of the buffer volume to pump volume may be used to determine a new buffer volume should the pump volume or cavity volume change. The buffer volume may be adjusted by rotating screw 66 . The number of turns of the screw (e.g. 5 turns) would result in a distance of 4 mm with a screw pitch of 75 mm.
Cavity
A
B
C
D
Cracking
Volume
Tire
Initial Tire
Buffer Volume
Final Tire
Needed
Volumes
Pressure
Angle
Size
[mm3]
Volume
pressure
[mm3]
pressure
Distance
Ratio
0.1 bar
180
2 × 1
1036
38 L
1.8 bar
459
2.2 bar
241 km
0.443
180
2 × 1
1036
38 L
1.8 bar
351
2.9 bar
490 km
0.339
180
2.7 × 0.5
699.5
38 L
1.8 bar
310
2.2 bar
355 km
0.443
180
2.7 × 0.5
699.5
38 L
1.8 bar
237
2.9 bar
727 km
0.339
0.3 bar
180
2 × 1
1036
38 L
1.8 bar
422
2.2 bar
137 km
0.407
180
2 × 1
1036
38 L
1.8 bar
329
2.9 bar
324 km
0.318
180
2.7 × 0.5
699.5
38 L
1.8 bar
285
2.2 bar
203 km
0.407
180
2.7 × 0.5
699.5
38 L
1.8 bar
222.5
2.9 bar
485 km
0.318
The maximum air pressure delivered by a peristaltic pump embedded in a tire can be fixed by setting the right volume of the pump tube and the buffer volume. The pump tube volume can be set by design with the dimensions of the tube sections and tube length. The buffer volume can also be set by design but can also be easily manually changed by the mean of a dedicated device or by interchanging appropriate parts before the valve. This can be implemented with either a set of tube with different lengths or a set of small tanks to be inserted before the valve.
Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.
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A self-inflating tire assembly includes an air tube connected to a tire and defining an air passageway, the air tube being composed of a flexible material operative to allow an air tube segment opposite a tire footprint to flatten, closing the passageway, and resiliently unflatten into an original configuration. The air tube is sequentially flattened by the tire footprint in a direction opposite to a tire direction of rotation to pump air along the passageway to an inlet device for exhaust from the passageway or to an outlet device for direction into the tire cavity. The inlet device is positioned within the annular passageway 180 degrees opposite the outlet device such that sequential flattening of the air tube by the tire footprint effects pumping of air along the air passageway with the tire rotating in either a forward or reverse direction of rotation. The invention further includes an outlet device for regulating the tire cavity pressure and flow into the cavity.
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BACKGROUND OF THE INVENTION
This invention relates to an apparatus for indicating the status of sheets, and has particular application to an apparatus for indicating the status of currency notes.
In automatic currency note handling apparatus, such as cash dispensers or note counters, it is often necessary to detect the passage of multiple notes and to detect folds therein and any local attachments such as adhesive tape, staples or paper clips. In some applications, such as in a cash dispenser, it may be desired to count double notes as two notes and dispense them to a customer, while any notes having local attachments or folds are diverted to a reject bin as being in an unfit condition for dispensing to a customer. On the other hand, in other applications it may be desired to divert multiple notes into a reject bin but to permit notes having folds or local attachments to be passed through the apparatus for further handling. Thus, in order to optimize the operation of automatic currency note handling apparatus, it is desirable to identify not only the presence of an abnormality in note flow, but also to identify the particular type of abnormality so that proper action can be taken.
An apparatus for indicating the status of sheets and which is capable of distinguishing between different types of abnormalities, for example between a double sheet and a sheet carrying a local attachment, is known from European Patent Application No. 82306037.1 (Publication No. 0, 080, 309). An apparatus known from this European application includes a datum roller and a follower roller between which currency notes are fed in operation, the datum roller having a fixed axis and the axis of the follower roller being movable relative to that of the datum roller. The follower roller is biased towards the datum roller, and the ends of the follower roller are each supported by a pivotable bracket whereby the axis of the follower roller is tiltable relative to that of the datum roller. Two sensors are respectively arranged adjacent the ends of the follower roller. In response to a note passing through the nip of the rollers, each sensor produces a change in its output voltage, the magnitude of the change being dependent on the amount by which the corresponding end of the follower roller is displaced from the platen roller. The output voltages of the sensors are applied to an analyzing circuit whereby it is possible to determine an abnormality in the note flow such as a double note or a note having a fold or a local attachment. The sensors may be implemented by linear variable differential transformers.
The disadvantage of the known apparatus described above is that it may not be capable of distinguishing between a double currency note and a single note carrying a centrally positioned adhesive tape extending across the whole width of the note, as in the case of two halves of a torn note joined together by adhesive tape (which is a situation commonly encountered). Thus, if a note passing through the apparatus has such centrally positioned tape of thickness equal to that of the note, the two ends of the follower roller will be displaced from the datum roller by the same amount as would be the case if a double note were passing through the nip of the rollers.
SUMMARY OF THE INVENTION
It is accordingly an object of this invention to provide an apparatus for indicating the status of sheets which apparatus does not suffer from the disadvantage referred to above.
In a preferred embodiment of this invention, there is provided an apparatus for indicating the status of sheets passing therethrough, comprising: first and second rollers between which said sheets pass in operation; means for mounting said first roller on a first axis of rotation; means for mounting said second roller so that its axis is pivotable relative to that of said first roller and so that it is biased towards said first roller to enable the ends of said second roller to be displaced from corresponding ends of said first roller in response to a said sheet passing between said first and second rollers; first and second sensing devices spaced apart along said second roller and each arranged to produce an output signal which changes in dependence on the amount of movement of the adjacent part of said second roller towards or away from said first roller; and biasing means for applying at least one pivoting moment to said second roller as a said sheet passes between said first and second rollers.
BRIEF DESCRIPTION OF THE DRAWING
The preferred embodiment of this invention will now be described by way of example with reference to the accompanying figures, in which:
FIG. 1 is a front, elevational view of a currency note status indicating apparatus made according to this invention;
FIG. 2 is a plan view of the apparatus shown in FIG. 1;
FIG. 3 is a side, elevational view of the apparatus shown in FIG. 1, taken along the line III--III of FIG. 1;
FIG. 4 is a part-sectional, elevational view taken along the line IV--IV of FIG. 1;
FIGS. 5A to 5F show a series of waveforms representing the outputs of the sensors of the apparatus of FIG. 1; and
FIG. 6 is a block diagram of a means for analyzing the outputs of the sensors of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 to 4, the currency note status indicating apparatus, designated generally as 9, includes first and second steel rollers 10 and 12 (shown partly broken away in FIG. 1) between which currency notes whose status is to be determined are passed in operation. The roller 10 has a fixed axis of rotation, and the axis of the roller 12 is movable relative to that of the roller 10. The length of each of the rollers 10 and 12 is somewhat greater than the lengths of the notes, so that the whole of each note passes between the rollers 10 and 12.
The rollers 10 and 12 are rotatably mounted between two fixed, parallel side plates 14 and 16 of a support frame 17 (FIG. 2). The roller 10 is supported by two shafts 18 (FIG. 3) respectively extending from the ends thereof and rotatably mounted on the side plates 14 and 16. The roller 12 is similarly supported by two shafts 20 respectively extending from the ends thereof and passing through clearance apertures (not shown) formed in the side plates 14 and 16. Meshing gear wheels 22 and 24 (FIG. 3) are respectively secured to the ends of the shafts 18 and 20 projecting beyond the side plate 14. Two shafts 26 and 28 (FIG. 1) are rotatably mounted one above the other between the side plates 14 and 16, the shafts 26 and 28 carrying cooperating rubber feed rolls 30 and 31. The shaft 28 is driven by an electric motor (not shown). Meshing gear wheels 32 and 34 (FIG. 3) are respectively secured to corresponding ends of the shafts 26 and 28 projecting beyond the side plate 14, the gear wheel 32 being connected to the gear wheel 22 via an intermediate gear wheel 36 rotatably mounted on the side plate 14.
Referring particularly to FIG. 3, the support shafts 20 for the roller 12 are rotatably supported by corresponding ends of support arms 38, the other ends of the arms 38 being rotatably mounted on the shaft 28. The support arms 38 permit the roller 12 to rest in contact with the roller 10 when no currency note is passing through the apparatus, and permit the roller 12 to be moved upwardly away from the roller 10 when notes are passing between them. Also, the mounting arrangement for the roller 12 permits the axis of this roller to be tilted relative to the axis of the roller 10 if, for example, a currency note having a local attachment at one side passes between the rollers 10, 12.
Two brushes 40 (shown partly broken away in FIG. 2) are mounted (via plates 41) between the side plates 14 and 16, each brush 40 engaging a respective one of the rollers 10 and 12 along the whole length thereof for the purpose of removing from the roller any dirt which may have been transferred to it from currency notes passing through the apparatus.
The apparatus 9 employs two sensors 42 and 43 (FIGS. 1-4) which are mounted on support brackets 44 and which are respectively positioned adjacent to the ends of the roller 12. Each sensor 42 and 43 has a sensing stylus 46 (FIG. 1) which engages the upper surface of a respective interface arm 48, the lower surface of each arm 48 being provided with a curved recess 49 (FIG. 4) which engages the roller 12. Each of the sensors 42 and 43 produces an output voltage that varies in response to movement of the respective sensing stylus 46, the magnitude of the voltage change being in direct proportion to the amount of stylus movement. The sensors 42 and 43 are preferably implemented by linear, variable differential transformers, such as model 1305 manufactured by Penny and Giles Limited of Christchurch, England.
The interface arms 48 (FIG. 4) are made of low friction, hard-wearing plastics material. Each arm 48 is pivotally mounted at one end on a respective stud 50 secured to the adjacent side plate 14 or 16, the arm 48 being urged into engagement with the roller 12 by means of a respective tension spring 52. The end of each spring 52 that is remote from the respective arm 48 is connected to a stud 54 that is secured to the adjacent side plate 14 or 16.
As mentioned previously, the axis of the roller 12 (FIG. 1) is tiltable relative to that of the roller 10. The apparatus includes a rocking means for applying a rocking moment to the roller 12 while a note is passing between the rollers 10 and 12, for a reason which will be explained hereinafter. The rocking means includes rubber biasing rolls 56 and 58 each of which is rotatably mounted on one end of a respective bell-crank lever 60 (seen best in FIG. 4) pivotally mounted on a shaft 62 extending between the side plates 14 and 16. The rolls 56 and 58 engage the roller 12 and are disposed on either side of the center of the roller 12. Two cam followers 64 and 65 are respectively mounted on those ends of the bellcrank levers 60 that are remote from the rolls 56 and 58. The cam followers 64 and 65, respectively, engage two cams 66 and 67 that are secured to the shaft 28. The cams 66 and 67 have the same configuration; however, they are angularly displaced with respect to each other on the shaft 28. Each cam 66 and 67 has a high region 68 (see FIG. 4) which extends over approximately one-third of the periphery of the cam, and the cams 66 and 67 are so arranged that the high region 68 of the cam 67 comes into engagement with the follower 65 immediately after the high region 68 of the cam 66 becomes disengaged from the follower 64. Thus, as the shaft 28 rotates, the roll 56 applies a rocking moment to the roller 12 (in a counterclockwise direction with reference to FIG. 1) when the high region 68 of the cam 66 is in contact with the follower 64. Immediately following the end of the application of this counterclockwise rocking moment, the roll 58 applies a rocking moment to the roller 12 in a clockwise direction (as viewed in FIG. 1) when the high region 68 of the cam 67 is in contact with the follower 65. It should be understood that the resilient nature of the rolls 56 and 58 permits a certain amount of movement of the roller 12 away from the roller 10, or permits a small tilting movement of the roller 12, to take place. Also, it should be understood that the gear wheels 22 and 24 intermesh to a sufficient extent to ensure that they remain in engagement with each other despite any displacement of the adjacent end of the roller 12 away from the roller 10 which may occur in operation.
In operation, the drive shaft 28 brings about rotation of the rollers 10 and 12 and the shaft 26 in the directions indicated by the arrows in FIG. 4 via the gear train 22, 24, 32, 34, and 36. Currency notes to be sensed, such as the note 70 shown in FIG. 2, are fed one by one to the apparatus 9 in the direction indicated by the arrow 72, the long dimension of each note being parallel to the axes of the shafts 26 and 28. Each note 70 is gripped in turn by the feed rolls 30 and 31 and is fed by them into the nip of the steel rollers 10 and 12, the note then passing between the rollers 10 and 12 and being driven by them out of the apparatus 9 for further processing.
Reference will now be made to FIGS. 5A to 5F in connection with a further explanation of the operation of the apparatus 9. As a single note 70 passes between the rollers 10 and 12, the roller 12 is displaced upwardly away from the roller 10, thereby bringing about an increase in the output voltages of the sensors 42 and 43 as shown in FIG. 5A which represents the output voltage of each of the sensors 42 and 3 when a single note passes between the rollers 10 and 12. FIG. 5B represents the output voltage of each of the sensors 42 and 43 when a double note passes between the rollers 10 and 12; in this case, the increase in output voltage is about twice that which occurs for a single note passing between the rollers 10, 12. In both FIGS. 5A and 5B, time t 1 represents the time when the single or double note enters the nip of the rollers 10 and 12, and time t 5 represents the time when the single or double note leaves the nip of the rollers.
FIGS. 5C and 5D, respectively, show the output voltages of the sensors 42 and 43 when the right-hand trailing corner (with reference to FIG. 2) of a note 70 carries a local attachment such as adhesive tape (or when this corner is folded over), times t 1 and t 5 again representing the times when the note enters and leaves the nip of the rollers 10 and 12. In this case, the increase in the output voltage of the sensor 42 is substantially the same as that shown of the sensor 42 is substantially the same as that in the case of a normal, single note passing between the rollers 10 and 12. However, with regard to the output voltage of the sensor 43 when the local attachment enters the nip of the rollers 10 and 12 at time t 4 , there is an additional increase in the output voltage of the sensor 43 due to the displacement of the adjacent end of the roller 12 away from the roller 10, the axis of the roller 12 tilting relative to that of the roller 10.
FIGS. 5E and 5F, respectively, show the output voltages which occur when there passes between the rollers 10 and 12 a note carrying a length of adhesive tape centrally positioned relative to the short edges of the note, as indicated by the attachment 74 indicated in dotted outline in FIG. 2. In the arrangement illustrated, at the time t 1 when such a note 70 enters the nip of the rollers 10 and 12, both followers 64 and 65 are in engagement with the low regions of the cams 66 and 67 so that initially both sensors 42 and 43 produce output voltages corresponding to the outputs which they produce when a double note passes between the rollers 10 and 12 (it being assumed that the thickness of the tape is substantially equal to the thickness of the note). Upon the high region 68 of the cam 66 coming into engagement with the follower 64 at time t 2 , the associated roll 56 bears down on the adjacent part or first half of the roller 12 so that the roller 12 rocks in a counterclockwise direction (with reference to FIG. 1) about the attachment 74, thereby bringing about an additional increase in the output voltage of the sensor 43 (FIG. 5F) and a decrease in the output voltage of the sensor 42 (FIG. 5E). Upon the high region 68 of the cam 67 coming into engagement with the follower 65 at time t 5 (at which time the high region 68 of the cam 66 moves out of engagement with the follower 64), the roll 58 bears down on the second half of the roller 12, and the roller 12 rocks in a clockwise direction about the attachment 74, thereby bringing about an increase in the output voltage of the sensor 42 and a decrease in the output voltage of the sensor 43. At time t 5 , the note leaves the nip of the rollers 10 and 12, whereupon, the output of each of the sensors 42 and 43 returns to its initial value. Also, in the arrangement illustrated, at time t 5 , the low region of the cam 67 returns into engagement with the follower 65.
Thus, by virtue of the pivotal mounting of the roller 12 and the cam-controlled biasing rolls 56 and 58, the apparatus 9 is capable of distinguishing between a double note and a single note having a local attachment in the form of a length of adhesive tape centrally positioned relative to the short edges of the note. A waveform such as that shown in FIG. 5B indicates a double note, and the waveforms shown in FIGS. 5E and 5F indicate a single note with a central local attachment.
Means for analyzing the outputs of note sensors in order to determine the status of notes are generally known, and such means do not form part of the present invention. For example, such means are disclosed in UK Patent Applications having Publications Nos. 2058725A and 2106081A and in European Patent Application having Publication No. 0064523. An example of a software approach for analyzing the status of notes in response to the outputs of the sensors 42 and 43 is schematically illustrated in FIG. 6 of the accompanying drawings.
Referring to FIG. 6, the outputs of sensors 42 and 43 are applied via respective amplifiers 76 to analog to digital input ports of a microprocessor 78. The microprocessor 78 can be implemented by a BBC microcomputer type B sold by Acorn Computer Ltd. of Cambridge, England. The microprocessor 78 is programmed to analyze the outputs of the sensors 42 and 43 in order to detect the passage through the apparatus 9 of a single note, double notes, or a note having a local attachment or fold. The output of the microprocessor 78 is applied to utilization means (not shown) which may, for example, include counting means arranged to count a double note as two notes, and is also applied to a diverter gate which diverts notes having local attachments or folds into a reject bin.
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A note checking apparatus for indicating whether normal single notes, double notes or notes having local attachments of folds are passing therethrough includes two rollers 10 and 12 between which the notes pass. The roller 10 has a fixed axis, and the roller 12 is supported by pivotably mounted arms 38 so that it is movable away from, and pivotable relative to, the roller 10 in response to notes passing between the rollers. Sensors 42 and 43 produce voltage output whose magnitude varies in dependence on the amount of movement of the ends of the roller 12 away from the roller 10. In order to enable the apparatus to distinguish between double notes and a single note having a central local attachment, there are provided biasing rolls 56 and 58 which, during the passage of single or multiple notes between the rollers 10 and 12, are arranged to apply to the roller 12 first a pivoting moment in one direction and then a pivoting moment in the opposite direction.
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BACKGROUND
Audio and video information may be compressed to remove redundancy within the information. This allows the information to be stored using less memory. It is common to store audio as MP3 format which uses a reduced amount of memory. The advantage of storing the information is in this way is that a fixed amount of memory, such as available in a portable MP3 player or the like, may actually store more audio information.
MP3 players are commonly found in various types of computing devices. Stand-alone computers can play MP3's, as can Personal Digital Assistants (quote PDAs”), telephones, and other devices. Any electronic device which includes some kind of processing element can be used to read and write compressed audio and video information.
SUMMARY
The present invention teaches such applications which are made possible by the form of compressed information. According to an embodiment, extra information is stored within the compressed information. This extra information may be information that is associated with the information, or may be encryption information. In another embodiment, an improved way of storing this information is described.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects will now be described in detail with reference to the accompanying drawings, wherein:
FIG. 1A shows a fixed media reader type of MP3 player;
FIG. 1B shows a moving media typed reader for an MP3;
FIG. 2 shows a flowchart of a signing a specified melody to an event on a PDA or other personal computer;
FIG. 3 shows a format of and MP3 which includes extra information therein;
FIG. 4 shows different kinds of content which can exist within the extra information;
FIG. 5 shows an encryption system for an MP3;
FIG. 6 shows the format of the encryption system;
FIG. 7 shows a flowchart of reading the encryption system;
FIG. 8 shows another embodiment in which battery life can be preserved in a moving reader type of compressed information system.
DETAILED DESCRIPTION
While the present embodiment describes storing audio information in MP3 format, it should be understood that this is an embodiment of the general concepts described herein which are applicable to any kind of or format of either compressed audio information or compressed video information. Typically, the compressed file of the type described herein is compressed relative to the original size file representing the information. While the embodiment refers to MP3's, it should be understood that these techniques are also applicable to other formats including other compressed audio formats, compressed moving video formats such as MPEGs, compressed shingle image formats such as JPEG's and others.
There are basically two different types of readers for this compressed information. A fixed type reader is shown in FIG. 1A . In this reader, the memory media 100 is inserted into an electronic device which includes a processor 125 therein. FIG. 1A shows the device 110 as being a portable telephone. However, the device may be any device, portable or otherwise, that includes a processor therein. Various types of readers and media of this type are known. For example, the media 100 may be complex flesh, as the media, on memory stick (Sony) for others. The media is typically a relatively compact size nonvolatile storage memory.
The memory is read by the device, which typically includes display 115 , user interface 120 which controls aspects of reading such as the track being read, and the processor/memory 125 . The processor and memory 125 may decode the compressed MP3 information, and the decoded information is outputted to the reproduction hardware which may include a speaker 126 and/or display screen 115 . This device is referred to herein as being a fixed reader, since the memory 100 is not moved during playback.
A second, moving type reader is shown in FIG. 1B . This device is effectively a legacy type device in which the information is spread over the surface of a physical part. A reading head is moved relative to the storage medium to obtain information from the different parts of the surface which store that information. The most common type of moving reader is a rotating disk reader. In this device, the MP3 information is stored on a round disk 155 which is rotated to receive the information therefrom. The reader 150 rotates the disk to receive the information which is sent to the PDA 160 and reproduced through the speakers. Other types of moving readers may include DVDs, mini disks, and other similar disk technology.
These compressed formats take up less space on the medium as compared with the uncompressed audio formats. This means, however, that the reader actually needs to read less data from the medium in order to reproduce the original data stream. For example, in order to play a specified one minute song, a moving reader 150 needs to read less data from an MP3 encoded disk 155 , then it would need to read from a regular CD. The reader reads less data and therefore there is extra time between the reading.
In addition, the processors which are associated with these readers often include significant computing power. For example, in a cellular phone, the reader may include electronics which carry out cellular phone functions, analog to digital conversion, and other complicated mathematical operations. These electronics may have sufficient processing power to carry out many other functions. This is especially true when the reader of the MP3 information is also carrying out another functions such as a PDA or cellular telephone.
According to an embodiment, the enhanced processing power is used for an additional function. An embodiment is described with reference to the flowchart of FIG. 2 which may be executed in any of the processors shown or described herein. This embodiment is intended to be used with a device/application which signals a user that an “event” has occurred. For example, when used in a cellular telephone embodiment, the “event” may be an incoming calls such as a ring tone in a conventional cellular telephone. In a PDA, the event may represent an appointment or other reminder for a user. A computer may signal the user about different events including ring tones, incoming faxes, reminders, and others. According to this embodiment, the information from the MP3 file is used as part of the signaling of the event.
The operation begins at 200 where the processor reads an MP3/compressed information. This information may represent a specific audio song being reproduced. 205 represents playing this information on demand. For example, there may be a play button or play function which signals the computer to play this information. At 210 , a part of the MP3, referred to herein as a “melody”, is assigned to the event. The melody that is assigned can be selected in many different ways. The Figure shows that the most often played melody may be selected. In this case, the system stores a list of the most commonly played melodies, and selects the most often played melody as the event reminder tone. Another alternative is that the last melody that was played becomes the event reminder tone. The melody that is played may actually be a clip from the MP3, or may be a melody line. At 215 , the melody line may optionally be extracted. This is done by reviewing the compressed audio information to determine the actual tones representing the notes of the melody line. The fundamental frequency within the music notes may be determined, the melody line extracted, and this melody line stored as notes and times of those notes. Since this kind of storage requires only storage of musical notes and times, this storage may require relatively little memory. Each of the melody lines may be assigned with a numerical designation, for example.
One system may also find the “chorus” of the song being played. For example, this may be postulated as the most commonly repeating block of melody line. Alternatively, an artificial intelligence system may analyze the content of the song to find the most likely portion that represents the chorus. The system may also assign the chorus to the event in an embodiment. Again this chorus may be the chorus of the most often played song or simply the chorus of the last played song.
This system may therefore continuously vary the signal that is associated with the event. Alternatively, the user may simply manually assign information to the event. Also, if the compressed information includes video information, either MPEG video information or associated video information stored within the MP3 as described herein, then the signaling of the event may also includes a video segment.
At 220 , the processing device monitors for the specific event. For example, the processor may monitor for an incoming telephone call, or may monitor for the time of reminder of the event. When the event is determined to occur at 220 , the melody which is obtained at 210 , 215 is played at 225 .
In this way, the device, which already includesan MP3 player, may use information from the MP3 material to assign a specified melody to a specified event. That melody may be an actual clip of audio or video information, or may be an extracted melody line. The melody may be user selectable, automatically selected, or constantly changing.
As described above, since the data is compressed, there is less data to read for a given clip of musical information. Hence, the reader can actually read the material from the medium faster than it would be able to read from comparable uncompressed readers. This effectively gives the reader some spare time.
In this embodiment, extra content is stored within the MP3, and the spare time is used to read and display this extra content. Existing formats such as MP3 already have the ability to store some extra content within the signal. For example, MP3 may store certain kinds of text about the signal being played. In this embodiment, the compressed information is in the format shown in FIG. 3 . The sound is stored as packets 300 , 310 and the like. Extra information may be interspersed between two adjacent packets. For example, extra information 305 may be stored between packet 1 and packet 2. Extra information such as 315 may be stored after packet 2. This may be done in conventional form, or may include additional area where more data can be stored.
The extra information such as 315 may be associated with the sound that is played at the time of the packet that comes after it. For example, while the sound at 310 is being played, the reader may also read the extra information 315 . The specific extra information 315 may be played at the time of packet 310 and therefore represent content that is associated with packet 310 . That information is played at the same time as the specific sound with which it is associated. The information 315 may not be the information itself, but may rather be an address indicating information that is somewhere else within the clip, or an address indicating some other destination for the information.
In addition, between two adjacent songs or programs there is often silence shown as 320 . Additional content 325 may be stored during these silences between the tracks. Extra content may also be stored at the end of the entire information, for example after the end of the whole album.
The content to be played during the packet 2 ( 310 ) may not necessarily be stored in 315 . Importantly, however, 315 stores some kind of trigger to play the content at address x. This content may rather be stored at 325 , but triggered by the extra information at 315 .
The specific content is shown in FIG. 4 . This content may include video information, still picture information, album liner type information such as notes, lyrics, web site links, and club links, links to information about other CDs or albums, and/or music videos for links to music videos. All of this information may be stored in multiple different resolutions, for example a first resolution for display on a PDA or telephone and a second resolution for display on a computer. The information may alternatively be stored as simply low resolution information with links to an Internet site that stores additional resolution information. In this case, the low resolution information may be displayed immediately, while the system first determines if the display is capable of displaying more detail. If so, then the system attempts to link to the broadband content to improve the resolution of the information which is displayed. The system may use a progressive scan type display where the first part of the display that is immediately displayed is a low resolution version, and this low resolution version is actually stored as part of the MP3. Additional information to improve the resolution may be obtained from the website link.
The extra information may simply be a link to date sensitive information. For example, it may be a link to the concert schedule for the artist that is playing the MP3 information. When the link is executed, the website storing this concert information is executed, thereby obtaining up to date, date sensitive information.
This information may be buffered, to be played at the time of the trigger 316 . Alternatively, the reading may simply hop around from address to address to play the information in real time.
The computer which runs this decoder may be a stand-alone computer with an Internet connection, or may be a cellular telephone which has Internet via cellular capability.
A recurring concern with compressed music forms such as MP3s occurs because they are so relatively easy to copy. An abuser could easily copy the entire content of their particular music program to MP3 form, then post that to a web site or newsgroup. This effectively allows anyone with Internet access to download the MP3. Once someone buys a disk legitimately, that person can provide the content of the desk too many other people in this way. This pirating may cost revenues to the recording industry.
According to this embodiment, a technique is described which uses an encryption system to ensure that royalties are properly paid for such items. The encryption code may be part of the additional information stored as shown in FIG. 4 . This system as shown in the context of a disk 500 , however this may also be used with other media as described herein. As in other embodiments, this system can include a reader which includes electronics to read specified information from an optical disk.
In the embodiment, the disk has a unique serial number 502 which is provided by the manufacturer, and these unique to the specific disk. The processor takes this serial number at 504 , as well as the music content 506 that is to be stored on the disk.
The writer 510 combines the disk serial number with the music content 506 using an encryption function shown as 515 . For example, the encryption function as described herein may be a one-way function of a type that produces a large number. The theory of encryption using large numbers is well-established. Briefly speaking, usually this uses a factoring system where decoding to check the veracity of the large number is easy, but attempting to form of valid number surreptitiously is difficult. For example, a code may be selected which might require 35 years of brute force effort in order to form the codes surreptitiously. The large number 522 is then stored on the disk associated with the music content shown as 520 . The code is therefore keyed to the content on the disk, in a form which may follow the content shown in FIG. 6 . The content 600 may be mixed with encryption information 605 which may include an encryption key, content checksum, disk ID, content ID, and encrypted information.
In operation, the reader may operate to read the disk as well as reading information determining whether the disk is authorized. At 700 , the system reads from the disk. Initially, a threshold test may be carried out at 702 determining if the disk is a stamped disk or some kind of recordable disk. A stamped disk may automatically be played in an embodiment, since these are so much more difficult to counterfeit. It is also difficult to individualize such stamped disks. However, in an alternative embodiment, a pre recorded disk may also be tested in a similar way.
If 702 determines that the currently played disk is not a stamped disk, then 705 may check the veracity of the encrypted number 522 on the disk using the local (public) key of a public key encryption system. This key may be stored locally in all readers, and using known cryptographic techniques, the knowledge of the decryption key tells you nothing about the encryption key. The accuracy may be tested only once, or may be tested every few seconds. If the result of the test is okay at 710 , then the information is played at 720 . If not, the reader may refuse to play the disk at 715 .
This system may require that the cryptographic technology be added to all readers. However, this cryptographic technology may prevent surreptitious copying. In an embodiment, the system may allow the user to buy licenses for various MP3 technologies. When a license is purchased for specific technologies, the user is given an encrypted key or onetime use software that produces the encrypted key for one disk ID. For example, the user may upload the information, and received back information that includes the encryption information thereon. This may have significant advantages of allowing the system that assigns the key to determine who should get the royalties. Another embodiment may allow disks to be prepurchased which have a special key thereon enabling them to be written with MP3 information. The user pays for that special key much in the same way that they pay for any license. Of course, time IDs which allow the user to copy as many disks as they want in a specified time, or unlimited IDs, can also be purchased.
The above system has described this technique for use with MP3's and audio. However, the same techniques may be used for programs and computer information stored on disks. For example, a programs stored on a prerecorded disk may be automatically read, while a program stored on a recordable disk may require additional security information. This may also be used with a videodisc or any other type of entertainment media.
Another embodiment, shown with reference to FIG. 8 , relates mostly to moving media such as CDs and DVDs. MP3 is that are stored on this kind of moving media can convey the information much faster than is needed and as described above can provide spare capacity. However, this also means that the conventional moving techniques may be much more than necessary to play back the disk. When operating a portable device such as in MP3 reader that operates from a battery, the spinning of the disk may use a lot of the battery power. During playing, the media is conventionally continuously moved. This may waste battery power compared to what is really necessary to read the information from the disk. The embodiment shown at FIG. 8 may conserve battery power. At 800 , a play command is received. This is followed by 805 which commands moving the media in a way that fills the buffer. The buffer may be for example a sufficient buffer to store five minutes of information. At this time, at 810 , the media movement is terminated so that no further battery power is used to read the media. The system then proceeds to read from the buffer at 810 . At 815 , when the buffer reaches a specified percentage of emptiness (shown here as a percent) which may be 5 percent, the process repeats with the media being spun up, and reading occurring to fill the buffer.
This embodiment may also be usable with non compressed desks. For example, conventional CD readers read data at a specified rate often called 1×. However, readers which read much faster than this are well established. It is very simple for a reader to read at 40× as of this writing, and readers which read at even higher speeds are known and under development. Accordingly, this system may also be used with a reader that reads faster than 1×.
Although only a few embodiments have been disclosed in detail above, other modifications are possible. For example, and primarily, while the above refers primarily to MP3's, other compressed formats are equally applicable to this system. All such modifications are intended to be encompassed within the following claims, in which:
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Compressed entertainment content such as audio or video or both includes additional aspects and operations associated their way. The compressed audio may be used to signal computers such as a telephone or reminder for an appointment. A melody line may be extracted from the audio, or the audio may be used exactly as it is. Another aspect stores traders within the entertainment content such as in MP3. Those traders are used to trigger the system to retrieve other parts of the content to be displayed at the same time that that particular part of the MP3 is being play. The content may include video or text, or maybe links to other content such as broadband content four times sensitive content. Another aspect describes encryption which is keyed to the disk ID to prevent playing oven illegally copied disk. Another aspect reads a specified amount of information then spins down the disk to conserve battery power.
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BACKGROUND OF THE INVENTION
The invention concerns N-substituted 2-chloro-7-fluoro-10-piperazino-10, 11-dihydrodibenzo (b,f) thiepins of the general formula I ##STR2## in which R represents an aminocarbonyl, amino-oximinomethyl (amidoxime), 1,3-dioxolan-2-yl or 1,3-dioxan-2-yl group, and their addition salts with pharmaceutically acceptable organic and inorganic acids.
The compounds of the invention are highly potent antidopaminergic, non-cataleptic neuroleptic agents useful for the treatment of schizophrenia. According to recent pharmacological assay results, the compounds are surprisingly of low-toxicity and are expected to be substantially free of the common undesired extrapyramidal side effects (i.e. lowered motor coordination and related disturbances). Their acid addition salts, e.g. hydrochlorides, maleates and especially methanesulfonates, can be used in the formulation of dosage forms for pharmacological evaluation and therapeutic application.
The basic 10,11-dihydrodibenzo (b, f) thiepin skeleton of the compounds of formula I is a well-known carrier system for a number of neuroleptic substances from which several have found practical use in pharmacotherapy of schizophrenia, e.g. clorotepin (8-chloro-10-(4-methylpiperazino)-10,11-dihydrodibenzo (b,f) thiepin, Metysova J. et al, Acta Biol. Med. Ger. 39, 723, 1980), oxyprothepin (8-methylthio-10-(4-(3-hydroxypropyl) piperazino)-10, 11-dihydrodibenzo (b,f)-thiepin, Taussigova D. et al, Activ. Nerv. Supper. 16, 163, 1974), oxyprothepin decanoate (8-methylthio-10-(4-(3-decanoyloxypropyl)-piperazino)-10,11-dihydrodibenzo (b,f) thiepin, Zapletalek M. et al, Activ. Nerv. Super. 21, 138, 1979) and zotepin (2-chloro-11-(2-dimethylaminoethoxy)dibenzo (b,f) thiepin, Uchida S et al, Arzneim.-Forsch. 29, 1588, 1979).
Common disadvantages of all these compounds are their cataleptic action in rats and the corresponding extrapyramidal side effects in patients. The typical structural feature of the compounds of formula I, which evidently modifies their pharmacological profile in the desired direction, is the N-substituent --CH 2 CH 2 R on the piperazine N 4 . The relevant literature (Jilek J. O. et al, Collect. Czech. Chem. Commun. 36, 2226, 1971; 39, 3153, 1974; Rajsner M. et al, ibid. 42, 3079, 1977) describes only several compounds of the general formula II ##STR3## wherein R has the same meansing as in formula I and R 1 is a hydrogen or a fluorine atom. All these compounds, some of which differ from those of formula I merely by the position of the chlorine and fluorine atoms on the tricyclic skeleton, are also very potent neuroleptic agents, but simultaneously cause a significant cataleptic activity and, consequently, elicit extra-pyramidal side effects in patients. One can only conclude that the noncataleptic character of the compounds of formula I, together with their high antidopaminergic activity in biochemical and pharmacological tests (cf. Sayed Y. and garrison J. M., Psychopharmacol. Bull. 19 (2), 283-288, 1983, "The dopamine hypothesis of schizophrenia and the antagonistic action of neuroleptic drugs--a review"), results from the specific location of the halogen (i.e. chlorine and fluorine) atoms on the skeleton, in combination with the particular structure of the piperazine N 4 substituent.
SUMMARY OF THE INVENTION
It is, therefore, an object according to the present invention to find new tricyclic compounds that do not provoke such undesirable side effects.
A typical and most interesting compound of the present invention has the structure 3-(4-(2-chloro-7-fluoro-10,11-dihydrodibenzo (b,f) thiepin-10-yl) piperazino) propionamide, which was pharmacologically tested as the methanesulfonate (compound A). This compound was tested using oral administration, and the numerical data given were calculated per base. Acute toxicity was evaluated in mice, and the result, obtained in 48 h, is considered representative: LD 50 =336 mg/kg in male mice and 316 mg/kg in female mice. Longer evaluation of the toxicity test leads to lower LD 50 values, which is not the result of toxicity of the compounds, but rather a deep central depression of the animals which perish due to insufficient feed and water intake. For comparison, the value of acute toxicity of clozapine, i.e. 8-chloro-11-(4-methylpiperazine)-5H-dibenzo (b,e)-(1,4)diazepine (Lindt S. et al, Farmaco, Ed. Prat. 26, 585, 1971) is LD 50 =199 mg/kg. The acute toxicity of compound A in male rats is LD 50 =654 mg/kg. In the test of inhibition of spontaneous locomotor activity in mice, the medium active dose of compound A, D 50 =1.05 mg/kg (clozapine is approx. 4 times less active; chlorpromazine is 5 times less active and haloperidol is approx. twice as active). Results in this test correspond to the central depressant, i.e. sedative, activity of the compounds. In the rota-rod test in mice, the disturbances of the motor coordination are evaluated: the medium effective dose ED 50 =2.0 mg/kg; the same in rats, ED 50 =19.5 mg/kg. At the dose of 50 mg/kg, the compound A lacks cataleptic activity in rats (clozapine behaves similarly). In the test of antiapomorphine action in rats, compound 1 at doses of 20 and 50 mg/kg, by 2 h after the administration, significantly inhibits the agitation, but does not affect the apomorphine-elicited stereotypes (clozapine at the same doses effects neither agitation nor stereotypes). In the test of inhibition of apomorphine emesis in dogs, the threshold activity dose of compound A is 2 mg/kg by 4 h after the administration (within 24 h the effect disappears). In the test of apomorphine-induced climbing behavior of mice, the medium effective dose of compound A is PD 50 =2.9 mg/kg (chlorpromazine has approx. 50%, and clozapine 20% of this activity; haloperidol is more active). In the interval of 3 h after the administration, compound A intensively increases the level of homovanillic acid (as the main dopamine metabolite) in corpus striatum and tuberculum olfactorium of the rat brain. Threshold doses which significantly increase the homovanillic acid concentration of 5 mg/kg for corpus striatum, and 2 mg/kg for tuberculum olfactorium. This test is the most important criterion of the antidopaminergic activity of the compounds; clozapine has about 1/10 of the activity in both mentioned brain structures. Moreover, compound A at a dose of 20 mg/kg does not significantly affect the dopamine levels in either of the structures (clozapine slightly decreases dopamine levels). For checking the affinity of compound A to dopamine receptors in the two brain structures, the inhibition of 0.5 nM 3 H-spiperone, i.e. 8-(4-(4-fluorophenyl)-4-oxobutyl)-1-phenyl-1,3,8-triazaspiro (4,5) decan-4-one binding is evaluated. The inhibitory concentration of compound A is IC 50 =49.74 nM for corpus striatum and 30.56 nM for tuberculum olfactorium. Clozapine in the same test is approx. 5 times weaker, and haloperidol 4 to 5 times more active. In conclusion, the tests performed prove that compound A is noncataleptic and has 5 to 10 times higher antidopaminergic activity than clozapine.
A further compound of the invention is 1-(2-chloro-7-fluoro-10, 11-dihydrodibenzo (b,f) thiepin-10-yl)-4-(2-(1,3-dioxolan-2-yl)ethyl)piperazine, which also was tested as the methanesulfonate (compound B). This compound and the following ones were likewise administered orally, and the data is calculated per bases. Acute toxicity in mice is LD 50 =350 mg/kg. Discoordinating effect in the rota-rod test in mice is ED 50 =3.5 mg/kg. At the dose of 50 mg/kg, it has no cataleptic effect in rats, and at the same dose it only mildly potentiates the cataleptogenic effect of perphenazine. At the same dose, there is only a slight indication of antiapomorphine effect in rats. At the dose of 80 mg/kg, after an interval of 3 h, it increases the homovanillic acid level in the rat brain striatum by 504%; simultaneously it lowers the dopamine level by 25%.
The invention further includes 1-(2-chloro-7-fluoro-10, 11-dihydrodibenzo (b,f) thiepin-10-yl)-4-(2-(1,3-dioxan-2-yl) ethyl)piperazine, which is also tested as the methanesulfonate (compound C). Acute toxicity in mice, i.e. LD 50 is higher than 500 mg/kg; on intravenous administration, LD 50 =77.6 mg/kg. Discoordinating activity in the rota-rod test in mice turns out to be ED 50 =2.86 mg/kg. At the dose of 50 mg/kg, compound C has no cataleptic effect and only mildly potentiates the cataleptogenic effect of perphenazine in rats. At the same dose, it does not reveal any antiapomorphine effect in rats. At the dose of 20 mg/kg (3 h interval) it increases the homovanillic acid level in the rat striatum by 400% (clozapine at the same dose, by 200%); the dopamine level is not affected. The affinity of compound C to dopamine receptors in striatum on the basis of release of 3 H spiperone is approximately the same as with clozapine.
Finally, 3-(4-(2-chloro-7-fluoro-10,11-dihydrodibenzo (b,f)-thiepin-10-yl) piperazino)propionamidoxime, which is also included within the scope of the invention, is tested in the form of the dimaleate (compound D). Acute toxicity in mice is LD 50 =320 mg/kg. In the test of affecting the motility of mice according to Ther, the medium effective dose of compound D is 50 mg/kg. At the dose of 80 mg/kg (3 h after the administration) this compound increases homovanillic acid level in rat striatum by more than 300%; the increase is significant already after a dose of 20 mg/kg. The reported results indicate that compounds B, C, and D are approximately comparable with regard to their pharmacological profiles to the aforementioned compound A.
The subject compounds of formula I of the present invention are available by common reactions from intermediary compounds of formulas III, IV, or V ##STR4## (for their preparation, cf. Jilek J. O. et al. Collect. Czech. Chem. Commun. 40, 2887, 1975) or by interconversion of other compounds of formula I.
Compound A of formula I, wherein R is an aminocarbonyl group, can be prepared best from compound IV by its addition reaction with acrylamide. This reaction can be conducted under various conditions, preferably by the procedure of Example 1, infra in tert-butanol at a temperature of 50°-55° C., in the presence of benzyltrimethyl-ammonium hydroxide and a small amount of sulfur. This procedure affords the crystalline compound A in yields of approx. 90% of theory. The product crystallizes from ethanol in two modifications: a more stable one, melting at 183°-184° C., and a less stable one, having a lower m.p. of 154°-155° C. Neutralization of compound A base with maleic and methanesulfonic acids gives, respectively, neutral maleate, m.p. 124°-128° C., poorly soluble in water, and monomethanesulfonate, m.p. 172°-173° C., excellently water-soluble.
Compound A can also be prepared by a substitution reaction of compound III with 3-(1-piperazinyl)propionamide (obtained according to U.S. Pat. No. 3,352,866), preferably by refluxing the reaction mixture containing a 100-150% excess of the latter reactant with a small amount of chloroform; the crystalline base is obtained in a yield of approx. 60% of theory. Concurrent dehydrochlorination reaction gives a certain amount of neutral 2-chloro-7-fluorodibenzo (b, f) thiepin, m.p. 98° C.
Compound B of formula I, wherein R is a 1,3-dioxolan-2-yl, can be prepared by substitution reaction of compound IV with 2-(2-chloroethyl)-1,3-dioxolane (obtained according to Ratouis R., Roissier J. R., Bull. Soc. Chim. France 1966, 2963), preferably in boiling toluene, in the presence of triethylamine for binding the formed hydrogen chloride. The resulting non-homogeneous reaction product is purified by column chromatography on aluminium oxide; the purified crystalline base, melting at 112°-114° C., is obtained in a yield of over 50% of theory. Its neutral maleate, m.p. 166°-168° C., is slightly soluble in water, whereas its monomethanesulfonate, melting at 158°-159° C., is readily water-soluble.
Compound C of formula I, wherein R is 1,3-dioxan-2-yl, is prepared by a quite similar substitution reaction of compound IV with 2-(2-chloroethyl)-1,3-dioxane (Ratouis R., Boissier J. R., l.c.). In this case, the chromatographic purification of the crude base is not necessary, and the crystalline base, melting at 150.5°-152.5° C., is obtained in a yield of approx. 65% of theory. Neutral maleate, m.p. 184°-185° C. is poorly soluble in water, and monomethanesulfonate, m.p. 202°-204° C., is again excellently water-soluble.
Compound D of formula I, wherein R is an amino-oximinomethyl group C(NH 2 )═NOH, is prepared by reacting the corresponding nitrile V with hydroxylamine in boiling methanol. The so-obtained crude base in neutralized with maleic acid, to give crystalline dimaleate, which crystallizes as a hemihydrate melting at 159°-163° C. (ethanol-ether).
The identity of all compounds of the invention referred to herein has been verified both analytically and spectrographically.
Acid addition salts of the products, insofar as they are moderately water-soluble, are convenient for the formulation of solid oral dosage forms (i.e. tablets, coated tablets, capsules), whereas those salts that are readily soluble in water can also be formulated into liquid dosage forms, either oral (drops) or parenteral (injection solutions).
Further particulars of the preparative procedures are illustrated by the subsequent non-limitative examples.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
3-(4-(2-Chloro-7-fluoro-10,11-dihydrodibenzo(b,f) thiepin-10-yl)piperazino)propionamide (formula I, R is CONH 2 )
A mixture of tert-butanol (400 ml), 2-chloro-7-fluoro-10-piperazino-10,11-dihydrodibenzo(b,f)thiepin (40.0 g), elemental sulfur (0.45 g), 40% methanolic benzyltrimethylammonium hydroxide solution (4 ml) and acrylamide (36.5 g) is stirred for 15 hours in a water bath at 50°-55° C. At first, the reaction mixture is heterogeneous, but after approx. 8 hours of stirring and warming it forms a clear yellow solution. When the reaction is completed, the solution is allowed to stand at room temperature overnight in order to crystalline. The product is collected on a filter and washed successively with small amounts of tert-butanol, toluene and hexane, and then dried to constant weight. The obtained first-crop material (35.4 g, 74% of theory) melts at 172°-178° C.
Mother liquors are evaporated under reduced pressure from a water bath maintained at 70°-80° C. The residue (43.5 g) is shaken at 30°-35° C. with a two-phase system consisting of toluene (350 ml) and water (400 ml), the organic phase is washed with warm water (3×250 ml), the toluene solution is filtered and the product is extracted from the filtrate with a solution of methanesulfonic acid (10 g) in water (100 ml), and finally, with water (60 ml). The combined aqueous solutions are filtered with active carbon (4 g), the filtrate is made alkaline by the addition of aqueous ammonia (30 ml) and the separated second-crop product is taken into chloroform. The organic layer is washed with warm water (80 ml), dried over anhydrous potassium carbonate, filtered and evaporated under reduced pressure to dryness. The residue is dissolved in hot toluene (22 ml), and the solution is allowed to crystallize at room temperature. After standing overnight, the product is separated, washed successively with small amounts of toluene and hexane, and dried in vacuo to give the purified second-crop material (10.1 g, 21% of theory) melting at 174°-175° C. The total yield is 45.5 g (95%).
The pure base is obtained by chromatography of a sample of the product on a column packed with aluminium oxide (neutral, activity II). Elution of the column with benzene removes a minor quantity of the material formed by less polar impurities, and a mixture of benzene with 5% of ethanol then washes out the chromatographically uniform desired base (3.7 g), which can be purified by crystallization from a mixture of boiling ethanol (10 ml) and petroleum ether (10 ml). Another crystallization from ethanol alone affords a more stable, higher-melting crystal modification, having a m.p. of 183°-184° C. Its elemental analysis corresponds to the summary formula C 21 H 23 ClFN 3 OS. It seldom happens that the chromatographic purification of a sample and subsequent crystallization of the resulting homogeneous base yields the corresponding less stable, lower-melting modification with a m.p. of 154°-155° C. (ethanol). Both these modifications have identical 1 H NMR spectra (in C 2 HCl 3 ), whereas their IR absorption spectra in nujol show minor differences.
The crude product melting at 172°-178° C. may sometimes contain certain amounts of the starting base; this can be checked by thin-layer chromatography on silica gel. In such a case, the following purification procedure is recommended: The crude base (34.5 g) is suspended in a solution of methanesulfonic acid (10 g) in water (500 ml). By moderate warming of the suspension to approx. 50° C., the bases are converted into soluble methanesulfonates and a clear solution is formed. The obtained yellow solution is filtered while hot with active carbon (10 g), the filtrate is made alkaline under stirring by slow addition of aqueous ammonia (35 ml), toluene (70 ml) is then added, and the mixture is stirred for another hour and then allowed to stand at room temperature for 12 hours. The separated crystalline product is collected on a filter, successively washed with water (50 ml), toluene (20 ml) and hexane (20 ml), and then dried in vacuo to give the purified base (31.8 g) melting at 175°-179° C. The purification effect of this procedure results from the fact that the unreacted starting base remains dissolved in toluene added after making the solution of methanesulfonates alkaline with aqueous ammonia.
If the corresponding pure methanesulfonate is required, the obtained base (10.0 g) and methanesulfonic acid (2.28 g) are dissolved in ethanol (50 ml), the solution is filtered, the filtrate is diluted with hexane (50 ml) and then the mixture is allowed to stand at room temperature for 12 hours to crystallize. Crystals are separated, washed with an ethanol-hexane mixture, and then dried in vacuo. The yield is 10.3 g (84%) of the methanesulfonate salt melting at 171°-172° C. Crystallization from ethanol-ether give an analytical sample having a m.p. of 172°-173° C.; its composition corresponds to the summary formula C 22 H 27 ClFN 3 O 4 S 2 .
Neutralization of the base (15.1 g) dissolved in hot ethanol (170 ml) by adding a solution of maleic acid (4.2 g) in ethanol (15 ml) provides the neutral maleate (13.2 g), which can be purified by crystallization from ethanol to a constant m.p. of 124°-128° C., and has the composition C 22 H 27 ClFN 3 O 5 S.
EXAMPLE 2
3-(4-(2-Chloro-7-fluoro-10,11-dihydrodibenzo (b,f) thiepin-10-yl)piperazino)propionamide (I, R=CONH 2 )
A mixture of 2,10-dichloro-7-fluoro-10,11-dihydrodibenzo(b,f)-thiepin (2.8 g), 3-(1-piperazinyl)propionamide (3.2 g) and chloroform (10 ml) is refluxed with stirring for 8 hours. The solvent is than evaporated under reduced pressure, and the residue is extracted by shaking with a two-phase system consisting of benzene (30 ml) and a solution of methanesulfonic acid (4 g) in water (50 ml). The clear aqueous solution is separated and then made alkaline with aqueous ammonia (10 ml). The so-formed suspension of the amorphous base is diluted with ethanol (100 ml), and the mixture is briefly warmed to boiling. The resultant clear solution is then allowed to crystallize at room temperature for 6 hours. The crystalline product is separated, washed with a small amount of ethanol, and then dried in vacuo. The obtained base (2.35 g, 60% of theory) melts at 179°-182° C.; it can be purified by crystallization from ethanol to give the title compound having a m.p. of 182°-184° C. and which is identical with the product of the preceding example 1.
EXAMPLE 3
1-(2-Chloro-7-fluoro-10,11-dihydrodibenzo(b,f)thiepin-10-yl)-4-(2-(1,3-dioxolan-2-yl) ethyl)piperazine (I, R=1,3-dioxolan-2-yl)
A mixture of 2-chloro-7-fluoro-10-piperazino-10,11-dihydro-dibenzo(b,f)thiepin (10.9 g), toluene (70 ml), triethylamine (10.9 g) and 2-(2-chloroethyl)-1, 3-dioxolane (16.5 g) is refluxed under stirring for 24 hours. After cooling, the precipitate is filtered off, the filtrate is washed with water, dried over anhydrous potassium carbonate, filtered with active carbon, and then the filtrate is evaporated under reduced pressure. The obtained non-homogeneous residue (17.6 g) is dissolved in benzene and chromatographed on a column packed with neutral aluminium oxide (activity II, 400 g). By elution of the column with benzene, some non-crystallizing material (5.9 g) is first washed out, followed by the desired crystalline base (7.6 g, 54% of theory) melting at 110°-114° C. Subsequent crystallization from benzene provides the pure base, which melts at 112°-114° C.; its elemental analysis corresponds to the presumed composition C 23 H 26 CLFN 2 O 2 S. Neutralization of the base with maleic acid in ethanol gives the neutral maleate C 27 H 30 ClFN 2 O 6 S; after crystallization from ethanol, the pure substance melts at 166°-168° C. The product is slightly soluble in water. Neutralization of another sample of the above base with methanesulfonic acid in ethanol, and subsequent addition of ether, yields the monomethanesulfonate C 24 H 30 ClFN 2 O 5 S 2 , which, after crystallization from an ethanol--ether mixture, melts at 158°-159° C. This salt is excellently water-soluble: it provides better than 10% aqueous solutions.
EXAMPLE 4
1-(2-Chloro-7-fluoro-10,11-dihydrodibenzo(b,f)thiepin-10-yl)-4-(2-(1,3-dioxan-2-yl)ethyl)piperazine (I, R=1, 3-dioxan-2-yl)
A mixture of 2-chloro-7-fluoro-10-piperazino-10,11-dihydro-dibenzo(b,f)thiepin (10.0 g), toluene (60 ml), triethylamine (10 g) and 2-(2-chloroethyl)-1,3-dioxane (15.3 g) is refluxed under stirring for 23 hours. On cooling, the precipitate is filtered off and washed with benzene. The combined filtrates are then washed with water, dried over anhydrous potassium carbonate, filtered with a small amount of active carbon, and evaporated under reduced pressure to dryness. The residue (19.0 g) crystallizes rapidly while standing. Another crystallization from a mixture of benzene (50 ml) and petroleum ether (50 ml) yields 8.5 g (65%) of the desired base, melting at 150.5°-152° C. Repeating the crystallization from the same solvent system does not increase the m.p. any more; the product is analytically pure, and its elemental analysis corresponds to the composition C 24 H 28 ClFN 2 O 2 S. Neutralization of the base, with maleic acid in a mixture of equal amounts of benzene, acetone and ethanol, provides the neutral maleate C 28 H 32 ClFN 2 O 6 S, which crystallizes from ethanol and melts in the pure state at 184°-185° C. This salt is only very slightly soluble in water. Neutralization of base with methanesulfonic acid in ethanol gives the monomethanesulfonate C 25 H 32 ClFN 2 O 5 S 2 , which crystallizes from ethanol and melts at 201°-203° C. This salt is excellently water-soluble.
EXAMPLE 5
3-(4-(2-Chloro-7-fluoro-10,11-dihydrodibenzo(b,f) thiepin-10-yl)piperazino) propionamidoxime (I. R is C(NH 2 )═NOH)
A sodium methoxide solution, prepared by dissolving sodium metal (0.25 g) in methanol (6 ml), is treated with hydroxylamine hydrochloride (0.74 g). After a brief stirring, 3-(4-(2-chloro-7-fluoro-10,11-dihydrodibenzo(b,f)thiepin-10-yl) piperazino) propionitrile (3.54 g) is added. The mixture is refluxed for 7.5 hours, filtered on cooling, and then the filtrate is evaporated under reduced pressure to give 4.0 g (approx. the theoretical amount) of the non-crystalline base. Neutralization of a portion (3.1 g) of the crude material with maleic acid (2.5 g) in ethanol (30 ml) gives the dimaleate (2.5 g), which can be purified by crystallization from a mixture of 96% ethanol and ether to give the pure salt hemihydrate C 29 H 32 ClFN 4 O 9 S.0.5H 2 O, melting at 161°-163° C.
The starting nitrile, which has been described in the literature merely as its maleate, can easily be prepared in the form of they crystalline base, m.p. 97°-99° C. (ethanol). This base is used as the starting material for the above described preparation.
Although the invention is described and illustrated with reference to a plurality of embodiments thereof, it is to be expressly understood that it is in no way limited to the disclosure of such preferred embodiments but is capable of numerous modifications within the scope of the appended claims.
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N-substituted 2-chloro-7-fluoro-10-piperazino-10,11-dihydrodibenzo(b,f)thiepins are disclosed of the general formula I, ##STR1## in which R represents an aminocarbonyl, amino-oximinomethyl, 1,3-dioxolan-2-yl or 1,3-dioxan-2-yl, group and their addition salts with convenient organic and inorganic acids. These compounds are highly potent antidopaminergic, non-cataleptic neuroleptics of use in the treatment of schizophrenia. According to recent pharmacological assay results, the subject compounds are expected to be substantially free of the usual undesired extrapyramidal side effects. They can be obtained by common preparative methods from the respective starting compounds of formula III, IV or V, or also by appropriate interconversion reactions of other compounds of formula I. If required, the resulting bases are neutralized with suitable acids, preferably methanesulfonic, maleic or hydrochloric acid, to yield the corresponding addition salts that can be used in formulating proper dosage forms for pharmacological evaluation and therapeutical application.
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FIELD OF THE INVENTION
[0001] The invention relates to the field of printing systems, and in particular, to management of printing systems.
BACKGROUND
[0002] Printers are common peripheral devices attached to computers. A printer allows a computer user to make a hard copy of documents that are created in a variety of applications and programs on a computer. To function properly, a channel of communication is established (e.g., via a network connection) between the printer and the computer to enable the printer to receive commands and information from the host computer.
[0003] Once a connection is established between a workstation and the printer, printing software is implemented at a print server to manage a print job from order entry and management through the complete printing process. The printing software may simultaneously manage in excess of thousands of print jobs that have been spooled (or queued) for production. One type of printer management is the accounting and management of printer resource consumption.
[0004] In order for the operator of inkjet printing system to be adequately compensated for producing print jobs it is necessary to monitor resource consumption associated with a particular print job. Currently, print engines within printing systems have the ability to report constant counter-based values on a print job basis to the printing software. These values include information such as job start/stop time, number of errors encountered, stops/starts, ink usage, and page count. Each of these items is an additive value, where a counter is kept and reported.
[0005] However some systems within a printing system are variable in that they may be on or off for different durations during the printing of a specific job. For instance, an ink dryer is the largest consumer of energy within inkjet printing systems. The operation of an ink dryer may vary widely between different print jobs, making it difficult to track dryer energy consumption attributable to individual print jobs. Thus, achieving an accurate reporting for energy consumption attributable variable systems is difficult.
[0006] Accordingly, a mechanism for tracking and reporting variable energy usage associated with producing a print job is desired.
SUMMARY
[0007] In one embodiment, a printer is disclosed. The printer includes one or more sub-systems having a capability of a different magnitude of operation based on print job properties and a controller. The controller includes a monitor to track a first operation time for each of the sub-systems during printing of a first print job and track a second operation time for each of the sub-systems during printing of a second print job.
[0008] In another embodiment, a method is disclosed. The method includes receiving a first print job at a printer having one or more subsystems having a capability of a different magnitude of operation based on print job properties, monitoring a first operation time for each of one or more sub-systems during printing of the first print job, receiving a second print job at the printer and monitoring a second operation time for each of one or more sub-systems during printing of a second print job at the printer
[0009] In yet another embodiment, a printing system is disclosed. The printing system includes a server having a printing software product and a printer, communicatively coupled to the server. The printer includes one or more sub-systems having a capability of a different magnitude of operation based on print job properties and a controller. The controller includes a monitor to track a first operation time for each of the sub-systems during printing of a first print job and track a second operation time for each of the sub-systems during printing of a second print job.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A better understanding of the present invention can be obtained from the following detailed description in conjunction with the following drawings, in which:
[0011] FIG. 1 illustrates one embodiment of a data processing system network;
[0012] FIG. 2 illustrates one embodiment of a printer; and
[0013] FIG. 3 is a flow diagram illustrating one embodiment for tracking energy consumption within a printer.
DETAILED DESCRIPTION
[0014] A mechanism for tracking and reporting variable energy usage associated with producing a print job is described. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some of these specific details. In other instances, well-known structures and devices are shown in block diagram form to avoid obscuring the underlying principles of the present invention.
[0015] Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
[0016] FIG. 1 illustrates one embodiment of a data processing system network 100 . Network 100 includes a data processing system 102 , which may be either a desktop or a mobile data processing system, coupled via communications link 104 to network 106 . In one embodiment, data processing system 102 is a conventional data processing system including a processor, local memory, nonvolatile storage, and input/output devices such as a keyboard, mouse, trackball, and the like, all in accordance with the known art. In one embodiment, data processing system 102 includes and employs the Windows operating system, or other operating system, and/or network drivers permitting data processing system 102 to communicate with network 106 for the purposes of employing resources within network 106 .
[0017] Network 106 may be a local area network (LAN) or any other network over which print requests may be submitted to a remote printer or print server. Communications link 104 may be in the form of a network adapter, docking station, or the like, and supports communications between data processing system 102 and network 106 employing a network communications protocol such as Ethernet, the AS/400 Network, or the like.
[0018] According to one embodiment, network 106 includes a print server 108 that serves print requests over network 106 received via communications link 110 between print server 108 and network 106 . Print server 108 subsequently transmits the print requests via communications link 110 to one of printers 109 for printing, which are coupled to network 106 via communications links 111 .
[0019] Although described as separate entities, other embodiments may include print server 108 being incorporated in one or more of the printers 109 . However in other embodiments, the print server and printer may be physically separate entities. Therefore, the data processing system network 100 depicted in FIG. 1 is selected for the purposes of explaining and illustrating the present invention and is not intended to imply architectural limitations. Those skilled in the art will recognize that various additional components may be utilized in conjunction with the present invention.
[0020] According to one embodiment, print server 108 implements a printing software product that manages the printing of documents from data processing system 102 and one or more of printers 109 . In other embodiments, the printing software product manages the printing of documents from multiple data processing systems 102 to the one or more printers 109 .
[0021] In a further embodiment, the printing software product may be implemented using either InfoPrint Manager (IPM) or InfoPrint ProcessDirector (IPPD), although other types of printing software may be used instead. In yet a further embodiment, the print application at data processing system 102 interacts with the printing software product to provide for efficient transmission of print jobs. In one embodiment, the printing software product communicates with printers 109 via a SNMP network management protocol.
[0022] FIG. 2 illustrates an embodiment of a printer 109 . Printer 109 includes a control unit 210 and a print engine 230 . According to one embodiment, control unit 210 processes and renders objects received from print server 108 and provides sheet maps for printing to print engine 230 . Control unit 150 includes a rasterizer 212 that is implemented to process image objects received at control unit 150 by performing a raster image process (RIP) to convert an image described in a vector graphics format (e.g., shapes) into a raster image (e.g., pixels) for output to print engine 230 .
[0023] In one embodiment, print engine 230 includes one or more fixed, wide-array inkjet print head having one or more nozzles that are implemented to spray droplets of ink onto a medium (e.g., paper) in order to execute a print job. However, print engine 230 may include other types of ink jet print heads, as well as a moving print head design.
[0024] Control unit 210 also includes a monitor 214 that monitors resources consumed for each print job printed at printer 109 . In one embodiment, monitor 214 tracks the usage of variable sub-systems within printer 109 . In such an embodiment, variable sub-systems include those that may incur different magnitudes of operation time during each print job depending on the properties of a particular print job. For example, print engine 230 will incur more operation time during a large print job than during a small print job. Thus, by tracking the operation time of print engine 230 during each print job the energy consumed by each of the print jobs can be calculated and reported.
[0025] In a further embodiment, monitor 214 tracks the operation time of an ink dryer 250 that is implemented to dry ink applied by print engine 230 to the medium. During printer 109 operation, dryer 250 is heated up to the specified temperature as a job is printed. Further, energy is transferred, based on ink coverage and the medium properties, as the medium and ink pass over dryer 250 . This causes dryer 250 to cool. As dryer 250 cools the heaters are to be turned back on in order to maintain the temperature at a specified temperature range. Thus, heavy ink coverage requires dryer 250 to be turned on more frequently than lower ink coverage, causing the power to vary.
[0026] In one embodiment, monitor 214 tracks the on/off status of dryer 250 over time to acquire a total duration of operation time. In such an embodiment, monitor 214 monitors the total amount of time the dryer 250 heaters are active during a print job. The active time of the heaters directly correlates to the amount of energy used by dryer 250 during a print job, which in turn has a direct impact to the cost of energy used to print the job. Since power usage at dryer 250 is linear related to the active dryer time, power consumption can easily be calculated. In one embodiment, power consumption for a print job is calculated at control unit 210 before being reported to the printing software product, along with other print job information.
[0027] However in other embodiments, the duration of active dryer 250 time is forwarded to the printing software product, which calculates the power consumption. Subsequently, the printing software product generation of a report results regarding the usage of printer 109 . The report may be incorporated into a maintenance billing report for printer 109 . In another embodiment, monitor 214 also tracks the status of print engine 230 and other systems (e.g., processing power) at printer 109 to acquire a total duration of active time.
[0028] FIG. 3 is a flow diagram illustrating one embodiment for tracking variable energy consumption at printer 109 . At processing block 310 , a print job begins printing at print engine 230 . At processing block 320 , monitor 214 begins tracking the status of print engine 230 . As discussed above, monitor 214 tracks the duration of active operation time for print engine 230 .
[0029] At processing block 330 , dryer 250 is activated. At processing block 340 , monitor 214 begins tracking the status of dryer 250 . Once print engine 230 and dryer 250 operation have been completed, control unit 210 calculates power consumption for print engine 230 , dryer 250 and other variable components within printer 109 , processing block 340 . At processing block 350 , the calculated power consumption values are forwarded to the printing software product.
[0030] The above described mechanism integrates variable systems, such as print engine and dryer state, over time to collect a total usage amount which could be reported along with counter-based job information.
[0031] Whereas many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description, it is to be understood that any particular embodiment shown and described by way of illustration is in no way intended to be considered limiting. Therefore, references to details of various embodiments are not intended to limit the scope of the claims, which in themselves recite only those features regarded as essential to the invention.
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A printer is disclosed. The printer includes one or more sub-systems having a capability of a different magnitude of operation based on print job properties and a controller. The controller includes a monitor to track a first operation time for each of the sub-systems during printing of a first print job and track a second operation time for each of the sub-systems during printing of a second print job.
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BACKGROUND OF THE INVENTION
The present invention has to do with wellhead equipment used in connection with a pumping oil well, preferably one pumped with a rotated rod string. For years, a typical conventional pumping wellhead for a rotary pumping oil well has been constructed as shown in FIG. 1 . The assembly comprises from the bottom up: a flanged casing head attached to the well casing; a flanged tubing head having an internal hanger from which the well tubing string is suspended; a tubing head adapter having a flanged connection at its bottom end and a threaded connection of smaller diameter at its top end; a production blow-out preventer (B.O.P) body having top and bottom threaded connections and including side openings for receiving the B.O.P. ram components; a flow tee body having threaded bottom and top connections and a threaded or flanged side opening for connecting with a flow line; a polished rod stuffing box; and a rotary drive assembly for rotating the well's rod string to power a downhole progressive cavity pump. These components, except for the rotary drive assembly, combine to form a vertical central bore extending therethrough. The polished rod of the rod string extends through this central bore.
The combination of the tubing head adapter, B.O.P. body and flow tee body components is commonly collectively referred to as a ‘pumping tree’.
The assembly of wellhead components above the tubing head is usually referred to collectively as the ‘Christmas tree’.
A recent improvement in the production wellhead art is disclosed in Canadian patent 2,197,584, issued Jul. 7, 1998 and re-issued May 16, 2000. This patent is owned by the present applicant. More particularly, this patent teaches integrating the tubing head adapter, B.O.P. body and flow tee body into a unitary structure, referred to as an ‘integral or composite pumping tree’, by forging, casting or machining a single steel body. The composite pumping tree is illustrated in prior art FIGS. 2 and 2 a and forms the lower end of the Christmas tree.
Another recent improvement in the production wellhead art is disclosed in Canadian patent application 2,280,581, filed by the present applicant. This patent application teaches integrating a tubing head adapter, shut-off valve body, B.O.P. body, and flow tee body into a composite pumping tree. This pumping tree is illustrated in prior art FIG. 3 .
As previously stated, the rotary drive assembly usually has a stuffing box at its bottom end. The primary function of the stuffing box is to prevent upward leaking of fluid around the rotating polished rod. The stuffing box comprises a body or housing containing annular packing, which seals between the housing and the polished rod of the rod string.
Rotation of the polished rod eventually produces wear of the stuffing box packing. Therefore, changing the packing is part of the regular oilfield maintenance program.
Prior art FIGS. 1, 2 and 3 show a rotary drive assembly mounted to the stuffing box by an ‘open’ frame. The frame has side ‘windows’ which enable access to the stuffing box packing gland, so as to change out the packing. However this frame introduces significant vertical separation between the rotary drive assembly and the pumping tree. This is undesirable as the rotary drive assembly vibrates when operating and applies offset forces that can create damage to the wellhead below. It is desirable to minimize the spacing between the rotary drive assembly and the pumping tree.
A modified rotary drive assembly is shown in FIG. 4 . In this unit, the stuffing box housing is now integral with the rotary drive assembly. This variation has had the benefit of shortening the distance between the rotary drive assembly and the pumping tree.
However, it is more difficult to change out the packing of the stuffing box illustrated in FIG. 4 . This process now requires:
shutting off the rotary drive assembly;
closing the production B.O.P by rotating the ram screws to advance the B.O.P rams into engagement with the polished rod;
providing a service rig having a line which is attached to the polished rod to suspend the rod string;
disconnecting the rod clamp normally suspending the rod string from and drivably connecting it with the rotary drive assembly;
disconnecting the rotary drive assembly from the pumping tree;
lifting the rotary drive assembly up using a second line from the service rig;
securing a rod clamp to the polished rod below the rotary drive assembly, to secure the rod string;
then fully removing the rotary drive assembly;
replacing the packing; and
re-assembling the equipment.
This process can also be dangerous. Since the rod string is driven and rotated, it has a built-in torque. This torque can generate a back-spin force, which can cause injury to personnel in various situations.
With this background in mind, it is an objective of the present invention to provide a polished rod locking assembly, forming part of the pumping tree and preferably being an integral component of the tree, which locking assembly can be actuated to clamp onto the polished rod to prevent back-spin and to grip the polished rod with sufficient force so as to suspend the weight of the rod string.
It is another objective to provide a leverage assembly in conjunction with the locking assembly, which is operative to apply high axial torque to the locking means to better secure the rod string.
It is another objective to provide a locking means capable of functioning like a blind ram to seal off the vertical bore of the wellhead, when the polished rod has parted in the stuffing box.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, a polished rod locking assembly (“PRL assembly”) is provided for inclusion as part of the pumping tree of a wellhead. This PRL assembly can be closed to clamp onto and frictionally engage the polished rod, to prevent back-spin, and to grip it with sufficient force so as to be able to suspend the rod string from the wellhead during stuffing box maintenance. These actions and results are hereafter collectively referred to as “securing” the polished rod. More particularly, the PRL assembly comprises:
body means, which may be a separate component in a pumping tree formed of connected components or which preferably is integrated into a one piece integral pumping tree;
the body means forms a central bore (which forms part of the pumping tree vertical bore) and a pair of opposed, preferably horizontal, radial side openings. The side openings are internally threaded along part of their length and extend between the body means' outer peripheral surface and the central bore;
an externally threaded locking member is positioned in each body side opening. These locking members can be radially advanced to frictionally engage the polished rod. Each locking member preferally comprises an inner cylindrical member and an outer, rotatable, threaded shaft. The shaft functions, when rotated or screwed, to advance or retract the inner member. The cylindrical member and shaft are interconnected so that the inner member does not rotate while the rotating shaft pushes or pulls it. The inner member has a vertically grooved inner end face which will embrace the polished rod as it contacts and frictionally engages it. More preferably, the inner member is formed in two parts. The innermost part is horizontally pivotally connected to the outer part and there is a slight clearance between the two parts. The outer part closely fits the internal surface of the side opening and remains stationary. The innermost part can tilt to a limited extent to accommodate misalignment of the polished rod. Each locking member seals against the surface forming the side opening in which it is contained. The outer end of the locking member protrudes from the body means;
the inner end of an external lever arm is connected, preferably at right angle, with the protruding outer end of one of the locking members, for rotation or turning thereof. Movement of the outer end of the arm will cause the locking member to turn to a limited extent about its axis. Threaded means, such as a swing bolt having an annular head, is pivotally connected by means, such as a bolt, with the outer end of the arm. A post is anchored to the body means or tree. The post supports a rotatable sleeve at its outer end. The swing bolt extends through the opening formed by the sleeve. A nut, threaded on the end of the swing bolt, can be turned with relatively low torque to induce a relatively powerful lineal pull by the swing bolt on the arm. This causes relatively high torque to be applied to the locking member which in turn applies high lineal, inwardly directed force on the polished rod.
As a consequence, the locking members can be activated by hand turning their outer ends, to bring their inner end faces into firm contact with the polished rod. The arm and swing bolt assembly can then be introduced and operated to bias the locking member with considerable lineal force against the polished rod to ensure sufficient frictional engagement to secure the heavy rod string.
The specific described assembly provides a lever arm for turning the locking member and a mechanical means for biasing the arm's free end with a powerful lineal force to cause the locking member to secure the polished rod.
In another aspect, the PRL assembly is constructed so that it can operate as a “blind ram” to close the vertical bore of the pumping tree. More particularly, the body means and locking members are modified so that one locking member can retract sufficiently to enable the other locking member to extend across the vertical bore to close it. The other locking member carries seal means suitable for sealing the vertical bore from the radial openings when the locking member is in the closed position.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a prior art wellhead for a rotary pumping well comprising a pumping tree formed of interconnected separate components, the wellhead having a rotary drive assembly at its upper end;
FIG. 2 is a side view of a prior art wellhead for a rotary pumping well, incorporating an integral or composite pumping tree;
FIG. 2 a is a partly broken away perspective view of a prior art composite pumping tree;
FIG. 3 is a side view of a prior art wellhead incorporating an integral pumping tree having an integral shut-off valve;
FIG. 4 is a side view of a wellhead for a rotary pumping well comprising an integral pumping tree and having a PRL assembly constructed as an integral part of the tubing head adapter, the wellhead having a rotary drive assembly incorporating an integral stuffing box;
FIG. 5 is a side view of a wellhead incorporating an integral pumping tree having a shut-off valve and a PRL assembly constructed as an integral part of the tubing head adapter section of the tree;
FIG. 6 is a side view of a wellhead incorporating an integral pumping tree having a PRL assembly located above the production rod B.O.P.;
FIG. 7 is a side view in section of one embodiment of the PRL assembly;
FIG. 8 is a plan view in section of the assembly of FIG. 7;
FIG. 9 is a sectional side view showing part of the PRL assembly of FIG. 7, positioned within a partly shown housing or body and engaging a polished rod;
FIG. 10 is a sectional side view showing a self-aligning locking member positioned within a partly shown housing and engaging a polished rod;
FIG. 11 is a sectional plan view of the assembly of FIG. 10;
FIG. 12 is a sectional plan view showing a locking member connected with a leverage assembly;
FIG. 13 is a sectional side view showing an upper PRL assembly coupled with a leverage assembly, together with a lower production rod B.O.P.;
FIG. 14 is an external side view of part of the assembly of FIG. 13;
FIG. 15 is a sectional plan view of a PRL assembly, adapted to convert to a blind ram assembly covering the vertical bore, in an open position;
FIG. 16 is a sectional plan view of the PRL assembly of FIG. 15, in a closed rod-engaging position; and
FIG. 17 is a sectional plan view of the PRL assembly of FIG. 16, in a closed blind ram position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
One embodiment of the PRL assembly 1 is illustrated in FIGS. 4, 5 , 7 , 8 and 9 . This PRL assembly 1 comprises a body means 2 having a vertical central bore 3 extending therethrough. The PRL assembly 1 forms part of the bottom connection 31 of an integral production pumping tree 4 . The bottom connection 31 is adapted to mate and connect with the top connection 5 of a wellhead tubing head 6 . The PRL assembly bore 3 forms part of the vertical internal bore 67 of the wellhead 7 , through which the polished rod 8 extends and through which fluid is produced.
The body means 2 forms a pair of opposed horizontal radial openings 9 extending between its outer peripheral surface means 10 and the bore 3 . Each radial opening 9 has inner and outer sections 11 , 12 . The opening sections 11 , 12 have offset centerlines 14 , 13 . The outer opening section 12 has a larger diameter than the inner opening section 11 , so that a shoulder 15 is formed at their junction.
A pair of cylindrical members 16 are positioned in the radial opening inner sections 11 and are slidable therealong. Each cylindrical member 16 has inner and outer ends 17 , 18 . The inner end 17 of the cylindrical member 16 has an end face 19 forming a vertical groove 100 , for conforming with and engaging the polished rod 8 .
A pair of tubular gland assemblies 20 are threaded into the opening outer sections 12 . The gland assemblies 20 form part of the body means 2 . In the embodiment of FIGS. 8 and 9, each gland assembly 20 comprises an externally threaded tube 21 , an outer ring 22 , packing 23 and an inner ring 24 abutting the shoulder 15 . The threaded tube 21 can be actuated to energize the packing 23 . The tube 21 is also internally threaded.
A pair of screws or shafts 26 , having externally threaded outer ends 27 , extend through the gland assemblies 20 and engage the outer ends 18 of the cylindrical members 16 . The outer end 27 of each shaft 26 protrudes out of its associated gland assembly 20 so that it is accessible for rotation. The shaft 26 and cylindrical member 16 together make up a unit referred to as a locking member 50 .
Each shaft 26 has a T-shaped head 25 at its inner end, which is received in a correspondingly T-shaped slot 28 formed in the outer end 18 of its associated cylindrical member 16 . As a result of this connection and the offset centerlines, the shaft 26 and cylindrical member 16 are connected for axial movement together but the shaft can be turned without rotating the cylindrical member.
As illustrated, the PRL assembly radial openings 9 are positioned between stud holes 30 of the bottom connection 31 of the pumping tree 4 .
It is to be noted that in this previously described embodiment:
the body means 2 forms part of the bottom flanged connection 31 of an integral pumping tree 4 ; and
the axial centerlines 14 , 13 of each associated shaft 26 and cylindrical member 16 are offset and the two elements are connected by a T-shaped head 25 and slot 28 arrangement, whereby the elements are tied together and move as a unit axially, but the threaded shaft 26 (which generates the lineal locking force) can rotate without turning the cylindrical member 16 (which will be locked with the vertical rod 8 ).
In operation, each gland tube 21 can be screwed in, to compress its packing 23 and provide a seal around the unthreaded inner end 29 of the contained shaft 26 . To lock the polished rod 8 , the shafts 26 are advanced inwardly, biasing the locking members 16 into firm contact with the polished rod 8 .
In a variant, the inner end portions of the polished rod locking members 16 can pivot to align with the polished rod 8 , to thereby prevent damage to the rod's surface.
When the B.O.P. rams are closed about the polished rod 8 , the latter can be tilted slightly. If the polished rod cylindrical members 16 are rigidly fixed and perpendicular to the axis of the bore 3 , they can damage the tilted polished rod.
In this alternative assembly, shown in FIGS. 10 and 11, each cylindrical member 16 is formed in two parts, an inner part 16 a and an outer part 16 b . The parts 16 a , 16 b are connected so that they move together axially as a unit, but inner part 16 a can pivot slightly to self-align with the polished rod 8 . More particularly the inner part 16 a has a spherical nose 40 which is received in a spherical cavity 41 formed in the inner end of outer part 16 b . There is a slight clearance 31 between the cylindrical member parts 16 a , 16 b . A horizontal bolt 43 holds the parts 16 a , 16 b together while allowing part 16 a to pivot when it is fully inserted into the vertical bore 3 and has cleared the inner surface 32 of the tree side wall 33 . To prevent the inner part 16 a getting separated should the bolt 43 break, it has a short thread 44 which can be threaded past a short thread 45 formed by the outer part 16 b . The shaft 26 has a centerline 46 and the cylindrical member 16 has a centerline 47 , which centerlines are offset one from the other.
O-rings 101 are mounted around each cylindrical outer part 16 b , for sealing against the adjacent inside surface 65 of the radial opening 9 in which the part is contained. It will be noted that the gland assembly 20 in this embodiment does not contain packing.
The PRL assembly 1 has been described in terms of a body means 2 which is provided by two partial segments of the bottom connection 31 , positioned between pairs of bolt holes 48 as shown in FIGS. 4, 5 and 18 . This design is useful when the radial openings 9 are of relatively small diameter, as are the contained components. When it is desirable to use components of greater diameter, then the body means 2 involves a complete transverse layer of the tree 4 , as shown in FIG. 6 .
The PRL assembly 1 comprises a leverage assembly 51 which is designed with the following concept in mind:
the shafts 26 can be hand turned with a wrench to bring the cylindrical member end faces 19 into firm contact with the polished rod 8 —this is referred to as “hand tightening” the locking members 50 ;
the leverage assembly 51 can then be used to apply a much greater rotational torque to one of the shafts 26 to thereby increase the frictional force with which the end faces 19 secure the polished rod 8 .
The leverage assembly 51 is illustrated in FIGS. 12, 13 and 14 . It comprises a post 52 affixed to the tree 4 . The post 52 extends outwardly in parallel with the adjacent shaft 26 . A sleeve 53 is rotatably mounted on the outer end of the post 52 . The sleeve 53 can turn on the post 52 . The sleeve 53 forms a through-hole 69 . A horizontal, externally threaded swing bolt 54 extends through the through-hole 69 . At its inner end the swing bolt 54 has an annular head 55 . A nut 56 is screwed onto the outer end 57 of the swing bolt 54 . The nut 56 abuts the sleeve 53 . An arm 58 extends between the swing bolt's annular head 55 and the shaft 26 . The arm 58 has a hollow box-like section as shown in FIG. 12 . At its lower end, the arm 58 has a transverse hexagonal opening 59 . A hexagonal nut 60 is fixed on the shaft's outer end 27 . When the arm 58 is added to the leverage assembly 51 , its lower end opening 59 receives the shaft nut 60 and the arm 58 engages the nut 60 , so that they will turn together. At its upper end, the arm 58 has a second transverse opening 61 . A bolt 62 extends through the arm upper opening 61 and through the opening 63 of the swing bolt annular head 55 . A nut 64 locks the bolt 62 in place, to effect a pivoting connection between the upper end of the vertical arm 58 and the inner end of the horizontal swing bolt 54 .
From the foregoing, it will be appreciated:
that the swing bolt nut 56 can be turned to cause the swing bolt 54 to linearly retract to the right (having reference to FIG. 14 ), thereby applying a powerful pull on the bolt 62 linking the arm 58 and swing bolt 54 ; and
this bias or pull applied to the upper end of the arm 58 applies powerful torque to the shaft nut 60 , causing the shaft 26 to advance to linearly bias the cylindrical member 16 into tight frictional engagement with the polished rod 8 .
In another embodiment shown in FIGS. 15-17, the PRL assembly 1 comprises relatively long and short gland members 20 a , 20 b . One cylindrical member 16 c is longer than the other cylindrical member 16 d . One gland assembly 20 a is relatively longer than the other gland assembly 20 b . The gland assembly 20 a forms a longer cavity 70 a for accommodating the cylindrical member 16 c in the retracted or open position shown in FIG. 15 . The gland assembly 20 b forms a cavity 70 b which is adapted to accommodate the cylindrical member 16 d in the ‘blind’ position shown in FIG. 17, thereby enabling the cylindrical member 16 c to cover or extend across the vertical bore 3 . The cylindrical member 16 c carries a suitable seal 68 for sealing the vertical bore 3 and the radial openings 9 .
From the foregoing it will be understood that the body means 2 and the locking members 50 co-operate to enable one cylindrical member 16 c to extend transversely across the vertical bore 3 to close and seal it.
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The assembly functions to clamp onto and frictionally engage the polished rod of a well's rod string, with sufficient force to suspend the string from the wellhead. The assembly comprises an annular body forming opposed, radial, internally threaded side openings extending from its outer circumferential surface to its central vertical bore. An externally threaded locking member is positioned in each side opening and protrudes externally. The locking members can be manually threaded inwardly to engage the polished rod. An external leverage assembly is anchored to the body and engages one of the locking members. This leverage assembly can be manually turned to tighten the locking member against the polished rod with powerful axial force to provide enhanced gripping.
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This is a continuation of application Ser. No. 08/380,097, filed Jan. 27, 1995 now abandoned.
BACKGROUND OF THE INVENTION
The well known complications of blood transfusion namely incompatibility reactions, disease transmission, immunosuppression and the storage limitations of erythrocytes points to the need for the development of blood substitutes devoid of these shortcomings. Blood substitutes will have numerous applications provided they are safe, meet the viscosity and flow requirements, have long in vivo and shelf life and are cost effective. The products currently under development include perfluorocarbons and Hb-based oxygen carriers. Each of these preparations offer advantages and disadvantages but none appears to be useful for making an artificial blood substitute.
The present invention provides a modified hemoglobin and describes the use of the modified hemoglobin as a component of a blood substitute composition. It is well known that the hemoglobin molecule is present in erythrocytes and acts as the agent for the transport of oxygen in mammalian circulatory systems by binding and releasing oxygen. Hemoglobin is a conjugated protein with an approximate molecular weight of 64,000. It contains basic proteins, the globins and ferroprotoporphyrin or heme. It is essentially a tetramer consisting of two alpha chains each containing 141 amino acids and two beta chains each containing 146 amino acids. The binding site for oxygen in each of the monomers which make up the tetramer is the Fe +2 molecule in the heme molecule. The oxygen binding capability is modified by the presence of 2,3-di-phospho glycerate (2,3-DPG).The 2,3-DPG is reversibly attached to the central cavity of the Hb which is formed by the steric configuration of the hemoglobin molecule. It is known that when hemoglobin is separated from erythrocytes by hemolysis, it retains its ability to bind oxygen but loses its ability to readily release oxygen which is facilitated by the presence of 2,3-DPG. Even though free hemoglobin is commercially available as a genetically engineered material, its use as an oxygen carrier has not been possible because of its instability and the problem of the releasability of bound oxygen. In the blood circulation, free hemoglobin breaks down into its dimer and monomeric subunits which cannot be retained because of their relatively small size. These small fragments of hemoglobin are readily filtered by the kidneys and may pass through the subendotheilium. The fragments will also bind NO (endotheilial cell derived smooth muscle relaxing factor). The binding of NO causes elevation of the systemic and pulmonary vascular resistance.
The present invention provides a chemically modified form of hemoglobin that is stabilized and can efficiently bind and release oxygen. In addition the chemically modified hemoglobin may be polymerized to increase its molecular weight and increase its stability so that it will have a longer half life in the circulatory system and may be used as a stable oxygen transport mediator which is useful as the basis of a blood substitute. The chemical modification is achieved by the use of clofibric acid derivatives.
SUMMARY OF THE INVENTION
The present invention is directed to a modified form of hemoglobin which is prepared by reacting hemoglobin with a mono-, di-, tri- or tetrafunctional effector compound that will covalently bind to the central cavity of said hemoglobin and stabilize said hemoglobin against degradation by establishing intramolecular bridges and will modify the oxygen affinity of said hemoglobin.
Natural or mutant hemoglobin, obtained from a natural source or by genetically engineered processes, may be utilized in the practice of the invention. The compounds that may be reacted with hemoglobin are of the formulas: ##STR1## wherein R is a bond between the carbon atoms of the phenyl rings; ##STR2## n is 1 or 2; r is 1, 2 or 3 and B is the residue of a compound having an hydroxyl group which reacts with a carboxyl group to form an active ester which reacts rapidly (instantaneously to 3 hours) with a primary amino group. These compounds include N-hydroxysuccinimide, N-hydroxysulfosuccinimide; 3,5-dibromo-salicylic acid; N-hydroxyphthalimide and the like. N-hydroxysulfosuccinimide and 3,5-dibromo-salicylic acid are the preferred compounds for the synthesis of active esters when more soluble products are desired. ##STR3## wherein R is as defined above; B is as defined above; n is 1 or 2 and r is as defined above. ##STR4## wherein A is a bond between the carbon atoms of the phenyl rings, CH 2 ; ##STR5## --S--; --SO--; --SO 2 --; --CH 2 CH 2 --; or --CH═CH--. Q is --NH--, a bond between the carbon of the phenyl ring and the carbonyl group; or --CH 2 --; and B' is H or is the same as B which is defined above, provided that at least one B' is B, r is as defined above. ##STR6## wherein B and r are as defined above and m is 3. ##STR7## wherein B is the same as defined above.
Accordingly it is an object of the invention to provide compounds which may be used to prepare modified hemoglobin.
It is also an object of the invention to prepare a modified hemoglobin which may be used to prepare an artificial blood substitute.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 2 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 3 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 4 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 5 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 6 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 7 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 8 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 9 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 10 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 11 is a diagram which depicts structures of compounds which may be used to prepare esters to preppare modified hemoglobin.
FIG. 12 is a diagram which depicts structures of compounds which may be used to prepare esters to prepare modified hemoglobin.
FIG. 13 is a diagram which depicts structures of compounds which may be used to prepare modified hemoglobin which have been converted into the active ester form by esterification with N-hydroxy succinimide.
FIG. 14 is a flow sheet which shows the reactions which are used to make a difunctional compound for use in the invention.
FIG. 15 is a flow sheet whioch shows four different methods of preparing compounds to make the esters of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Some of the compounds of the invention which are used to prepare the active ester intermediates are known compounds and some are novel compounds. All of the active esters are novel compounds.
The preferred compounds of the invention are set forth in FIGS. 1-13 of the drawings and procedures for their preparation are shown in FIGS. 14-15.
Hemoglobin from any source may be reacted with the compounds of the invention to form the modified hemoglobin of the invention. Normal or mutant hemoglobins may be used as a starting material . Examples of these hemoglobins are described in Hematology, 3rd Edition, Williams et al., McGraw Hill, NY (1983), pp599-603, which is incorporated by reference. A preferred hemoglobin is Presbyterian hemoglobin, which is described in FEBS Lett.92:53 (1978) which is incorporated by reference. Other preferred hermoglobins are mutants, naturally or genetically engineered in which additional lysine and/or arginine residues are expressed within the central cavity of the hemoglobin molecule.
Although the applicants do not wish to be bound by any theory under which the invention is based, it is believed that the compounds of the invention react with the free amino groups in the hemoglobin molecule which are present on the lysine or arginine residue. It is known that in the central cavity of hemoglobin there are lysine residues and in the case of Presbyterian hemoglobin, there is an additional lysine residue which is substituted for an asparagine residue in each beta chain. It is believed that the presence of an addition lysine residue in Presbyterian hemoglobin provides an additional binding site for the compounds of the invention.
Generally, a mole ratio from 1:1 to 20:1 of effector compound to hemoglobin is used to prepare the modified hemoglobin although this ratio may be varied depending upon the desired results. If the hemoglobin is not prepared by genetic engineering, it will be necessary to purify the hemoglobin to remove any red cell stroma or other blood components using column chromatography.
The effector compounds may be reacted with the hemoglobin by directly adding the effector compound to a solution of hemoglobin which is dissolved in a suitable buffer (e.g. 0.1M HEPES buffer at pH 7.4). After completion of the reaction, the product is purified and recovered by column chromatography free of effector compound and degraded products. The degree of binding may be ascertained by changes in the oxygen equilibrium curve in a Hemox analyzer using the procedure set forth in J. Ned. Chem, (1989) Vol. 32, No. 10, 2352, which is incorporated by reference.
In order to prepare a blood substitute composition, the modified hemoglobin of the invention is polymerized to a weight average molecular weight of about 130,000 to 10,000,000, and preferably from 500,000 to 2,000,000. The blood substitute composition may be prepared and the polymerization of the modified hemoglobin may be carried out by using glutaraldehyde or other linking agent using the procedures set forth in Sehgal et al, Surgery, 95, 433-438 (1984); Sehgal, et al., Transfusions, 23, 158-162 (1983); Tam et al. Pro. Nat. Acad. Sci. U.S.A., 73, 2128-2131 (1976); Bunn et al., Amer. J. Hematol., 42,112-117 (1993); and Bunn et al. J. Exp. Med, 129, 909-924 (1969), all of which are incorporated by reference.
The blood substitute composition may be prepared using an effective amount e.g. 7% w/v of the modified hemoglobin in an isotonic aqueous medium which may also contain conventional electrolytes. The techniques of preparing blood substitute compositions is discussed in Nance SJ Ed.,Blood Safety, Current Chalenges,Am. Assoc. of Blood Banks, Bethesda, Md. (1992) pp151-167, which is incorporated by reference.
The following Examples describe the preparation of preferred compounds of the invention.
EXAMPLE 1
To a stirring solution of N-aminophenoxyisobutyric acid, (3.9 g (0.02 mole) in 2N NaOH (5 ml in 75 ml of tetrahydrofuran cooled in an salt ice bath, is added a solution of 2.90 g. (0.01 mole) of 1,1-methylene-bis-(3-chloro-4-isocyanato) benzene in 25 ml of tetrahydrofuran, dropwise during a period of one-half hour. At the end, the stirring was continued for 1 hour at room temperature. Most of the tetrahydrofuran was removed under vacuum distillation and 2.5 ml of 2N NaOH and 25 ml of water is added and the solution decolorized by charcoal and filtration. To the filtrate, 10% sulfuric acid is added to provide a pH of 2.0. The off-white powder was filtered, washed with water and air dried. The yield is 4.5 g. (70%) mp 282-285° C. The NMR and elemental analysis is consistent with the following structure: ##STR8##
EXAMPLE 2
A mixture of 383 mg. (1 mmole) of 2-(4-(3,5- dichlorophenylureido)phenoxy)-2-methyl-propionic acid prepared according to Example 4 of U.S. Pat. No. 5,093,367 and 126 mg. (1.1 mmole) of N-hydroxysuccinimide, 26 mg. (1.1 mmole) of dicyclohexylcarbodiimide in 15 ml of tetrahydrofuran was stirred at room temperature for 4 hours, Dicyclohexylurea formed and was filtered off. The solid product was washed with 5 ml of tetrahydrofuran and evaporation under vacuum yielded 450 mg of a powder. mp 106-162° C. The NMR and elemental 2 analysis is consistent with the N-hydroxysuccinimide ester of 2-(4-(3,5-dichlorophenylureido)phenoxy)-2-methyl-propionic acid.
EXAMPLE 3
A compound of the formula: ##STR9## is reacted with 1 equivalent of triethylamine in tetrahydofuran and gradually 1 equivalent of ethyl chloroformate is added to yield the mixed anhydride of the compound of formula (g). One equivalent of the beta-benzyl ester of aspartic acid dissolved in 1 equivalent of 2N NaOH in water is added to the mixed anhydride with stirring over an ice bath for one-half hour. The reaction mixture is allowed to stand for 2 hours at room temperature. The product is acidified with 10% sulfuric acid and is extracted with ethyl acetate and evaporated to dryness to yield the benzyl aspartate ester of compound (g). The product is reacted with N-hydroxy phthalimide in the presence of 1 equivalent of dicyclhexylcarbodiimide. The product is extracted and hydrogenated in methanol over 5% Pd-carbon at 60 psi for 2 hours. The benzyl group is removed to yield the free acid. Glutamic acid derivatives may be prepared similiarly using one equivalent of gamma benzyl glutamic acid instead of the beta benzyl ester of gamma aspartic acid: ##STR10##
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The present invention provides a chemically modified form of hemoglobin that is stabilized and can efficiently bind and release oxygen. In addition the chemically modified hemoglobin may be polymerized to increase its molecular weight and increase its stability so that it will have a longer half life in the circulatory system and may be used as a stable oxygen transport mediator which is useful as the basis of a blood substitute.
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BACKGROUND
[0001] The current invention is related to powering notification appliance circuits (NACs), and in particular to a system and method for providing boost voltage and load-sharing for a plurality of NACs.
[0002] Emergency systems, such as fire systems, often contain one or more NACs. These NACs provide power to several emergency notification devices such as, but not limited to, strobe lights and sirens. Each notification device has a specified working voltage and current. Regulations require these NACs to continuously provide a proper working voltage and current in order to ensure continuous, uninterrupted operation of the emergency notification devices. Therefore, a power source must supply enough power to the one or more NACs to provide a working voltage and current to each notification device, taking into account any voltage drops such as those caused by wiring impedances and power switches.
[0003] Traditionally, NACs have been powered through the use of a single power supply. The power supply often contains an AC power source that is converted from AC to DC power. If this power supply malfunctions, the NACs are powered entirely by a backup power source. The backup power source usually consists of a backup battery. Batteries can only operate at a given voltage for a limited amount of time before the voltage of the battery drops. Once the voltage of the battery falls below the required working voltage of the NAC, the notification devices will fail to function as specified.
SUMMARY
[0004] A system and method that provides a working voltage and current to one or more notification appliance circuits (NACs) includes a plurality of primary power supplies, and a backup power source, which provide power to the one or more NACs. Each primary power supply regulates its output voltage so that each supply sources an approximately equal current to the one or more NACs. Each primary power supply consists of an AC source, an AC-DC converter, a switching network, a load-sharing controller, and a boost regulator circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a block diagram of an embodiment of the present invention.
[0006] FIG. 2 is a block diagram of an embodiment of a primary power supply of the present invention.
[0007] FIG. 3 is a flow chart illustrating a method of providing load-sharing and boosted voltage for one or more NACs according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0008] The present invention describes an electrical power system that provides a working voltage and current to one or more notification appliance circuits (NACs). In particular, the system contains a plurality of primary power supplies, and one or more backup power sources. Each primary power supply contains an AC power source, an AC-DC converter, a boost regulator circuit, a load-sharing controller, and a switching network. The backup power source provides power to each of the primary power supplies in the event that a primary power supply's AC power source is unavailable or malfunctioning. The boost regulator circuit of each primary power supply boosts the voltage supplied to the respective primary power supply from the backup power source when the backup power source's voltage is no longer sufficient for the power system to supply a working voltage and current to the one or more NACs.
[0009] FIG. 1 is a block diagram illustrating an embodiment of electrical power system 10 for providing power to one or more NACs 16 a - 16 n. System 10 includes primary power supplies 12 a - 12 n, backup power source 14 , load-sharing bus 18 , and power supply path 20 . Each of the NACs 16 a - 16 n contain notification devices 22 a - 22 n. Notification devices 22 a - 22 n may be any notification device such as a siren or a strobe light. While illustrated schematically as a single backup power source, a plurality of backup sources may be used, such that each primary power supply 12 a - 12 n has its own dedicated backup power source 14 . Backup power source 14 may comprise one or more batteries.
[0010] The combination of primary power supplies 12 a - 12 n provide load-sharing for NACs 16 a - 16 n. Load-sharing is used in electrical power systems to provide a current to a load using multiple power sources in parallel. The circuit is designed such that each power source provides an approximately equal fraction of the total current of the system. This configuration provides redundancy and reliability, and eliminates the need for a single power source to provide large output currents to one or more loads.
[0011] Load-sharing in system 10 consists of providing a combined current from primary power supplies 12 a - 12 n to NACs 16 a - 16 n such that each primary power supply 12 a - 12 n provides an approximately equal current, and the combined current is greater than the current provided by any single primary power supply. For example, if NACs 16 a - 16 n require 30 amperes, each primary power supply 12 a - 12 n will regulate its output such that the current is approximately equal to 30/n amperes. If there are three primary power supplies, each source will provide a current that is approximately 10 amperes.
[0012] Load-sharing bus 18 is used to provide each primary power supply 12 a - 12 n with a voltage proportional to the highest current provided by any of primary power supplies 12 a - 12 n. Each primary power supply 12 a - 12 n may then compare the voltage on load-sharing bus 18 with a voltage representative of its own output current. If the voltage on load-sharing bus 18 is greater than the voltage representative of its own output current, the respective primary power supply will adjust its output voltage such that it outputs an approximately equal current to that communicated on load-sharing bus 18 . If the voltage on load-sharing bus 18 is not greater than the voltage of the respective primary power supply, the respective primary power supply will not adjust its output current.
[0013] If one of primary power supplies 12 a - 12 n fails to operate correctly, backup power source 14 will provide power in place of the unavailable primary power supply. For example, if there are three primary power supplies, all supplying 10 amperes of current, and one of the power supplies becomes unavailable, backup power source 14 will supply sufficient voltage to provide 10 amperes of current in place of the unavailable primary power supply.
[0014] In an alternate embodiment, backup power source 14 may take over and supply power in place of all primary power supplies 12 a - 12 n in the event that any one of primary power supplies 12 a - 12 n is unavailable or malfunctioning. In the example above, if one of the three primary power supplies becomes unavailable, all three primary power supplies will stop providing power, and backup power source 14 will take over and provide all 30 amperes to NACs 16 a - 16 n.
[0015] FIG. 2 is a block diagram of a primary power supply 12 . Primary power supply 12 includes AC power source 30 , AC-DC converter 32 , switching network 34 , boost regulator circuit 36 , backup power source input 38 , load-sharing controller 40 , diode 42 , output 44 , load-sharing output path 46 , load-sharing input path 48 , and load-sharing control path 50 . Backup power source input 38 receives power from backup power source 14 . AC power source 30 may be any readily available electrical power source and is typically AC mains power provided by a power utility company. AC-DC converter 32 converts the output of AC power source 30 to a DC output for supplying NACs 16 a - 16 n with a working voltage and current.
[0016] Switching network 34 is used to select between the output of AC-DC converter 32 , and the output of boost regulator circuit 36 . Switching network 34 selects the output of AC-DC converter 32 when AC power source 30 is operational. If AC power source 30 is unavailable or malfunctioning, switching network 34 selects the output of boost regulator circuit 36 .
[0017] Boost regulator circuit 36 operates to boost the voltage from backup power source 14 when a respective AC power source 32 is unavailable and backup power source 14 is not supplying enough voltage for power system 10 to provide a working voltage and current to NACs 16 a - 16 n. When the voltage of backup power source 14 falls below the voltage needed for system 10 to provide a working voltage and current to NACs 16 a - 16 n, respective boost regulator circuit 36 of each unavailable primary power supply 12 a - 12 n boosts the voltage from backup power source 14 such that a sufficient voltage for system 10 to provide a working voltage and current to each of the NACs 16 a - 16 n is provided.
[0018] For example, if two out of three primary power supplies are malfunctioning, and NACs 16 a - 16 n require a total of 30 amperes of current to operate, backup power source 14 must supply a sufficient voltage to each of the two unavailable primary power supplies to produce the missing 10 amperes of current. If the voltage necessary to produce the 10 amperes of current for each unavailable primary power supply is 22.5 volts, then each boost regulator circuit 36 of the unavailable primary power supplies will operate when the backup voltage source 14 is producing a voltage less than 22.5 volts on respective backup source input 38 . If no primary power supply is operating on backup power, boost regulator circuit 36 may operate to charge backup power source 14 .
[0019] Load-sharing controller 40 operates to regulate the output current on output 44 . Load-sharing controller 40 senses the current on output 44 and communicates to load-sharing output path 46 a reference voltage proportional to the output current. This reference voltage is communicated to load-sharing bus 18 through diode 42 . Diode 42 acts to diode OR the reference voltages of each of primary power supplies 12 a - 12 n. Therefore, the reference voltage is only communicated onto load-sharing bus 18 if the reference voltage is higher than the reference voltage that is already on load-sharing bus 18 . This ensures that load-sharing bus 18 will always contain the reference voltage of the primary power supply that is producing the greatest output current.
[0020] Load-sharing controller 40 uses load-sharing control path 50 to regulate the current on output 44 based upon the reference voltage on load-sharing bus 18 . If the reference voltage produced by load-sharing controller 40 is lower than the reference voltage on load-sharing bus 18 , load-sharing controller 40 will regulate the output voltage from AC-DC converter 32 or boost regulator circuit 36 , depending on which is selected, such that the output current on output 44 produces a reference voltage approximately equal to that of the reference voltage on load-sharing bus 18 .
[0021] FIG. 3 is a flowchart illustrating a detailed method 60 of providing load-sharing and boosted voltage for one or more NACs 16 a - 16 n. At step 62 , all primary power supplies 12 a - 12 n are functional. At step 64 , output voltages of each primary power supply are regulated such that each primary power supply provides approximately equal current to NACs 16 a - 16 n. At step 66 , it is determined if all primary power supplies 12 a - 12 n are operational. If one of the primary power supplies 12 a - 12 n is unavailable then power system 10 proceeds to step 68 . If all primary power supplies are operational, then power system 10 returns to step 64 and continues to regulate the output voltage of each primary power supply. At step 68 , switching network 34 of the primary power supply that is unavailable selects power from backup power source 14 . At step 70 , it is determined if backup power source 14 is supplying a sufficient voltage to provide a working voltage and current to NACs 16 a - 16 n. If backup power source 14 is not supplying a sufficient voltage, then power system 10 proceeds to step 72 . If backup power source 14 is supplying sufficient voltage, then power system 10 returns to step 64 and continues to regulate the output voltage of each primary power supply. At step 72 , boost regulator circuit 36 of the primary power supply that is unavailable boosts the voltage of backup power source 14 to a voltage that is sufficient to provide NACs 16 a - 16 n with a working voltage and current. After step 72 , power system 10 returns to step 64 and continues to regulate the output voltage of each primary power supply, including those primary power supplies providing output voltage from backup power source 14 .
[0022] In this way, the present invention describes an electrical power system that provides a working voltage and current to one or more notification appliance circuits (NACs). Although the present invention has been described with reference to preferred 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 invention.
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A power system includes one or more notification circuits for powering notification devices, a backup power source, and a plurality of primary power supplies. The primary power supplies are configured to provide a combined current to the notification circuits. Each primary power supply regulates its output current to equal a highest output current provided by one of the primary power supplies so that each contributes approximately the same current to the load. The primary power supplies also include boost regulator circuits for boosting the voltage of the backup power supply.
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This application is a division of Ser. No. 08/101,360, filed Aug. 3, 1993, now U.S. Pat. No. 5,561,861.
BACKGROUND OF THE INVENTION
The present invention relates generally to protective body garments such as commonly worn by surgical and other medical personnel, especially disposable surgical gowns, and relates more particularly to the provision of a single-ply circularly-knitted cuff for use in such garments to encircle body openings in the garment, such as the wrist openings at the end of the sleeves of a surgical gown.
As is well known, it is of paramount importance in the performance of surgical and many other medical procedures that sterile conditions be maintained and, toward this end, physicians, nurses and other medical personnel participating in or present during such procedures virtually always wear sterilized protective body garments over substantially the entirety of the person's body, along with taking other precautions and sterility measures, to minimize the risk of transmitting bacteria, germs, diseases and the like between the patient and the medical personnel.
One common protective garment of this type is a surgical gown worn about the upper body and typically comprising a torso-encircling main body portion, normally opening along its back panel with tie strings or the like to close the garment about the wearer's body, and a pair of sleeves extending from opposite sides of the main body portion for covering the wearer's arms.
For enhanced maintenance of sterility, it is desirable to provide such surgical gowns with cuff portions at the ends of the sleeves to conform to the wearer's wrists. A knitted cuff, commonly of a tubular circularly-knitted fabric, is preferable for this purpose.
One on-going problem continually facing the medical industry is how to accomplish the overriding objective of continuing to improve and advance the sterility of surgical and other medical environments while at the same time avoiding or at least minimizing unnecessary increases in medical and health care costs. Toward this end, the medical industry has turned in recent years to the use of disposable one-time or limited use surgical gowns which can be manufactured inexpensively from non-woven textile materials and eliminate the necessity and expense attendant to other garments of cleaning and sterilizing the garments after each use.
While disposable surgical gowns and like protective medical garments have proved to be an effective cost-saving measure, concern has developed that the material and fabrication costs associated with the provision of knitted cuffs on such garments is disproportionately high in relation to the remainder of the garments.
Typically, the knitted cuff on disposable surgical gowns is formed of a circularly-knitted rib-type textile fabric which is fabricated in extended lengths and made into individual cuffs during the gown fabrication process by cutting the circular fabric to discrete lengths, everting the cut fabric portion upon itself into a double-ply cuff to provide a finished edge at the fold line thusly produced, and then sewing the adjacent cut edges to the end of a sleeve.
Although a two-ply cuff is undesirable in that the dual thickness of fabric and the labor involved in the cutting and sewing process contributes to increased costs in the garment, the two-ply cuff is considered necessary from a functional standpoint to provide a finished end edge to the cuff so that it will not unravel and potentially shed fibers that may, for example, find their way into a surgical site.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved knitted cuff which is suitable for use in disposable surgical gowns and like protective medical garments and which is largely of a single-ply construction to reduce the attendant costs of manufacturing such garments. A further object of the present invention is to provide an improved cuff which will additionally reduce and simplify inventory and labor costs and procedures involved in the fabrication of such garments. The present invention also seeks to provide an improved method of fabricating disposable surgical gowns and the like by the use of the improved cuff.
Basically, the cuff of the present invention may be utilized in substantially any protective body garment of the type commonly worn by surgical and other medical personnel which comprises a main body for covering a portion of the wearer's body and an opening in the main body for extension therethrough of an extremity of the wearer's body. Typically and preferably, the cuff of the present invention will be utilized in disposable surgical gowns of the type having a main body robe portion for covering the wearer's torso and arms, with the robe portion having a pair of arm sleeves terminating at wrist openings therein for extension respectively therethrough of the wearer's arms. However, the invention is equally applicable as well to cuffs on other medical garments, e.g., on the leg portions of lower body medical garments.
In any case, a cuff according to the present invention is affixed to the garment body in surrounding relation to the opening or openings thereof. In accordance with the present invention, each such cuff basically comprises a circularly-knitted fabric tube having a main cuff body portion of a single-ply knitted construction terminating at an outer end of the cuff in an integral turned welt forming a finished cuff edge.
In the preferred embodiment, the circularly-knitted fabric tube of each cuff comprises a plurality of body yarns and an elastic yarn formed in needle loops extending in circumferential courses and axial wales. The turned welt of each cuff comprises a welt beginning course, a welt ending course, and a plurality of intervening courses, the welt beginning and ending courses being connected with one another by a set of connecting needle loops formed in selected spaced wales, e.g., every fourth wale, and the intervening courses comprising needle loops formed only in wales other than the selected spaced wales and in yarn floats across such wales.
The main cuff body portion preferably includes at least selected courses which have needle loops formed in every wale and, thus, the main cuff body portion is of a greater diameter than the turned welt of the cuff as a result of the absence of needle loops in the selected spaced wales of the welt's intervening courses, thereby forming the cuff of a tapered configuration.
For example, in the preferred embodiment, the main cuff body portion of each cuff comprises a first annular region adjacent the turned welt having courses formed of alternating needle loops and yarn floats and courses formed entirely of successive needle loops appearing in every wale, and a second annular region adjacent the first annular region having courses formed of alternating needle loops and tuck stitches and courses formed entirely of successive needle loops appearing in every wale.
It is preferred to form alternating and intervening courses of the circularly-knitted fabric tube with S-twist and Z-twist yarns so as to cooperatively provide a flattening effect on the fabric tube.
According to another aspect of the present invention, the single-ply cuff as described above enables a unique method for fabricating disposable and like surgical gowns to be carried out without the heretofore conventional necessity of cutting and folding a cuff preparatory to sewing to a gown. More specifically, in accordance with the present method, surgical gowns are fabricated by initially fabricating main body robe portions for the surgical gowns, with each robe portion having a pair of arm sleeves terminating at respective wrist openings therein. Then, a plurality of discrete individual annular cuff blanks are knitted for the surgical gowns on a circular knitting machine. Basically, the knitting of each blank comprises the steps of forming on the circular knitting machine an annular turned welt presenting a finished cuff edge, knitting integrally to the welt an annular main cuff body portion of a single-ply knitted construction, and then discharging from the knitting machine the integral welt and main cuff body portion as a discrete complete cuff blank upon completion of the knitting of the main cuff body portion. Such cuff blanks require no cutting, folding or other structural modification and can be easily inventoried in such form until needed for incorporation in the surgical gown, without any such intervening cutting, folding or other structural modification of the cuff blanks. The fabrication of the surgical gown is completed by affixing the main cuff body portion of one respective cuff blank to each sleeve of each robe portion in surrounding relation to the sleeve's wrist opening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a surgical gown having cuffs in accordance with the present invention;
FIG. 2 is an enlarged perspective view of one cuff of the surgical gown of FIG. 1;
FIG. 3 is an axial cross-sectional view of the cuff of FIG. 2, taken along line 3 — 3 thereof;
FIG. 4 is an enlarged cross-sectional view of the turned welt forming the finished outer edge of the cuff of FIG. 3;
FIG. 5 is a substantially enlarged, somewhat schematic diagram of the stitch construction of the turned welt of FIG. 4;
FIG. 6 is a substantially enlarged, somewhat schematic diagram of the stitch construction of one region of the single-ply main cuff body portion of the cuff of FIGS. 2 and 3; and
FIG. 7 is a similar substantially enlarged schematic diagram of the stitch construction of another region of the single-ply main cuff body portion of the cuff of FIGS. 2 and 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings and initially to FIG. 1, a surgical gown of the disposable type in which the cuff of the present invention is preferably embodied is indicated generally at 10 . Of course, as those persons skilled in the art will recognize and understand, the cuff of the present invention is equally suitable for use in reusable surgical gowns as well as in various other medical and like use garments, e.g., as ankle cuffs on surgical pants, and accordingly it is to be understood that the present invention is applicable to all such medical and like garments and is not limited to disposable surgical gowns, the description herein being provided solely as one illustrative and exemplary embodiment of the present invention.
The gown 10 basically includes a main body robe portion 12 sewn of a plurality of fabric panels (not indicated) into the shape of a human's upper body for protectively covering the wearer's torso and arms. A neck opening 14 is formed at the upper end of the robe portion 12 and the robe portion 12 includes a pair of sleeves 16 extending outwardly from opposite sides and terminating at wrist openings 18 . To facilitate placement of the gown 10 onto, and removal of the gown from, the wearer's body, a lengthwise slit-like opening 20 extends downwardly from the neck opening 14 for the full length of the robe portion 12 intermediate the sleeves 16 . Suitable tie strings 22 , 24 are provided at opposite sides of the opening 20 to secure the gown 10 in place once properly positioned on the wearer's body. A pair of annular cuffs 26 are sewn or otherwise secured to the respective free ends of the sleeves 16 to surround the wrist openings 18 .
Preferably, the robe portion 12 of the gown 10 is fabricated of a sufficiently inexpensive material to be disposable, e.g., a conventional non-woven textile material, whereby the gown 10 may be discarded after only a single use or possible a limited number of uses. The cuffs 26 are fabricated of a knitted construction, preferably circularly knitted and elasticized, so as to conform closely to the wearer's wrists.
As best seen in FIGS. 2 - 4 , the cuffs 26 are predominantly of a single-ply circularly-knitted construction for economical conservation of materials, with a small two-ply annular welt 28 at the outer axial end of the cuff to form a finished cuff edge 28 ′. More particularly, each cuff 26 is formed as a circularly-knitted fabric tube, generally indicated at 30 in FIGS. 2 and 3, having a main cuff body portion 32 entirely of a single-ply knitted construction integrally knitted at its outer end with the two-ply turned welt 28 .
Each cuff 26 is of a suitable axial length for use as a wrist cuff, preferably approximately three and three-quarters inches, of which the turned welt occupies less than approximately one-half inch of the overall cuff length. Each cuff 26 is tapered diametrically along its length, the turned welt 28 being of the smallest diametric dimension, preferably approximately two and one-half inches, and the main cuff body portion 32 having an increasing diametric dimension axially away from the turned welt 28 , preferably reaching a diameter of approximately four inches at the opposite axial end of the cuff 26 . The predominant length 35 of the main cuff body portion 32 is knitted with a ribbed stitch construction forming a plurality of circumferentially-spaced axially-extending ribs indicated at 34 .
As best seen in FIG. 4, the turned welt 28 includes an inner ply 36 and an outer ply 38 formed of a continuous extent of circularly-knitted fabric axially folded intermediately along its length to form the finished edge 28 ′, with the opposite ends of the inner and outer plies 36 , 38 being integrally knitted with one another by connecting stitches, representatively indicated at 40 , spaced circumferentially about the cuff 26 and with the outer ply 38 being integrally knitted also with the main cuff body portion 32 .
The annular region 42 of the main cuff body portion 32 immediately adjacent and directly knitted integrally with the outer ply 38 of the turned welt 28 generally follows the same stitch construction of the turned welt 28 for a relatively short axial extent of the cuff 26 , e.g., approximately one-half inch, and then merges integrally into the predominant ribbed region 35 of the main cuff body portion 32 .
The particular knitted stitch construction of the cuff 26 and the knitting method by which it is formed may best be understood with reference to FIGS. 5 - 7 . Each knitted cuff 26 is preferably formed on a circular hosiery knitting machine which may be of a variety of suitable single or multi-feed types commonly known within the knitting industry, although a multi-feed machine is preferred. Such knitting machines basically include a rotatable needle cylinder of a relatively small diameter with axial needle slots formed in spaced relation to one another about the outer circumferential surface of the cylinder. A plurality of latch-type knitting needles, each having a yarn receiving hook and a closable latch assembly, are reciprocably disposed within the axial cylinder slots. Preferably, the knitting machine has four knitting stations at which yarn feeding fingers or other feeding instruments are positioned for movement into and out of yarn feeding disposition adjacent the upper end of the needle cylinder to feed yarn to the needles thereat. The needles are operatively manipulated within their respective slots of the cylinder by stationary cams positioned adjacent the cylinder to engage and act on cam butts formed on the needles during the rotation of the needle cylinder. The knitting machine is operable to carry out the knitting of each cuff 26 beginning with the turned welt 28 and continuing therefrom through the main cuff body portion 32 . An appropriate control drum or similar control arrangement of a conventional construction is provided on the machine for determining the necessary transitional changes in the machine operation to form each portion of the cuff 26 .
For the knitting of the cuffs 26 in accordance with the preferred embodiment of the present invention, the knitting machine is initially set up with one yarn feeding finger at each of the four knitting stations of the machine equipped with an appropriate body yarn, e.g., a texturized multi-filament polyester or nylon yarn, suitable for forming the main fabric structure of the cuff. In addition, a designated one of the knitting stations is set up with another of its yarn feeding fingers equipped with an uncovered elastomer filamentary yarn to be fed to the needles simultaneously with the body yarn at such knitting station.
As will be understood, the needle and yarn manipulations carried out by the circular knitting machine serves to stitch the yarns fed to the needles at the various knitting stations into successive needle loops which extend in the resultant fabric in circumferentially-extending courses of needle loops and axially-extending wales of needle loops.
The initial knitting of the turned welt 28 at the beginning of the knitting process and the resultant stitch construction is shown in FIG. 5 . To begin the knitting of a cuff 26 , the knitting station having both elastic and body yarns is activated to feed the yarns simultaneously to every other needle in the needle cylinder so that the yarns are interlaced alternately in front of and behind the succeeding needles to form an initial fabric course C- 1 of the elastic and body yarns E, B, respectively, which will serve as a so-called “makeup” selvage edge. At the next succeeding knitting station, another body yarn B, preferably identical to that of the first knitting station, is fed to every needle of the knitting machine to form a second fabric course C- 2 wherein the successive needle loops thereof are drawn alternately to opposite sides of the elastic and body yarns E, B of course C- 1 . At the next succeeding knitting station, i.e., the third station of the machine, a third body yarn B, again preferably identical to the other body yarns B, is fed in a so-called three-by-one fashion to three of every four successive needles in the cylinder to form a third course C- 3 having a repeating pattern of three successive needle loops in three succeeding fabric wales (e.g., wales W- 3 , W- 4 , W- 5 ) followed by a single wale float in the intervening fabric wales (e.g., wales W- 2 , W- 6 ) of the body yarn B. The fourth knitting station feeds its body yarn B, also preferably identical to the other body yarns B, in the identical three-by-one manner as the third knitting station, thereby forming an identical succeeding course C- 4 .
Having completed one full revolution of the needle cylinder, the cylinder begins its second revolution with the first knitting station again feeding its elastic and body yarns E, B simultaneously to every other needle, thereby shedding the initial makeup course C- 1 and this time forming the elastic and body yarns E, B in plated needle loops in every other fabric wale (e.g., wales W- 1 , W- 3 , W- 5 , et seq.) and single wale floats in every intervening wale (e.g., wales W- 2 , W- 4 , W- 6 , et seq.). At the second knitting station, however, the control arrangement of the knitting machine changes the needle manipulation so that the yarn feeding finger and the needles cooperate to stitch needle loops in the same three-by-one manner as previously performed at the third and fourth knitting stations. In this manner, every fourth needle remains inactivated and thereby these needles continue to hold the needle loops of the body yarn B previously formed at the second knitting station during the first cylinder revolution. The operation of the third and fourth knitting stations remains unchanged.
During the third and each succeeding needle revolution of the needle cylinder for a predetermined number of cylinder revolutions sufficient to form the welt 28 , the knitting operation performed at the four knitting stations of the machine during the second machine revolution is repeated successively, whereby every fourth needle of the cylinder continues throughout to hold the needle loops formed thereon at the second knitting station during the first cylinder revolution. After completion of the predetermined number of cylinder revolutions has knitted a sufficient number of succeeding fabric courses to form the welt 28 , the machine's control arrangement again alters the needle manipulation at the second knitting station to activate every needle thereat during one selected cylinder revolution, thereby forming a plain-knit fabric course C-X and casting-off therefrom the needle loops previously held on such needles, which needle loops thereby form the connecting stitches 40 and, in turn, complete the formation of the turned welt 28 .
For a predetermined number of succeeding revolutions of the needle cylinder thereafter, the second knitting station is returned to the three-by-one manner of knitting operation followed during the previous formation of the welt 28 , while the operation of the fourth knitting station is altered to activate every needle to form plain-knit courses. The knitting operation at the first and third knitting stations remains unchanged. In this manner, the annular region 42 of the cuff 26 is knitted integrally with the outer ply 38 of the welt 28 in essentially the same knit construction as the welt 28 , excepting only that the courses formed by the fourth knitting station are of a plain knit rather than a three-by-one knit/float construction. The knitted construction of the annular region 42 thusly formed is depicted in FIG. 6 wherein course C-F represents the one-by-one knit/float construction formed at the first knitting station, courses C-F 1 and C-F 2 represent the knitted construction formed by the three-by-one knit/float operation of the second and third knitting stations, and course C-P represents the plain-knit construction formed by the operation of the fourth knitting station.
Upon completion of knitting of the annular region 42 of the cuff 26 , the knitting operation at the first, second and third stations is changed to produce the ribbed construction of the annular region 35 . Specifically, the first and third knitting stations are altered to operate in a so-called one-by-seven tuck/knit manner wherein every eighth needle in the cylinder is activated only to a tuck position sufficient to receive a newly-fed yarn but not to cast off a held previously-formed needle loop, while the seven succeeding intervening needles are fully activated to a knit position, thereby forming courses having seven succeeding needle loops alternating with single-wale intervening tuck stitches, as represented by courses C-T in FIG. 7 . The operation of the second knitting station is altered to activate all cylinder needles thereat so as to form plain-knit courses, while the fourth knitting station continues to operate in such manner, as represented by courses C-P in FIG. 7 . This manner of operation of the knitting machine continues for a sufficient number of cylinder revolutions (substantially greater in number than during the formation of the welt 28 and the annular region 42 ) to fabricate the remaining axial length of the cuff 26 . As will be understood, the tuck stitches alternating every eighth wale in the resultantly knitted fabric produce the axial ribs 34 through the annular fabric region 35 .
Upon completion of knitting of the ribbed fabric region 35 , the first and third knitting stations are deactivated and the second and fourth knitting stations are converted to knit in a one-by-one knit/tuck manner for a small number of final cylinder revolutions, after which the feed fingers at every knitting station are deactivated and the cuff 26 is thereby cast off the needles of the cylinder during the next succeeding revolution. The knitting machine then immediately begins the entire knitting process once again to begin the formation of another knitted cuff 26 .
As will be readily understood by those persons skilled in the art, knitted cuffs can be fabricated in a variety of other knitted constructions than the specific construction described above, using a variety of other alternative forms of knitting machines, for example but without limitation, knitting machines having a greater or fewer number of knitting stations and yarn feed fingers and knitting machines having a dial with reciprocable dial transfer jacks or other dial elements for use in forming the turned welt. Likewise, various additional or alternative yarns could be utilized, including additional elastic yarns. It has however been found to be preferable to utilize yarns having opposing S and Z twists to counteract one another and, in turn, cooperate in imposing a flattening effect on the knitted fabric. For example, in the embodiment just described, it is preferred that the body yarns fed at the first and third knitting stations have an opposing twist to the body yarns fed at the second and fourth knitting stations, whereby the torque of the yarns counteract one another to flatten the tubular fabric.
Advantageously, the knitted cuffs 26 produced by the present invention in the manner above-described uniquely enable the methodology by which surgical gowns are fabricated to be streamlined so as to reduce not only material costs but also fabrication time and labor costs. As previously described, conventional cuffs are formed from a continuously knitted length of a rib-type circularly-knitted fabric by initially cutting a desired length of the fabric, folding it axially into a double-ply configuration to form a finished edge at the fold location, and then sewing the two plies at the opposite end of the folded fabric to the sleeve of a surgical gown. This procedure disadvantageously necessitates the laborious and time-consuming post-knitting steps of cutting and folding the fabric preparatory to sewing, which of course adds to the overall cost of the surgical garment.
In substantial contrast, as will be understood from the foregoing description, the cuffs 26 in accordance with the present invention are knitted and cast off the circular knitting machine in the form of discrete individual cuffs blanks which are ready without any cutting, folding or other structural modification for immediate sewing into a surgical gown or other garment. Accordingly, cuff blanks fabricated in accordance with the present invention eliminate two labor-intensive steps from conventional fabrication methods and, in turn, eliminate the work-in-process inventory and storage requirements attendant to such intermediary steps. Of course, of equal significance is the advantage that the present cuff significantly reduces material costs by providing a one-ply cuff in replacement of the conventional two-ply cuff.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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A novel method of fabricating surgical gowns basically comprises the steps of fabricating main body robe portions for the gowns, each having a pair of arm sleeves terminating at respective wrist openings, knitting on a circular knitting machine a plurality of discreet individual annular cuff blanks for the gowns, and affixing, e.g., by sewing, one cuff blank to each sleeve of each robe portion in surrounding relation to the sleeve's wrist: openings. According to the invention, each cuff blank is knitted to have an annular main cuff body portion entirely of a single ply knitted construction, with an annular turned welt integrally knitted with one end of the cuff body. The material and fabrication costs associated with disposable surgical gowns and like medical garments may thereby be significantly reduced.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage of, and claims priority to, Patent Cooperation Treaty Application No. PCT/GB2015/050652, filed on Mar. 6, 2015, which claims priority to Great Britain Application No. GB1404184.2 filed on Mar. 10, 2014, each of which applications are hereby incorporated herein by reference in their entireties.
BACKGROUND
[0002] In the field of composite material components, it is known to produce components for vehicles, including aircraft, from composite materials, such as multi-layer fibre-reinforced resins and the like. It is also known that some elements manufactured from composite materials may experience localised stresses in or between the layers of fibre reinforcement.
SUMMARY
[0003] The present application relates to methods and systems for design and fabrication of composite material components and in particular, but not exclusively, to methods and systems that operate to identify potential problem areas and revise the design of those areas prior to fabrication.
[0004] Particular and preferred aspects are set forth in the appended claims.
[0005] Viewed from a first aspect, the present teachings relate to a method of designing a composite component for manufacture using a pre-impregnated uni-directional or woven material; the method comprising: creating a design for a composite component comprising multiple layers of pre-impregnated uni-directional or woven material; defining within the design a division of the design into a plurality of macroscale elements; for each macroscale element, defining a microscale relative volume element, determining model parameters for the microscale relative volume element, and upscaling the microscale relative volume element to provide a set of model parameters describing the macroscale element; using the set of model parameters for each macroscale element to analyse the design to identify the presence or absence of regions where structures likely to be detrimental to the integrity of the component would be expected to occur when manufacturing a component according to the design; if regions where structures likely to be detrimental to the integrity of the component would be expected to occur are identified, making data describing these regions available to a redesign process. Thereby and efficient process of design for manufacture can be carried out, thereby reducing the amount of time manufacturing candidate designs for testing before a design can be approved for manufacture.
[0006] Viewed from another aspect, the present teachings relate to a method of manufacturing a composite component, the method comprising: designing a composite component according to the approach of the present teachings; and manufacturing the component using pre-impregnated uni-directional or woven material.
[0007] Viewed from a further aspect, the present teachings relate to a computer program product comprising processor implementable instructions for causing a programmable computer to carry out the method according to the present disclosure.
BRIEF DESCRIPTION OF THE FIGURES
[0008] Examples in accordance with the present teachings will now be set forth by reference to the accompanying drawings, in which:
[0009] FIGS. 1A and 1B illustrates schematically how imperfections can arise in a multi-layer structure when subjected to debulking;
[0010] FIG. 2 is a micrograph image illustrating wrinkles in a multi-layer structure of the type illustrates schematically in FIG. 1 ;
[0011] FIG. 3 is a schematic representation of a part of a multilayer structure showing macro- and micro-elements defined therein;
[0012] FIG. 4 illustrates a comparison between higher order continuum modelling and standard finite element analysis modelling;
[0013] FIGS. 5A and 5B illustrate examples of higher order continuum modelling of radius consolidation internal buckling situations; and
[0014] FIG. 6 illustrates steps in an iterative design process.
[0015] While the presently described approach is susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that drawings and detailed description thereto are not intended to limit the scope to the particular form disclosed, but on the contrary, the scope is to cover all modifications, equivalents and alternatives falling within the spirit and scope as defined by the appended claims
DETAILED DESCRIPTION
[0016] The present teachings relate to design of composite components in which the design process includes steps that can identify likely areas for wrinkling to occur when fabricating a composite component according to the design. Such wrinkles can occur in various layers of a multi-layer uni-directional material used to form a composite component. In some composite manufacturing techniques, layers of uni-directional or woven material that will form reinforcing fibres in the completed component are laid up on or in a mould to create the shape of the component. Next a debulking process is carried out to press the layers together tightly in the mould. The layers of material may be pre-impregnated with a resin that is then caused to flow between the layers to create resin bonds therebetween and then cure by applying heat and/or pressure to the layers after debulking. Thus a composite component is made from fibre-reinforced resin and having multiple layers of fibre-reinforcement material in the component.
[0017] It has been identified that when fabricating components according to the above method, that individual ones of the layers can be deformed or distorted in some way as part of the lay-up and debulking processes. These distortions can include wrinkles or buckling in ones of the layers as the layers are pressed down into the mould as part of the debulking process. It will be appreciated that having wrinkling or buckling in the layers of a component fabricated from pre-impregnated uni-directional material is likely to compromise the structural integrity of the component, leading to an inherent weakness in the component in the region of the wrinkles and thus a manufactured component would likely need to be discarded, if the defect is noticed during quality assurance and testing. Accordingly, a component design may need to be made much thicker and heavier in order to reliably achieve a required strength during manufacture.
[0018] These principles of manufacturing difficulty with respect to wrinkling and buckling are illustrative examples of a wider contemplation of manufacturing defects. Thus although a modelling process as described herein is applicable to determining wrinkling issues in a composite component, other internal structure characteristics can also be understood from the modelling result, for example uneven fibre volume or porosity.
[0019] FIG. 1 illustrates in schematic terms how a debulking process could cause wrinkles to form in individual ones of the layers of a multi-layer composite component during manufacture. This figure illustrates the specific example of wrinkling around a corner radius, although it will be appreciated that a variety of component shapes and configurations could lead to wrinkling. FIG. 1A shows a mould 1 onto which four layers 3 a, 3 , 3 c, 3 d of pre-impregnated uni-directional material have been placed. FIG. 1B then illustrates the application of pressure for debulking in the form of arrows 5 that indicate an applied force. As can be seen in region 7 , the layers 3 a, 3 b, 3 c all suffer from some level of wrinkling as the layers are pressed closer together and closer to the mould such that the same amount of layer material has to fit into a smaller volume. As can be seen, the layer material is unable to move away from the region 7 due to the stop end 1 a that forms a part of the mould near the region 7 .
[0020] It will be appreciated that such wrinkling can be reduced by designing component curves and radii and choosing materials and processes of a composite element to allow space for the layers to move relative to one another during debulking. Such an approach thus allows the excess material that could form a wrinkle to move relative to the other layers so as to move away from the region in which less material is required after debulking than before debulking. Such moved material may be accommodated in other parts of the component without causing wrinkling.
[0021] Thus it can be seen that to be able to identify areas in a design where wrinkling may occur during a design stage before fabrication could have utility in the manufacture of composite components. The reader will appreciate that advantages of composite laminates are often compromised by high costs, long development time, and poor quality due to multiple defects, particularly in massive complex parts such as those found in aerospace applications. Thus an approach that can reduce the likelihood of manufacturing defects and reduce the amount of time required to repeated manufacture of test elements for testing prior to finalising a design for production manufacture may have widespread application in the composites industry.
[0022] However, it has also been established that to model the behaviour of even a simple composite component consisting of a small number of layers using conventional modelling approaches, such as finite element analysis, to capture the deformation of each layer require, even in these times of inexpensive and powerful computers, an excessive amount of computing power and time. To model a complex component such as may be required for an aircraft using such conventional techniques would take years of processing time, even with an extremely large resource of modern computer processors.
[0023] The present teachings however include an approach for modelling and subsequent analysis of a composite component design that significantly reduces the number of computations required and hence brings the analysis of a design for wrinkle problems into the realms of realistic possibility. This approach is described in more detail hereinunder.
[0024] The approach taken in developing the presently described techniques uses a higher order continuum method to model the behaviour of component in order to identify from a component design the likelihood for wrinkling to cause problems in manufacture and thus facilitate a redesign of the component if necessary.
[0025] Classical continuum methods can be used for modelling of stresses in complex structures and are operated by dividing the complex structures into representative volume elements. Such methods require the characteristic length scale of variations in the stress field (the distribution of stress of the state of stress in a component) to be much greater than the size of representative volume element “RVE” of that material. For such cases the stress, as in bending of an isotropic material, stresses may be considered uniform over the RVE.
[0026] In both cured and to a greater extend in uncured carbon fibre laminates, the relative weakness of the interface between layers gives plies the freedom to deform and bend independently. As a result when such a material is subjected to bending, the stress varies rapidly over a length scale proportional to the layer thickness. If the method is applied such that the size of the RVE is much greater than the layer thickness, the assumption that the stress field is uniform over the RVE is violated. For such cases higher order terms in the asymptotic expansions of the stresses, about a material point, become important. Variations in stresses over an element introduce internal bending moments at the loss of symmetry of the shear stresses. Continuum descriptions of such materials, at a scale greater than the layering, require the introduction of moment stresses (bending moments per unit area). The inclusion of higher order terms in the expansion of stress leads to a generalised higher order continuum.
[0027] Of the various higher order continuum or strain gradient continuum methods available (see G. Maugin and A. Metrikine (Eds.) Mechanics of Generalized Continua: One Hundred Years After the Cosserats, Springer, 2010), one example of a method suitable for modelling of composite components is the Cosserat continuum. A detailed discussion of the application of Cosserat continuum modelling to composite component design follows hereunder.
[0028] Cosserat continuums, introduced by the Cosserat brothers (see E. Cosserat and F. Cosserat. Theorie des corps deformables. Hermann, Paris, 1909) provides a natural framework where the macro-scale (average) description of a layered material can be derived. The effective large-scale material properties encapsulate both mechanical constitutive behaviour and the geometric heterogenities on the layer scale. As a result, such continuum models have no overt layer descriptions, but interfaces are assumed smeared across the laminate. Cosserat continuum models introduce independent rotational degrees of freedom at each material point, which allows the inclusion of bending moments per unit area or coupled stresses. Such continuum models have been developed to model a diverse array of physical systems, which exhibit a discrete nature at some intermediate length scale. These have included granular media (see R. De Borst Simulation of strain localization: a reappraisal of the Cosserat Continuum 1991), masonry structures (see I. Stefanou and J. Sulem Three-dimensional Cosserat homogenization of masonry structures:elasticity, 2008) and layered rock masses in geology (see C. Dai et al. Finite Element Analysis of Cosserat Theory for Layered Rock Masses 1993 and D. Adhikary and A. Dyskin A Cosserat Continuum Model for Layered Material, 1999).
[0029] In the presently discussed approach, techniques are applied for the development and application of a higher order continuum model for process modelling of uncured carbon fibres. In some examples, the presently disclosed techniques can provide the possibility of capturing the formation of small-scale defects in large aerospace structures, at a fraction of the computational cost of conventional methods. Such efficient modelling capabilities can provide the possibility of performing an iterative loop of analysis, in which input parameters such as material, component geometry and manufacturing conditions can be optimized to improve quality, efficiency and reliability of the manufacturing process.
[0030] As illustrated in FIG. 2 , a layered structure can suffer wrinkling during manufacture. The micrograph image of FIG. 2 generally corresponds to the conceptual illustration of wrinkling shown in FIG. 1 .
[0031] The anisotropy introduced by the layering means the macroscale elements are non-symmetric (as illustrated in FIG. 3 with reference to the stress parameters α. As a result, the computation for the model involves solving equilibrium equations for both conventional and moment stresses.
[0000]
∂
σ
xx
∂
x
+
∂
σ
zx
∂
z
+
f
x
=
0
,
∂
σ
xz
∂
x
+
∂
σ
zz
∂
z
+
f
z
=
0
and
∂
μ
xy
∂
x
+
σ
xz
-
σ
zx
+
m
y
=
0.
(
1
)
[0000] Where σ xx , σ zz , σ xz , and σ zx are conventional stresses, μ yx is the moment stress and f x , f z and m y are forces and internal moment respectively. These values are all averaged over the RVE (micro-element). This defines a Cosserat continuum representation of a layered material, whereby macroscale elements retain rotational degrees of freedom, Ω y .
[0032] As noted above, the present disclosure uses a definition of the macroscopic behaviour of a layered material by an equivalent continuum response. The approach of the present techniques thereby maintains the behaviour of layered structure without need to explicitly define the layers at a fine scale. This is achieved by introducing elements much greater than the layer thickness. As shown in FIG. 3 , a macro-element captures the average response of the all microscale elements within an RVE. Thus a macro-scale model can be derived from upscaling the microscale elements, limiting the number of degrees of freedom in the model, and consequently reducing the computational expense of the model. This homogenisation procedure can be summarised as follows. The macro and microscale descriptions are connected by the design of specific ‘mathematical operators’ adapted from methods introduced by Forest and Sab (see S. Forest and K. Sab Cosserat Overall Modeling of Heterogeneous Materials, 1998), the use of generalised eigenproblems which compute the relevant microscale modes which are to be captured on the macroscale (see N. Spillane et al. Abstract Robust Coarse Spaces for Systems of PDEs via Generalised Eigenproblems in the Overlaps, 2011) and an application Hill-Mandel criterion, generalised for a Cosserat Continuum, to ensure consistent strain energies across scales (see Mandel, J. Plasticite Classique et Viscoplasticite, CISM Lecture Notes, Udine, Italy, Springer-Verlag,1971 and R. Hill A self-consistent mechanics of composite materials. J. Mech. Phys. Solids, 1965 for the original criteria). The resulting Cosserat material properties for a uncured composite material, derived using this method, can be combined within a finite element formulation of equation (1), for which solutions can be obtained using any standard finite element solver.
[0033] In the application of these methods to composite component design, initially all layers and interfaces have been assumed identical and elastic, and the deformation and curvature measures can be assumed infinitesimal, following plane strain assumptions. These assumptions can be generalised to capture more general material models (viscous flow, friction and plasticity for example) and other processes such as cure kinetics and temperature distributions.
[0034] An example of the computational benefit derived from applying a higher-order continuum model, such as a Cosserat continuum model, will now be considered. This example employs a comparison between Cosserat continuum finite element analysis against a standard finite element analysis of a simple cantilever test for a multi-layered beam. The multi-layered beam used in the analysis consists of four isotropic elastic layers separated by a thin interface of shear stiffness k. The beam is clamped at one end and a transverse shear is applied to the face at the unclamped end. Solutions for increasing interlayer shear stiffness are calculated using Cosserat finite elements and standard finite elements, for which each layer and interface is modelled explicitly. FIG. 4 shows a plot of deflection of the right hand end against interlayer shear stiffness, for a multi-layered cantilever beam solved with standard finite element (A) and Cosserat finite elements (B). The analysis shown in FIG. 4 was prepared by adding the capability to calculate Cosserat finite elements in a commercially available finite element analysis tool named Abaqus™. Further examples of commercial packages to which such functionality could be added are discussed below.
[0035] It will be seen from FIG. 4 that the Cosserat finite elements give the same results as standard finite elements but requires significantly fewer elements requiring computational effort, of the order of 30 times fewer degrees of freedom (DOFs). Since computational time will scale, at best, with the square of the DOFs, the Cosserat finite elements provide for a calculation time approximately 900 times faster than conventional finite elements. For much larger calculations as seen in composite component design and manufacture applications, this difference is expected to diverge rapidly, with Cosserat finite elements showing even greater computational benefits over standard elements.
[0036] Further analyses conducted based upon the Cosserat finite element functionality produced in order to provide the comparison shown in FIG. 4 have been conducted for more structures and loading scenarios. For example, FIG. 5A shows an analysis of consolidation over a corner radius the lighter regions show areas in which in which layers of material are forced to shear over one other, a zone in which wrinkles are likely to form. In another example, FIG. 5B illustrates analysis to calculate internal wrinkle/buckling modes, with dark regions illustrating areas of greater vertical displacement. The Example in FIG. 5B shows an example where a rectangular block of material has been squashed on the right and left hand sides, while being constrained top and bottom. In each example, the finite elements, outlined by black boundaries, represent 8-10 layers, to make the physical changes more visible.
[0037] Thus comprehensive feedback can be presented to a designer while designing a composite component based upon efficient and time-effective analysis. Accordingly an iterative feedback process can be employed to provide a design for manufacture on a realistic timescale that moves at least a worthwhile part of defect testing of test-manufactured elements from to the design process.
[0038] The present disclosure outlines the application of a Multiscale Cosserat continuum framework to model the formation of wrinkling during consolidation of a laminate over a corner radii, a measure of the extent of wrinkling and thus a measure of the extent of defect likely to occur during manufacture is achieved. It is envisaged that this method can be used as part of an efficient iterative design procedure to minimise the possibility of wrinkles and other manufacturing induced defects. An outline of a possible design procedure is now described.
[0039] FIG. 6 shows an example of an iterative design approach for a composite component using Cosserat analysis to iteratively improve the design for a composite component that once manufactured will be made up of multiple layers of pre-impregnated uni-directional material. The process optionally includes manufacture of one or more components according to the design. In the example steps, the analysis used to inform the iterative process is concerned with the potential for defects caused by wrinkling in the layers of the component during manufacture. However the analysis may also be used to inform the design process in terms of other characteristics such as eventual bulk of the component in one or more parts of the component (for example where the dimensional envelope for the design requires certain parts of the design to provide an component that will fit between other elements of an assembled device or apparatus) and a predicted final fitness after cure for the component. These additional considerations may be used as well as or instead of the concern over wrinkling to inform the iterative process.
[0040] As illustrated in FIG. 6 , a component design is produced at step S 6 - 1 before being subjected to wrinkling analysis based upon a higher order continuum model at step S 6 - 3 . Although not illustrated, other analyses may be performed on the model with respect to, for example, projected weight, projected strength etc and these analyses may be conducted in parallel or in series with the wrinkling analysis of step S 6 - 3 .
[0041] The results of the analysis from step S 6 - 3 are then used to determine whether the design is likely to lead to wrinkling problems that would cause manufacturing defects. Thus at step S 6 - 5 , a test is performed to check whether the analysis results indicate potential manufacturing defects severe enough to cause the component design to be considered unacceptable. The threshold for likelihood of manufacturing defects can be set based upon the nature of the component and its intended use.
[0042] If the test at step S 6 - 5 determines that potential defects are severe enough to consider the design unacceptable, then at step S 6 - 7 the design is altered. The aim of the design alteration is to reduce the likelihood of wrinkling occurring during a manufacture in accordance with the design, without compromising the other key criteria for the design, which may include a dimensional envelope, strength requirements, etc. After the design alteration at step S 6 - 7 , the altered design is re-subjected to wrinkling analysis based upon the higher order continuum model at step S 6 - 3 .
[0043] Once the design has achieved a high enough level of manufacturability as against the test of wrinkling analysis, then the check at step S 6 - 5 will allow the design to proceed to step S 6 - 9 where the design is finalised for manufacture. This step may include a number of additional sub-steps, including outputting the design to a format that can be used in manufacture, but may also include the likes of design additions for post-cure surface finishing and minimum requirements for post-manufacture testing. This step may also or alternatively include defining post-manufacture testing parameters determined from the modelling in relation to demonstrating a final fitness after cure.
[0044] After the design has been finalised for manufacture at step S 6 - 9 , a component can be manufactured to the design at step S 6 - 11 . Manufacturing a component according to the design is an optional step and may be carried out separately to the design process. This separation may be physical (for example that the manufacture takes place at a location physically removed from the design location), temporal (for example that the manufacture takes place at a time long removed from the time of finalising the design) and/or fiscal (for example that the entity responsible for the manufacture is different to the entity that produced the design).
[0045] Thus it will be understood that the design of a composite component can be iteratively revised to reduce or eliminate design elements judged by way of modelling using a Cosserat continuum model to give rise to a likelihood of manufacturing defect.
[0046] As will be appreciated, the design of a composite component is typically performed using a software tool. There are many such tools available, for example Examples of well-known software tools for production of composite component designs include Abaqus™ produced by Dassault Systèmes Simulia Corp, ANSYS™ produced by ANSYS, Inc. and the Escript tool developed by the University of Queensland. The techniques of the present disclosure relating to optimisation of a design by way of using a Cosserat continuum model to analyse a design for a composite component that once manufactured will be made up of multiple layers of pre-impregnated uni-directional material can be used alongside or incorporated within such a software design tool.
[0047] In one example, the analysis can be provided by way of a so-called plugin module to the software design tool. On another example, the analysis can be conducted upon a design exported from the design tool by the analysis engine configured as a separate package. Whether a plugin or a separate software package, the analysis may be configured to analyse a design from the design tool and to provide an output highlighting areas of the design likely to cause manufacturing defect. In one example, the output from the analysis module could provide a visual indication overlaid to a view of the model showing areas of wrinkling that would be expected and the extent of that wrinkling. In some examples a colour-code system could show the extent of wrinkling expected. The output from the analysis module can then be used as an input to refine the design if need be, as discussed above.
[0048] Therefore, there has now been described an approach for efficiently and effectively analysing a composite element design to identify potential manufacturing defects before carrying out a step of manufacture. Thereby the design can be revised and re-analysed as many times as required to reach an acceptable design for manufacture. Once the design has been optimised in this way, manufacture can be carried out.
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A composite component can be designed for manufacture using a pre-impregnated uni-directional or woven material A design for a composite component comprising multiple layers of pre-impregnated uni-directional or woven material is created. Within the design a division of the design into a plurality of macroscale elements is defined. For each macroscale element, a microscale relative volume element is defined, model parameters for the microscale relative volume element are determined, and the microscale relative volume element is upscaled to provide a set of model parameters describing the macroscale element. The set of model parameters for each macroscale element is used to analyse the design to identify the presence or absence of regions where structures likely to be detrimental to the integrity of the component would be expected to occur when manufacturing a component according to the design. If regions where structures likely to be detrimental to the integrity of the component would be expected to occur are identified, data describing these regions is outputted to a redesign process.
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BACKGROUND OF THE INVENTION
This invention relates to a printer or typewriter, and more particularly to a printer or typewriter in which a ribbon supply is mounted on a stationary section of the machine and a print ribbon is passed through a print head on a carrier and is fed in relation to movement of the carrier.
In a printer or typewriter of the type described, and especially in a thermal printer or typewriter which has a thermal print head on a carrier, a print ribbon such as a ribbon having thermally transferrable ink thereon is fed an extent corresponding to a distance of and in a direction opposite to the direction of translatory movement of the carriage as the carriage advances to print a line of characters on a medium supported on a platen, or in other words, a print ribbon is fed in such a manner as to provide no relative movement between the medium and the print ribbon. If otherwise there is some relative movement between them, then ink once transferred to the medium will be diffused over the medium due to such relative movement and will blur the medium, resulting in poor print. A print ribbon feeding mechanism which attains such a print ribbon feeding manner as described just above is disclosed in a U.S. Pat. No. 3,855,448 and especially by an embodiment of FIG. 5 of the patent. This mechanism includes a clamp provided at a stationary section of the machine for clamping a used portion of a print ribbon while a print head is advancing, and a one-way roller provided on the carrier which allows the print ribbon to pass the same when the carrier advances but prevents the ribbon from passing in the opposite direction so that it draws out the ribbon from a supply reel when the carrier is returned to its leftmost end position while the ribbon is wound onto a takeup reel correspondingly. This arrangement, however, is somewhat disadvantageous in that a print ribbon is "fed" wastefully even when a carriage advances without printing any character, that is, without using the print ribbon, such as in a spacing or tabbing operation, since the print ribbon is fed an extent equal to a distance over which the carrier advances. Further, if a takeup reel is not appropriately driven to takeup a print ribbon in timed relationship with returning movement of the carrier in any position of the reel, then the ribbon may be either pulled so heavily to break or slackened between the takeup reel and the one-way roller to cause jamming. The patent, however, does not disclose any solution to this problem.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a printer having a print ribbon feed mechanism which provides a solution to such problems of conventional ribbon feed mechanisms and allows optimal feeding of a print ribbon, eliminating unnecessary consumption of the print ribbon.
It is another object of the invention to provide a new and efficient thermal ink transfer ribbon feed mechanism which can be advantageously employed in a thermal ink transfer printer in which a thermal transfer ink ribbon is used.
Other objects, advantages and features of the present invention will become apparent from the following detailed description of a preferred embodiment of the invention given in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly cutaway exploded perspective view of part of a printer according to the present invention;
FIG. 2 is an enlarged left-hand side elevational view, partly in section, of the printer of FIG. 1;
FIG. 3 is a vertical sectional view of a ribbon feed mechanism of the printer of FIG. 1;
FIG. 4 is a plan view showing an ink ribbon fed through a carrier in a left limit position; and
FIGS. 5 and 6 are rather enlarged plan views, in diagrammatic representation, showing an ink ribbon and a print head in different positions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a printer, indicated generally by the reference character P, includes a platen 1 extending horizontally between and supported at its opposite ends thereof on left and right side walls 4a and 4b of a frame 3 (partially illustrated for reasons of clarity) or stationary section of the printer P. A transverse operating bail 5 is rotatably supported on and extends across a major length of a rod 6 which extends in front of and in parallel relationship to the platen 1 between the side walls 4a and 4b. The operating bail 5 has bearing portions 7 and 8 at its opposite ends thereof at which it is supported on the rod 6. The bearing portion 7 has a lower lug 9 and an upper bent lug 11 formed on the lower and upper sides thereof, respectively. Tension springs 12 and 13 are connected to the spring hanger lugs 9 and 10, respectively, to urge the operating bail 5 counterclockwise about the rod 6. A pin 17 is secured to the lower lug 9 of the operating bail 5 and is received in an arcuate slot 16 formed in a forward end portion of a link 15 which is pivotally connected to the forward end of a plunger 14a of a solenoid 14. Thus, if the solenoid 14 is energized, the link 15 will be pulled back to rotate the operating bail 5 clockwise about the rod 6 against the urging of the springs 12 and 13.
A manually operable level 18 is supported for pivotal motion on a left end portion of a shaft 2 of the platen 1 and has a lower extension portion 18a which is positioned adjacent the bent lug 11 of the operating bail 5. A leaf spring 19 is secured to the side wall 4a and is resiliently abutted against a circumferential projection 20 formed on a bearing portion of the lever 18 to retain the lever 18 in any of its angular positions around the platen shaft 2. In one of the angular positions of the lever 18, the lower extension 18a is spaced from the bent lug 11 of the operating bail 5, and if the lever 18 is then turned counterclockwise in FIG. 2, the lower extension 18a of the lever 18 will be engaged to press the bent lug 11 to pivot the operating bail 5 clockwise against the springs 12 and 13.
A carrier 21 is supported at a lower rear portion thereof for sliding motion on the rod 6. The carrier 21 is substantially in L-shape in side view and has a recess 23 formed at a front end portion thereof (FIG. 2). A linear encoder 24 extends through the recess 23 of the carrier 21 between the side walls 4a, 4b of the frame 3. A support plate 28 of a substantially U-shape in plan is screwed to the carrier 21 and extends over a recess 27 formed between a pair of riser portions 25 and 26 at opposite lateral ends of a rear end portion of the carrier 21 as shown in FIG. 1, and an upstanding post 28a is provided on the left side of the support plate 21. A cap 43 is mounted, at its left end, on the remote end of the upstanding post 28a and, at its right end, on the upper end of a pin 34, designated more fully below.
A thermal print head 29 of a substantially rectangular shape in front elevation is supported at a lower end thereof for sliding motion on and for pivotal motion about the rod 6 and is located in position within the recess 27 of the carrier 21 so as to allow integral lateral movement thereof with the carrier 21 along the rod 6. The print head 29 has a column of heater or thermal elements (not shown) mounted thereon and electrically connected to a signal source (not shown) so as to be selectively energized to heat to allow ink to be transferred from a print ribbon 32 to a medium (not shown) supported on the platen 1 to effect printing of a character, as hereinafter described. The structure and configuration of the thermal elements and signal source for selectively energizing the thermal elements are well known in the art. A lateral slit 30 is formed in a portion of the print head 29 adjacent the riser portions 25, 26 of the carrier 21 and a downwardly bent rear marginal edge 5a of the operating bail 5 extends through the slit 30 of the print head 29 so as to allow the print head 29 to be pivoted back and forth about the rod 6 by the operating bail 5. A flexible flat cable 31 is connected to the print head 29 to provide for energization of the thermal elements on the print head 29.
Referring now to FIG. 2, when the lever 18 is its forwardmost position, as seen in FIG. 2, and the solenoid 14 is not energized, the operating bail 5 assumes, under the urging of the springs 12, 13, a position in which the print head 29 is resiliently pressed against the platen 1 as seen also from FIG. 5 (this position of the print head 29 will be hereinafter referred to as an "operative position"). In the operative position, the print head 29 can effect printing as hereinafter described. If, on one hand, the solenoid 14 is energized, then the link 15 will be pulled back against the the springs 12, 13 to pivot the carrier 21 clockwise about the rod 6 thereby to pivot the print head 29 in the same direction away from the platen 1 (this pivoted position of the print head 29 will be hereinafter referred to as a "first inoperative position). In the first inoperative position of the print head 29, printing operation cannot be effected actually. On the other hand, if the lever 18 is manually pivoted counterclockwise about the platen shaft 2, then the operating bail 5 will be pivoted clockwise about the rod 6 to pivot the print head 29, e.g., to the first inoperative position. The leaf spring 19, acting on the projection 20 of the lever 18, will retain the lever 18 and hence the print head 29 in the pivoted position and the first inoperative position, respectively. If the lever 18 is pivoted further in the same direction, then the print head 29 will be further pivoted away from the platen 1 to an allowable limit position (this position is indicated by phantom in FIG. 5 and will be hereinafter referred to as a "second inoperative position").
A lever 33 is located on the support plate 28 of the carrier 21 and is mounted at the right rear end 28c thereof for pivotal motion on a pin 34 on the support plate 28. The lever 33 has a projection 35 formed at the center of a rear marginal edge 33b thereof. A friction member 37 made of a frictional substance such as rubber is secured to a finger 36 formed at a left rear end portion of the lever 33. The lever 33 is urged to pivot in a clockwise direction in FIG. 4 about the pin 34 by a tension spring 38 so as to press the friction member 37 thereon against a guide member 39 secured to the left rear end 28b of the support plate 28. In this position of the friction member 37 and/or the lever 33, which will be hereinafter referred to as a "clamping position", a print ribbon 32 is normally clamped between the friction member 37 and the guide member 39.
Another lever 40 generally of a triangular shape is mounted at a central portion thereof for pivotal motion on a pin 41 extending between support plate 28 and the guide member 39. A projection 40a at the right end of the lever 40 is located adjacent a rear face of a leftward extension 29a of the print head 29 and another projection 40b at the left end of the lever 40 is located adjacent an oblique rear edge 33a of a left end portion of the lever 33. Thus, when the print head 29 is brought into the aforementioned operative position from, for example, the aforementioned first inoperative position, the lever 40 is pressed at the right end projection 40a thereof by the extension 29a to pivot in a counterclockwise direction about the pin 41 in FIG. 5, whereupon the lever 33 is pushed by the left end projection 40b of the lever 40 and is rotated in a counterclockwise direction about the pin 34 in FIG. 5 against the urging of the spring 38, displacing the friction member 37 from the clamping position into a releasing position (FIG. 5) in which the print ribbon 32 is clear of and free from the friction member 37. On the contrary, if the print head 29 is brought out of the operative position, then the lever 33 is permitted to be pivoted clockwise about the pin 34 into the clamping position as seen in FIGS. 4 and 6 by the urging of the spring 38 thereby to pivot the lever 40 clockwise about the pin 41.
A guide roller 42 is also supported for rotation on the pin 34, and a cap 43 is mounted at the top of the pin 34 and of a post 28a erected in a left rear portion of the support plate 28.
Referring now to FIGS. 1 to 3, a ribbon feed mechanism, generally designated at 44, is provided adjacent the left front corner of the printer P. The ribbon feed mechanism 44 includes a pair of shafts 46 and 47 secured to a base plate 45 of the printer frame 3 in a spaced relationship from each other. A gear 49 is rotatably mounted on a lower portion of the shaft 46 and has a wire drum 48 integrally formed therewith. The gear 49 is meshed with a drive gear 58 (see FIG. 4) mounted on an output power shaft 59a of a stepping motor 59 which is mounted on the printer frame 3. Another gear 51 is also rotatably mounted on an upper portion of the shaft 46 and has upper and lower cylindrical hubs 50a and 50b integrally formed therewith. A spring clutch 52 is mounted on and extends over a sleeve member 50c secured to the lower hub 50b of the gear 51 and an adjacent hublike portion 49a of the gear 49, as best shown in FIG. 3. The spring clutch 52 is arranged to transmit clockwise rotation of the gear 49 and counterclockwise rotation of the gear 51 to the gears 51 and 49, respectively, but allows no transmission either of counterclockwise rotation of the gear 49 or of clockwise rotation of the gear 51. Inner and outer flanged wheels 53 and 54 are rotatably mounted on the upper hub 50a of the gear 51 and the former is fitted in the latter in a manner of splined coupling (not specifically illustrated) so as to provide for integral rotation and axial displacement relative to each other. The inner wheel 53 has four fingers 57 extending upwardly from the top thereof. An annular friction member 56 made of a hard felt material is interposed between the flange 54a of the wheel 54 and the gear 51 and a compression spring 55 is interposed between the flanges 53a and 54a of the inner and outer wheels 53 and 54 to urge the wheel 53 axially upwardly away from the other wheel 54 and to urge the wheel 54 axially downwardly to press the annular friction member 56 against the gear 51 so as to allow integral rotation between the gear 51 and the wheels 53 and 54.
A gear 60 similar to the gear 51 is rotatably mounted on the shaft 47 and is meshed with the gear 51 so that energization of the motor 59 will rotate the gear 60 through the gears 58 and 49. The gear 60 has cylindrical upper and lower hubs 61a and 61b. A spring clutch 63 is mounted on and extends over a sleeve member 61c secured to the lower hub 61b of the gear 60 and a hublike portion 62a of a support 62 secured to the base plate 45. The spring clutch 63 is arranged to allow counterclockwise rotation of the gear 60 but allows no clockwise rotation of the same and hence allows no counterclockwise rotation of the gear 51 meshed with the gear 60. Inner and outer wheels 64 and 65 having flanges 64a and 65a, similar to the inner and outer wheels 53 and 54, respectively, are mounted rotatably on the upper hub 61a of the gear 61 and an annular friction member or wheel 67 is interposed between the gear 60 and the flange 65a of the outer wheel 65. A compression spring 66 is interposed between the inner and outer wheels 64 and 65 to urge the wheels 64, 65 axially away from each other thereby to press the annular friction member 67 against the gear 60. The inner wheel 64 has four fingers 68 extending upwardly from the top thereof.
An endless wire or cable 69 is secured at an intermediate portion thereof to the carrier 21 and extends substantially linearly between and around pulleys 70 and 71 which are rotatably mounted adjacent both side walls 4a, 4b of the printer frame 3, respectively. The wire 69 further extends from the pulleys 70, 71 to the wire drum 48 of the gear 49 around which it is wound in several turns. Thus, when the gear 49 is rotated by energization of the motor 59, the carrier 21 is moved to the right or left across the rod 6.
Referring to FIGS. 3 and 4, as the motor 59 is energized to rotate the gear 58 in the clockwise direction in FIG. 4, the gear 49 is rotated in the counterclockwise direction about the shaft 46 thereby to move the carrier 21 and the print head 29 in the rightward or forward direction. But, this rotation of the gear 49 will not be transmitted to the gear 51 due to the arrangement of the spring clutch 52 as described hereinabove. On the contrary, as the motor 59 is energized to rotate the gear 58 in the counterclockwise direction, the gear 49 is rotated in the clockwise direction thereby to move the carrier 21 and the print head 29 in the leftward or backward direction. The spring clutch 52 now transmits this rotation of the gear 49 to rotate the gear 51 in the same or clockwise direction. The gear 51 in turn rotates the gear 60 in the counterclockwise direction, this rotation of the gear 60 being allowed by the spring clutch 63 as described hereinabove.
Referring now to FIGS. 1 to 4, a ribbon cassette 72 may be mounted in position on the ribbon feed mechanism 44. The ribbon cassette 72 has a supply spool 73 and a takeup spool 74 contained therein. Both spools 73, 74 have axial sectoral holes 75 and 76 formed therein, and when the ribbon cassette 72 is set in position, the fingers 57 and 68 of the inner wheels 53 and 64 extend into the sectoral holes 75, 76 of the spools 73, 74, respectively, as seen from FIG. 3. Accordingly, if the inner wheel 53 or 64 is rotated, the spool 73 or 74 will be rotated thereby. The cassette 72 has openings 77 and 78 formed in a spaced relationship in a rear cassette wall 72a (FIG. 4) to allow a print ribbon 32, which may be a thermal ink transfer ribbon, to go out of and come back into the ribbon cassette 72, respectively. A rearwardly projected guide nose 79 is located adjacent the left opening 78 and has a rounded face 79a for guiding the print ribbon 32, while a guide roller 80 also for guiding the ribbon 32 is rotatably mounted in the right opening 77. Thus, the print ribbon 32 extends from the supply spool 73, passing the guide roller 80, going out of the cassette 72 from the opening 77, passing the guide roller 42, the print head 29 then the rounded face 79a of the guide nose 79 of the cassette 72, coming into the cassette 72 through the opening 78, to the takeup spool 74, as seen from FIG. 4.
The ribbon cassette 72 is constructed and located such that, when the carrier 21 is in the allowable leftmost limit position, the carrier 21 extends within a lateral range defined by the two openings 77 and 78 of the ribbon cassette 72 in order to facilitate replacement of the ribbon cassette 72 with another replacement ribbon cassette 72, as described hereinafter.
A lever 81 is pivotally mounted on an upright pin 83 secured to the side wall 4a and is urged to pivot in a counterclockwise direction about the pin 83 by a tension spring 84 (FIG. 1). Thus, when the print head 29 is in the operative position and hence the lug 11 of the operating bail 5 is in the rearmost position, the lever 81 is abutted at an end face 81b thereof by a flat side face 79b of the rearwardly projecting guide nose 79 of the ribbon cassette 72 to clamp the print ribbon 32 therebetween (this position of the lever 81 will be hereinafter referred to as a "clamping position"). But, if the operating bail 5 is pivoted to bring the print head 29 to the first inoperative position from the operative position, then the lug 11 of the operating bail 5 will be engaged to push the lever 81 to pivot clockwise against the urging of the spring 84 to a position in which the end face 81b thereof is spaced from the flat side face 79b of the guide nose 79 of the ribbon cassette 72, as seen in FIG. 4. If the operating bail 5 is further pivoted to bring the print head 29 to the second inoperative position, then the lever 81 will be further pivoted to provide a greater distance between the end face 81b of the lever 81 and the flat side face 79b of the guide nose 79 of the ribbon cassette 72, as seen in FIG. 6 (the last two positions of the lever 81 will be hereinafter referred to as a first releasing position and a second releasing position, respectively).
When a new ribbon cassette 72 is to be set in position, e.g., in place of an old or used up ribbon cassette 72, the carrier 21 may be brought to the leftmost limit position as seen in FIG. 4 and the lever 18 will be manually pivoted to its rearmost position to bring the print head 29 and hence the lever 33 to the second inoperative position and the second releasing position to bring the lever 81 to its second releasing position, as seen from phantom in FIG. 5, respectively. Then, in this position, after removal of the old cassette 72 which may have been on the ribbon feed mechanism 44, a new ribbon cassette 72 will be placed in position and a portion of a print ribbon 32 outside the cassette 72 may be threaded to pass around the roller 42, between the print head 29 and the platen 1, between the the friction member 37 and the guide member 39, and between the end face 81b of the lever 81 and the guide nose 79 of the ribbon cassette 72. In this position, the lever 18 will now be pivoted to its forwardmost position. As a result, the print head 29 will be brought to its operative position to hold a portion of the ribbon 32 against a medium (not shown) on the platen 1 and hence the lever 33 will be brought to its first releasing position while the lever 81 will be brought to its clamping position thereby to clamp another portion of the ribbon 32 between the end face 81b thereof and the flat side face 79b of the guide nose 79 of the ribbon cassette 72, as shown in full lines in FIG. 5, to allow subsequent printing operation by the print head 29. However, it is to be noted that, if a latching solenoid (not shown) is advantageously employed alternatively for the solenoid 14, then the print head 29 may be arrested in the first inoperative position when the solenoid 14 is not energized, as shown in full lines in FIG. 4.
When a character or symbol is to be printed, the stepping motor 59 is energized to advance the carrier 21 by increments corresponding in number to columns constituting each or the one character, and at each incremental position, heating elements (not shown) arranged in a column on the print head 29 are selectively energized to allow dot images of ink to be transferred to the medium or paper (not shown) on the platen 1 from the ribbon 32, as well known to those skilled in the art. During such movement of the carrier 21, the ribbon 32 is clamped by and between the end face 81b of the lever 81 and flat side face 79b of the guide nose 79 of the ribbon cassette 72, and hence, as the carrier 21 advances, a tensile force is applied to the ribbon 32 to urge it to unwind from and rotate the supply spool 73 in the counterclockwise direction in FIG. 4. Thereupon, the urging force acts to rotate the wheels 53 and 54 and the gear 51 in the counterclockwise direction, but since the gear 51 is held from counterclockwise rotation due to the arrangement of the spring clutch 63, only the wheels 53 and 54 are allowed to be rotated clockwise together with the supply spool 73 by the urging force due to a slip between the outer wheel 54 and the friction member 56. As a result, when the carrier 21 advances in the rightward direction for printing a character, the print ribbon 32 is unwound and supplied from the supply spool 73 by an extent corresponding to (that is, substantially twice of) a distance over which the carrier 21 moves.
On the other hand, when the carrier 21 advances rightwardly while no printing operation is effected, such as in a spacing or a tabbing operation, the solenoid 14 is energized so that the print head 29 and the lever 81 are held in their respective first inoperative positions releasing the print ribbon 32 while the lever 35 takes the clamping position, as seen in FIG. 4. Thus, during such movement of the carrier 21, the print ribbon 32 is clamped at a portion thereof by and between the lever 33 and the guide member 39, and hence a tensile force is applied to the ribbon 32 to unwind the ribbon 32 from the supply spool 73 and also from the takeup spool 74. As a result, the ribbon 32 is allowed to be supplied, on one hand, from the supply spool 73 in a similar manner as described above, but by an extent substantially equal to a distance over which the carrier 21 advances since here the print ribbon 32 is clamped on the carrier 21. On the other hand, the tensile force to unwind the ribbon 32 from the takeup spool 74 urges the spool 74 and hence the wheels 64 and 65 as well as the gear 60 in the clockwise direction about the shaft 62. Since the gear 60 is held from clockwise rotation by the arrangement of the spring clutch 63, only the takeup spool 74 and the wheels 64 and 65 are allowed to rotate in the clockwise direction due to the arrangement of the friction member 67, thereby discharging the ribbon 32 from the spool 74 substantially by the aforementioned extent, In this way, during movement of the carrier 21 without printing operation, the print ribbon 32 is not moved or fed relative to the print head 29, thereby decreasing consumption of or saving the print ribbon 32.
Also during returning movement of the carrier 21 in the leftward direction, the solenoid 14 is energized to position the print head 29 and the lever 81 in the respective first inoperative positions and the lever 33 in the clamping position, as seen in FIG. 6. But now, the motor 59 is energized to rotate the gear 49 in the reverse or clockwise direction in FIG. 4. Thus, as the carrier 21 moves backwards, the supply spool 73 is rotated clockwise to take up the ribbon 32 thereon correspondingly. On the other hand, clockwise rotation of the gear 51 rotates the gear 60 and as a result the takeup spool 74 is rotated in the counterclockwise direction to take up the ribbon 32 thereon.
Whether the print ribbon 32 is supplied from or taken up onto any of the supply and takeup spools 73 and 74, the gear 51 and/or the gear 60 are rotated a sufficient amount to take up the ribbon 32 by an extent much greater than a distance of movement of the carrier 29, but the arrangement of the frictional members 56 and 67 allows the ribbon 32 to be taken up only by a required distance, keeping the ribbon 32 taut between the carrier 21 and the ribbon cassette 72.
It is to be understood that the abovedescribed embodiment is merely illustrative of the invention. Numerous other arrangements may be derived by those skilled in the art without departing from the spirit and scope of the invention. For example, while in the embodiment described above the gear 49 which is connected to the motor 59 and has the wire drum 48 for the carrier indexing wire 69 is mounted in coaxial relationship with the supply spool 73 and the wheels 53 and 54, the gear 49 may otherwise be mounted in coaxial relationship with the takeup spool 74 and the wheels 64 and 65. In this modification, the direction of rotation of the motor 59 and the winding direction of the wire 69 will be reversed and the spring clutch 52 will cooperate with a portion of the stationary section 45 of the machine. It is thus contemplated that all such variations and modifications are to be construed in accordance with the following claims.
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A printer having a print ribbon feed mechanism is disclosed which allows optimal feeding of a print ribbon, eliminating unnecessary consumption of the ribbon. The mechanism includes first and second clamp means mounted on a stationary section and a print carrier of the machine, respectively, which are both controlled in accordance with movement of a print head from and to a print enabling position. Means are provided which are connected to a carrier indexing mechanism for impositively driving print ribbon supply and takeup spools disposed on the stationary section to wind a print ribbon onto them during a carrier return operation whereas they allow the ribbon to be unwound from the ribbon spools when the carrier advances.
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/482,151, filed on May 3, 2011, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Controlling particles and other contaminants has always been of paramount importance in semiconductor processing. As such, wafers that are processed into integrated circuits are stored and transported in enclosed environments, typically front opening boxes, sometimes known as FOUPS (front opening unified pods) and FOSBS (front opening shipping boxes). These wafer containers hold the wafers in spaced stacked arrays and have sealable doors that may be robotically opened. The containers also have features permitting conveyance and robotic access to the wafers. As the circuit sizes have decreased, the importance of the integrity of the wafer containment environment has increased. In advanced semiconductor processing, particularly 40 nm and below, moisture control of the wafers at or below 10% or 5% relative humidity (“RH”) has been found to be very beneficial or critical for desired integrated circuit yields. To control moisture inside the wafer carriers that transport and store wafers gas purge, such as nitrogen, is utilized to replace the ambient atmosphere.
SUMMARY OF THE INVENTION
[0003] Maintaining the wafer containment environment below 5% RH in FOUPS and FOSBS has been discovered to create particulate problems, particularly relating to the top wafer in the spaced stacked arrays, and particularly during transporting FOUPS by their robotic flange located on the top of FOUPS. Means to provide enhanced particulate control, particularly in applications where less that about 5% RH is maintained.
[0004] A particulate shield positioned above the top wafer in wafer containers such as FOUPS may be provided to prevent accumulation of particulates on wafers. The particulate shields or barriers may be formed of materials that are compatible to maintaining less than 5% RH, particularly materials that will not absorb meaningful amounts of water, and that will not bring absorbed moisture into the container. In embodiments, particular materials found to be suitable include cyclic olefin polymers, cyclic olefin copolymers, liquid crystal polymers. In particular embodiments, a FOUP may be provided with an additional slot above the industry standard 25 slots to receive a dedicated barrier. In embodiments, the barrier may be a solid thin shape that corresponds to or overlays the wafer shape. In embodiments, the barrier may have inherent charge properties opposite to the particulates found in the containers to thereby attract the particulates to the barrier. In embodiments the barrier may have apertures, such as slots, or other openings, to facilitate charge development for enhancing the attraction of particulates to the barrier. In embodiments the barrier may be retrofitted to existing wafer containers, such as FOUPS. In embodiments, the shield may be conforming to the interior structure of a specific FOUP configuration. In embodiments the 25 th slot may be used as a barrier protecting the wafer in the 24 th slot from particles shed from the top of the wafer container.
[0005] A feature and advantage of embodiments of the invention is that a barrier provides a shield intermediate the robotic flange/shell interface and the uppermost wafer. This region has been discovered to be a source of particles particularly when the wafer container is transported by the robotic flange. Said particles land on said barrier rather than the uppermost wafer.
[0006] A feature and advantage of embodiments of the invention is that a barrier may be formed from polycarbonate or polyetherimide or cyclic olefin copolymers, said polymers may be natural or with ultraviolet protection. Said polymers may have carbon powder, carbon fiber, and/or carbon nanotubes.
[0007] A feature and advantage of embodiments of the invention is that a barrier may be formed from polyetheretherketone, or liquid crystal polymer. Said polymers may be natural or may have carbon powder, carbon fiber, and/or carbon nano tubes.
[0008] A feature and advantage of embodiments of the invention is a process in which a container is purged with a purging gas, such as nitrogen, to maintain a RH below 5%, and further a barrier is provided to control particulates on the upper most wafers, the process may include the use of select materials for maintaining the RH below 5%. The select materials may be in the barrier. The select materials may also include other portions of the wafer container or the entirety or substantially the entirety of the wafer container. The select materials may be cyclic olefin polymers, cyclic olefin copolymers, liquid crystal polymers, polyetheretherketones.
[0009] Embodiments of the invention include a front opening wafer container with an additional slot for a barrier, a retrofitted barrier, a slotted barrier, an apertured barrier, a barrier conforming to the structural configuration of the container, a container with a plurality of barriers.
[0010] A feature and advantage of particular embodiments of the invention is that particulate control is provided for the top wafer in a front opening wafer container where the RH of the wafer container is maintained below 5%. The particulate control comprising a shield extending horizontally in a position directly above the uppermost wafer and positioned below the top wall structure of the wafer container.
[0011] A feature and advantage of particular embodiments is that apertures in the particle shield facilitate air or gas flow through the barrier allowing the shield to develop a charge from the gas passing against the surfaces of the shield.
DESCRIPTION OF THE FIGURES
[0012] FIG. 1 is a perspective view of a wafer container known as a FOUP which is suitable for the invention herein.
[0013] FIG. 2 is a perspective view of a container portion of a wafer container with a 26th slot and a particle shield for insertion therein.
[0014] FIG. 3 is an exploded perspective view of a FOUP with a particle shield suitable for assembly therewith or for retrofit.
[0015] FIG. 4 is a perspective view of a wafer shield suitable for retrofit on an assembled FOUP as is shown is FIG. 1
[0016] FIG. 5 is a top plan view illustrating the wafer shield of FIG. 4 on the interior wafer support structure of the FOUP of FIGS. 1 and 3 .
[0017] FIG. 6 is a perspective view looking upwardly into the container portion of a FOUP according to a configuration consistent with FIGS. 1 and 3 , also showing a portion of the bottom of said FOUP.
DETAILED DESCRIPTION
[0018] Referring to FIGS. 1 , 2 , and 3 , a front opening wafer container 20 known as a FOUP is illustrated and comprises generally a container portion 24 and a door 26 . The container portion has a an open front 27 and a door frame 27 . 2 sized to receive the door 26 . The container portion having a top 27 . 6 with a top wall 27 . 8 , a pair of sidewalls 28 , a backside 28 . 6 with a backside wall 28 . 8 , and a bottom 29 with a three groove kinematic coupling 30 . The door sealingly engages with the container portion and latches by way of a pair of latch mechanisms 32 . The door of FIG. 1 having manual handles 36 and keyholes 38 exposed on the front side 40 of the door. A robotic flange 44 is attached to the top of the container portion and is used for overhead transport of the wafer container during processing of the wafers therein. The components may be conventionally formed from injected molded thermoplastics such as polycarbonate. In other embodiments, components may be formed of low moisture absorbent material, one of or combinations of a cyclic olefin polymer, cyclic olefin copolymer, liquid crystal polymer, and polyetheretherketone.
[0019] Referring to FIGS. 2 and 3 , the container portion has an additional slot 48 dedicated to receiving a particle shield 50 . Said slot may be the 26th slot, one more than the conventional and industry standard number of slots in 300 mm wafer containers such as the configuration illustrated. In other embodiments, the 25 th slot may be sacrificed for the particle shield. The slots below the slot with the particle shield receive the wafers 51 . The shield is spaced from the top wall and the uppermost wafer for collecting or preventing particles generated from or originating from the top of container portion from landing on the uppermost wafer. In certain instances the stress imparted to the top wall structure 53 by the transporting the container by the robotic flange can generate or release particles from the top wall structure.
[0020] The particle shield may be configured to directly correspond to the size and shape of the wafers that will be received in the container and will be directly above the wafer in the 25th slot, the uppermost wafer slot 54 . In embodiments the shield may be shaped to substantially overlay the uppermost wafer. In embodiments, the particle shield may be slightly larger than the wafers to be contained in the wafer container. That is, about 0.5 to 2% greater in diametric measurement. In other embodiments, 2 to 5% larger in diametric measurement.
[0021] The wafer container has purge ports 56 for purging the interior of the wafer container when closed. Such purge ports may be located at the front or rear of the container portion typically on the bottom of same outside the kinematic couple plate 58 . Ports such as disclosed in U.S. Pat. No. 7,328,727 owned by the owner of this invention disclose suitable configurations of purge ports. Said patent is incorporated by reference herein.
[0022] The shield may be formed of a material having an inherent charge that is opposite to the charges carried by particles in the wafer container. Such opposite charge will cause the particles to be attracted to the shield and adhere thereto. The shield may also be formed of a material highly resistant to absorption of moisture, for example, cyclic olefin polymers, cyclic olefin copolymers, liquid crystal polymers, and polyetheretherketones.
[0023] The shield may be formed of any one of these materials or any combination of these materials or any of the materials in combination with other materials. The shield may also have conductive and/or static dissipative characteristics, provided by addition carbon powder, carbon fibers, and/or carbon nanotubes. By seating on a shelf in the 26th slot, with the shelf also being of a conductive material or at least static dissipative, and connected to ground, the shield will be effectively grounded.
[0024] In an application where the RH of the interior of the container is being maintained at low humidity level, for example less that 10% or less than 5%, use of the above materials helps to maintain the low RH. In embodiments, purge can lower the RH to less than 10% where it is maintained for at least 30 minutes. In embodiments, purge can lower the RH to less than 5% where it is maintained for at least 30 minutes. In embodiments, purge can lower the RH to less than 10% where it gradually ramps up. In embodiments, purge can lower the RH to less than 5% where it then gradually ramps up. Such low RH has been discovered to create a tendency to promote generation of particles, particularly at the top of interior of the container portion adjacent to the robotic flange 44 and associated with overhead transport of the container by way of the robotic flange. The presence of the shield overlaying the uppermost wafer precludes particles generated or present above the stack of wafers from falling on the uppermost wafer. The shield being formed of a low moisture absorbing material minimizes the ramp up of RH in the wafer container.
[0025] Referring to FIGS. 3 , 4 , 5 , and 6 , another embodiment of a wafer container 60 with associated particle shield 64 is illustrated. This shield may be sized to conform to the configuration of the F300 FOUP manufactured by Entegris, Inc. the owner of the instant application. The shield has a body portion 66 and tabs 68 and a central slot 70 . The shield is conformed to the top inside structure 76 of the F300 FOUP. The slot 70 fits around support structure, specifically the upper portion 78 on bridging member 79 of the wafer cassette portion 80 that attaches to the robotic flange 44 on the exterior of the container portion 24 . The wafer cassette portion has two sets 81 of wafer shelves connected by the bridging member. The slot 70 may be sized to be an interference fit such that the shield is retained in position. Alternatively detents, tangs, pawls, or fasteners may be utilized to retain the shield in place.
[0026] In addition to 300 mm wafer containers such a FOSB, the invention is suitable as well for 450 mm wafer containers, particularly those that utilize robotic flanges on the tops of the containers for transport.
[0027] This shield has apertures or openings configured as slots 82 that present a grate configuration. This allows purge gas or ambient atmosphere to pass through the apertures enhancing the gas to surface contact which is believed to increase the charge of the shield thus increasing the attraction of particles to the shield. The shield is positioned over the upper most wafer slot. In an alternative embodiment, two plates may over lay each other such that openings in one plate are horizontally offset from the openings in the other plate providing no direct vertical path for particles from above the two plates to the uppermost wafer. In another embodiment the apertures may angle from vertical such that no direct path or a reduced direct path for particles from the top of the wafer container to the wafer is provided whilst still allowing air or gas to pass through the plate for inducing a charge. In another embodiment, a plate may have two or more levels of particle collecting surfaces separated by vertical gaps through which the air or gas may pass through. Such air or gas may pass through the plate during purging or opening and/or closing of the door.
[0028] The particle shield may be sized to substantially overlay the wafer or entirely overlay the wafer. “Substantially” when used herein means more than 75%, that is, at least 75% of the area of the wafer is covered, by being directly vertically above the wafer, by the particle shield. In other embodiments, the top surface of the wafer will be 90% covered by the particle shield. In other embodiments, the particle shield will cover 100% of the wafer top surface area.
[0029] The particle shield may be placed such that there is a gap or a clearance of at least 1 cm between the particle shield and the uppermost wafer. In embodiments the clearance between the particle shield and the uppermost wafer is between 1 cm and 3 cm. In embodiments, there is a gap or clearance between the top wall structure and the particle shield of at least 0.5 cm. In embodiments, there is a gap between the top wall structure and the particle shield of at least 1 cm. In embodiments, there is a gap between the top wall structure and the particle shield of between 0.5 cm. and 2 cm.
[0030] This shield configuration also may be formed of a material having an inherent charge that is opposite to the charges carried by particles in the wafer container. Such opposite charge will cause the particles to be attracted to the shield and adhere thereto. The shield may also be formed of a material highly resistant to absorption of moisture, for example, cyclic olefin polymers, cyclic olefin copolymers, liquid crystal polymers, and polyetheretherketones. The shield may also have conductive and/or static dissipative characteristics, provided by addition carbon powder, carbon fibers, and/or carbon nanotubes. By engaging with the wafer cassette portion, and where the wafer cassette portion is formed of a conductive material or at least static dissipative, and connected to ground, the shield will be effectively grounded. In embodiments, the shield may be formed of metal.
[0031] Wafer container, seals, features, and other wafer container structure and components are illustrated in U.S. Pat. Nos. RE 38,221; 6,010,008; 6,267,245; 6,736268, 5,472,086; 5,785,186; 5,755,332; and PCT Publications. WO 2008/008270; WO 2009/089552. The patents and inventions of the publications are owned by the owner of the present application. Also, see U.S. Pat. No. 5,346,518 illustrating vapor removing elements. These patents and the publications are incorporated by reference herein.
[0032] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof; and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
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Particulate shields above the top wafer in wafer containers such as FOUPS prevent accumulation of particulates on wafers. The shields may be formed of materials that are compatible to maintaining less than 5% RH, particularly materials that will not absorb meaningful amounts of water, and that will not bring absorbed moisture into the container, for example cyclic olefin polymers, cyclic olefin copolymers, liquid crystal polymers. A FOUP may be provided with an additional slot above industry standard 25 slots to receive a dedicated barrier. In embodiments, the barrier may be a shape corresponding to a wafer. The barrier may have inherent charge properties opposite to the particulates in the containers to attract the particulates. The barrier may have apertures to facilitate charge development. The barrier may be retrofitted to existing wafer containers. The shield may conform to FOUP configuration.
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BACKGROUND OF THE INVENTION
The present invention relates to improvements in apparatus for processing wood pulp and other fibrous fluid suspensions, and methods for manufacturing the apparatus. More particularly, the apparatus and methods relate to an improved screen for wood pulp, for removing foreign particles from a pulp slurry.
In processing wood pulp, screens are utilized to separate acceptable fiber from unacceptable constituents in a slurry. In a typical screen, the slurry flows through a perforate, cylindrical screen plate, which may be smooth, or which may present a contoured surface toward the stock flowing through the screen, to increase the effective screening area. The screen plate openings are formed in different hole or hole and slot combinations for optimizing screening performance. To aid in passage of the acceptable pulp through the screen plate, and to avoid plugging, pulsations are generated in the slurry such as by passing a hydrofoil-shaped member past the screen plate. In order to give the screen plate strength to withstand the pressure differential across the surface, and to increase the screening capacity by presenting increased screening area, it has generally been the practice to provide a thickly-walled screen plate which is machined to present the desired surface. Machining the desired contour has required a time consuming and expensive process. Because of manufacturing restrictions in the machining process imposed at least in part by the machine tools themselves, total available open accepts flow area has been limited in known screen plates, and the final shape of the screen plate has been a compromise between the limitations of machining and the desired optimum screen shape.
In addition to the expensive costs of production and manufacturing, the type of screen described has been expensive to use and maintain in that, even if only a small area of screen is damaged, the entire screen plate, which includes the screening surface, mounting surfaces and support members must be replaced, thereby presenting a costly operating expense.
An additional problem encountered in operating screens using known screen plates is premature wear due to contaminants. In recycling waste paper, contaminants such as metals, sand, plastic, and glass are often present, and screen plates utilized to remove these contaminants experience rapid wear. In some instances, screen plates have been known to last less than seven days before failure has occurred. When heretofore known screen plates are used in such screens, the cost and time required for screen plate replacement is significant.
It is, accordingly, an object of the present invention to provide a screening apparatus and a screen plate design wherein the necessity of an expensive machining manufacturing process is eliminated.
A further object of the present invention is to provide a screen plate structure wherein various modifications and alternatives of screen plate shape can be attained without prohibitive manufacturing costs, and wherein contours can be utilized which were heretofore not considered possible because of manufacturing limitations.
A further object of the present invention is to provide a screen plate structure wherein, for a given screen plate area, increased screening capacity is possible for increased throughput pulp screening rates, and wherein a variety of sizes and shapes are possible for the screen plate openings.
Another object of the present invention is to provide a screen plate forming process and a screen plate structure which can utilize relatively thin material to produce an aggressive profile for increasing the hydraulic capacity of the screen.
Yet another object of the present invention is to provide a modular screen plate structure which simplifies screen plate changing and which eliminates the need to change an entire screen plate when only a portion of the plate is damaged or worn.
A still further object of the present invention is to provide a screen plate structure and manufacturing process therefor which substantially reduce the manufacturing costs of a screen plate while improving the screening efficiency and throughput thereof.
Still another object of the present invention is to provide a screen plate structure and method of manufacturing which is more resistant to abrasive wear than heretofore known screen plates, thereby increasing the useful life of the screen plate when screening slurries containing highly abrasive contaminants.
FEATURES OF THE INVENTION
In accordance with the concepts and objects of the invention, a screen plate is presented wherein relatively thin material is formed into a desired shape or contour, and the screen shape is formed in predetermined lengths and assembled into a modular type assembly. Forming the contours can be performed by stamping, pressing, or other bending techniques not requiring machining.
The various shapes or contours into which the material is formed provide mechanical strength and rigidity, which allow using thinner material than that previously used for screen plates. The thinner material allows for forming more aggressive contours, and makes possible the use of slot cutting techniques other than machining. Thus, thinner material properly formed with new and different slot openings can increase screening efficiency and capacity while retaining or even improving screen plate strength.
With the use of thin material, a laser beam may be utilized to cut openings or slots ranging from 0.004" to 0.020" wide. These openings may be formed in greater lengths than are presently available from currently used machining methods, and this increases the total available open accepts flow area and production rate for a given size screen plate.
The modular design employs a rigid, strengthening pilot back ring and a varying number of mid or support rings and flange rings, all connected by tie rods with the annular screen plates clamped between each ring. This permits various hole and slot combinations within the same assembly. The modular construction provides an inner contour permitting very close foil to plate gap settings. When a given section of the screen plate is damaged or worn out, only that section need to be replaced. The support rings, tie rods, and undamaged and unworn screen plate sections can be reused, thereby substantially reducing costs for repairing worn or damaged screens.
For highly abrasive applications, abrasive resistant inserts can be inserted in the screen plate and retained by the retaining rings of the modular construction. As wear occurs, the inserts can be replaced at much less cost than replacing entire screen plates.
Other objects, advantages, and features will become more apparent with the teaching of the principles of the present invention in connection with the disclosure of the preferred embodiments thereof in the specification, claims, and drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, with portions broken away, illustrating a pulp screen structure utilizing a screen plate constructed in accordance with the principles of the present invention;
FIG. 2 is an enlarged, fragmentary, sectional view taken substantially along line II--II of FIG. 1;
FIG. 3 is a detailed, fragmentary, plan view of a portion of the screen plate;
FIG. 4 is another fragmentary, enlarged, plan view of a screen plate, similar to FIG. 3, but of a different design insofar as the screen openings are concerned;
FIG. 5 is a perspective view of a portion of screen plate showing a form of plate contour that may be employed;
FIG. 6 is a fragmentary, perspective view illustrating another form of contour that may be employed for a screen plate;
FIG. 7 is a fragmentary, perspective view illustrating still another contour of screen plate that may be employed;
FIG. 8 is a fragmentary, perspective view illustrating still another contour of screen plate that may be employed;
FIG. 9 is a fragmentary, perspective view illustrating a still further contour of screen plate that may be employed; and
FIG. 10 is a fragmentary, perspective view illustrating a further contour of screen plate that may be employed.
FIG. 11 is an enlarged perspective view of a portion of a screen plate embodying the present invention, and showing a particular slot configuration in the screen plate.
FIG. 12 is a top plan view of the screen plate portion shown in FIG. 11.
FIG. 13 is a top plan view of a modified form of the screen plate shown in FIG. 12, showing a modification of the slot shown in FIG. 12.
FIG. 14 is a top plan view of yet another modified slot which may be used in screen plates of the present invention.
FIG. 15 is a top plan view of a screen plate embodying the present invention, and further showing two types of hole configurations that may be utilized.
FIG. 16 is a cross-sectional view through the screen plate shown in FIG. 15, taken along line XVI--XVI of FIG. 15.
FIG. 17 is a cross-sectional view of the screen plate shown in FIG. 15, taken along line XVII--XVII of FIG. 15.
FIG. 18 is a cross-sectional view through an apparatus for forming the screen plate sections of the present invention, showing one particular configuration therefore.
FIG. 19 is a cross-sectional view through the apparatus shown in FIG. 18, but depicting a subsequent step to that shown in FIG. 18.
FIG. 20 is a cross-sectional view similar to that shown in FIG. 18 and 19, but showing a third step in the forming process.
FIG. 21 is a cross-sectional view similar to that of the previous three drawings, but showing a fourth step in the forming process.
FIG. 22 is a cross-sectional view through an alternate embodiment of forming apparatus, to create the same configuration for the screen plate sections shown in FIGS. 18-21.
FIG. 23 is a cross-sectional view similar to FIG. 22, but showing the second step of the forming process.
FIG. 24 is a cross-sectional view similar to the previous two drawings, but showing a third step in the formation process.
FIG. 25 is a cross-sectional view through a forming apparatus similar to those of the previous three drawings, but showing a fourth step in the forming process.
FIG. 26. is a cross-sectional view similar to FIGS. 22 through 25, but showing a fifth step in the forming process.
FIG. 27 is a cross-sectional view similar to FIGS. 22 through 26, but showing a sixth step in the formation process.
FIG. 28 is a cross-sectional view through an apparatus for forming a corrugated screen plate section embodying the present invention, which apparatus simultaneously forms louvered slots similar to those shown in FIG. 16, while the corrugations are being formed.
FIG. 29 is a cross-sectional view through a modified form of a screen plate section embodying the present invention.
FIG 30 is a cross-sectional view through the screen plate section shown in FIG. 29, taken along line XXX--XXX of FIG. 29.
FIGS. 31 through 35 are views similar to that of FIG. 30, but showing modified forms of the screen plate inserts shown in FIG. 30.
FIG. 36 is a cross-sectional view through a mounting ring and two screen plate sections embodying the present invention, showing the mounting of the apparatus shown in FIG. 29.
FIG. 37 is a cross-sectional view through a mounting ring and two screen plate sections embodying the present invention, but showing a modified mounting slot and corresponding formation for the top of the screen plate section.
FIG. 38 is a cross-sectional view similar to FIG. 37, but showing a further modification of the mounting slot and the edge of the screen plate section.
FIG. 39 is a cross-sectional view similar to FIG. 37 and 39, but showing a still further modified embodiment of the mounting slot and the edge of the screen plate sections.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a screening apparatus 8 wherein previously treated pulp is screened to remove foreign elements such as sheaves, bark, knots, particles of wood, dirt, glass, plastic, and the like. A screen plate assembly is shown at 10, defining in the apparatus 8 an interior chamber 11 where the pulp to be screened flows in and an exterior chamber 12 where the screened pulp flows out after passing through the screen plate assembly. The assembly is enclosed in a housing 13 which has an inlet, not shown, for the entrance of pulp to be screened into the chamber 11, and an outlet, not shown, leading from the chamber 11 for the foreign material such as the sheaves, bark, and dirt. The accepted pulp flows out through an outlet 14.
The screen plate assembly 10 is stationary within the housing 13, and for aid in passing the liquid stock with pulp through the screen plate, and to help inhibit plugging, hydrofoils 18 are mounted for rotation within the cylindrical screen plate assembly. The hydrofoils 18 are supported on arms of a rotary driven shaft 19, and rotates in a clockwise direction, as viewed in FIG. 1. The hydrofoils shown are merely illustrative of a suitable type, and it should be understood that the present invention can be used for screen plates of various types for various pulse, turbulence and combination pulse and turbulence generating rotors.
The screen plate assembly 10 includes cylindrical screen sections 16 and 17 which, without support, are essentially flexible and require rigidifying or strengthening for use in the presssurized environment of screen apparatus 8. The necessary support and strengthening is provided by end rings 20 and 20a and intermediate support ring 21. Each of the rings has grooves, such as illustrated by the grooves 23 and 24 in the ring 21 shown in FIG. 2. The grooves 23 and 24 are circular to hold the screen sections in a substantially cylindrical shape. The grooves 23 and 24 have a radial dimension substantially equal to the radial thickness of the shaped screen plates.
The screen plates are formed from relatively thin material compared to the heretofore known machined screen plates. The thin material is formed into various shapes or contours, generally undulated, so as to present a substantial amount of screening area to the stock. FIGS. 5 through 10 illustrate contours which may be used, and which are capable of attainment with the structure and manufacturing methods of the present invention.
During assembly, each of the shaped screen plates is positioned into the grooves in the end ring 20 or 20a and the intermediate ring 21, and the rings are pulled together to force the screen plates into the grooves. For this purpose, axially extending rods 22 are provided, spaced circumferentially from each other, and the rods are provided at their ends with threads and nuts 22a so that the nuts can be tightened to pull the end rings toward each other and force the ends of the screen plates into the grooves. The grooves are preferably tapered so that the slot becomes narrower in an inward direction toward the bottom of the groove, as indicated by the illustration of FIG. 2. When the rods are tightened, the screen plates are pushed tightly into the tapered grooves so that the screen plates are held firmly in a fixed position, circumferentially. With screen assemblies of different lengths, the screens can be longer or shorter, or even greater in number, and additional reinforcing intermediate rings such as 21 may be employed between the ends of each of the adjacent screens.
Screening openings such as 25 and 26 extend through the thin, screen material, as indicated by the screens 16 and 17 shown in FIGS. 2, 3, and 4. Depending upon the types of stock to be screened and the specific problems of screening, different combinations of slots or holes may be employed, and the thin material used in the present screen plate assembly can be provided with holes or slots of different sizes and shapes through manufacturing techniques, including the use of laser beam cutting, or other hole forming processes such as punching. The holes or slots may be created before, during, or after the formation of the undulations in the sheet-like material. The slots may range from 0.004" to 0.02" wide and be in greater lengths than presently possible, wherein screen plate openings are formed by machining processes. The variety of sizes and lengths of openings that can be formed in a screen made of thin material can substantially increase the total available open accepts flow area of the screen, and thereby increase the production rate for a given size screen plate.
The present modular design employing one or more mid or support rings, such as shown at 21, and end rings, such as shown at 20 and 20a, allows for use or screen sections of different lengths and with different hole and slot combinations. Any number of sections of any length may be used, and a wide variety of combinations of slot sizes and shapes, as well as screen plate contours, can be provided in a single screen. If wear or damage to any of the cylindrical screen sections occurs, the section can be replaced by loosening the axial tie rods and replacing or exchanging the section. This also enables replacement with substitute sections of different hole or slot arrangements so that, with a given piece of screening machinery, different screening operations can be achieved through easy replacement of screen sections. As will be seen from the drawing of FIG. 1, access to the interior of the housing 13 is readily afforded by removal of the end plate 13a through removal of the bolts 13b. This permits withdrawal of the screen assembly for ready exchange or replacement of the screen sections.
The thin material of the screen sections may be stainless steel or similar sheet metal which is formed in a generally cylindrical shape having undulations extending around the circumference of the screen. In a simplified form, the undulations shown in FIG. 5 may take the form of a series of upright and inverted U-shaped sections 27a and 27b, or, in other words, the screen essentially consists of a series of deep corrugations.
These corrugations may be modified as illustrated in FIG. 6 by a shaping of the U-shaped sections, and as illustrated in FIG. 6, the U-shaped section may be formed so that one sidewall 28a of the U is a straight, substantially radial wall, whereas the other wall 28b has lower and upper straight portions 28c and 28d joined by a circumferential flat wall portion 28e. The flat wall portion may perform an additional filtering or screening function and may include the same or different perforations than the remainder of the screen. The flat, part circumferential portion also adds circumferential rib strength to the overall screen.
In the arrangement of FIG. 7, the undulations take the form of outwardly extending V-shaped ridges 29 having side walls 29a and 29b. The inner base of the side walls is joined by a flat, generally partially circumferentially extending planar portion 29c. Again, all of the areas may supply screening openings and strengthen the screen structure.
In the arrangement of FIG. 8, the screen is formed by a series of ridges 30 with planar side walls 30a and 30b. At the base of one side wall 30b is a generally part circumferentially extending planar portion 30c which is joined to a curved base 30d. This arrangement functions to provide additional strength and screening area.
FIG. 9 illustrates a screen formed of a series of ridges 31, with the ridges having side walls 31a and 31b of unequal length so that the angular slope of the side wall 31a is less than the slope of the side wall 31b. This again provides strength and provides a good cleaning effect relative to the hydrofoil which is moved past the inner surface of the curved screen.
FIG. 10 illustrates a screen formed with a series of ridges 32, each having one flat side wall 32a with a shorter opposing side wall 32b. At the base of the shorter side wall is a flat, generally partly circumferentially extending portion 32c which joins a radially outwardly extending U-shaped portion 32d.
As will be observed from FIGS. 5 through 10, the substantial variety of screen shapes that can be accomplished exceeds that of shapes heretofore available. While a number of screen shapes or profiles have been shown in FIGS. 5 through 10, shapes other than those shown may also be used advantageously. Those shown are not intended to be limiting on the shapes useful in the present invention, but are merely representative of some useful shapes. The screen shapes can be achieved with a press forming apparatus handling the relatively thin screen material at a relatively minimal manufacturing cost relative to a procedure which requires substantial machining.
Under previously known screen plate manufacturing techniques, there are geometric limitations on the openings that can be provided in the screen plate, in an attempt to maximize the open flow area and to provide slotted arrangements. As a result of the modular, reinforced structure of the present screen plate assemblies, which allows utilization of relatively thin material, other slot forming processes are available. For example, laser burning and punching are not practical with the relatively-thick walled screen plates used previously, but do work well with the relatively-thin walled screen plates of the present invention. Thus, flow area can be maximized by laser cutting a variety of nonlinear-type openings in the screen plate. By way of example, several openings are shown in FIGS. 11 through 17 which may be utilized. It should be recognized that a virtually infinite variety of shapes and sizes other than those illustrated can also be used.
FIG. 11 shows, perspectively, screen plate openings having a generally circular portion 50 with a linear portion 52 extending therefrom. These openings are shown in a top plan view in FIG. 12.
FIG. 13 illustrates a modification of the openings shown in FIGS. 11 and 12, in which a curved portion 54 is provided opposite the circular portion 50 on the linear section 52.
In FIG. 14, a zig-zag opening 56 is illustrated, which may extend substantially the entire length of a screen plate section, or may be provided in a series of patterns along the length of the screen plate section.
Further, slotted profile arrangements may be provided to achieve aggressive or agitative profiles which enhance full performance. Several of these are shown in FIGS. 15, 16, and 17. In FIG. 15, louvered openings 58 are shown, in which a dome 60 is raised upwardly from the opening 62. In yet another embodiment of opening shown in FIG. 15, a flap 64 is left between two substantially parallel slot openings 66 and 68, which are joined at 70. Thus, the flap 64 is attached at only one end and is otherwise defined by the slot openings 66, 68, and 70.
Either of the embodiments shown in FIG. 15 can be readily formed by piercing or punching techniques to be described subsequently herein. The various openings can be used individually or in combination on a single screen plate section, or in a plurality of sections in a single screen apparatus. In some applications of the screen baskets embodying the present invention, electrical, mechanical, or chemical polishing may be utilized to enhance the hydraulic capacity or throughput of the slotted surface. However, one of the advantages of the present invention is that the strengthening provided by the modular structure allows the use of thin material which can be formed gently by bending. Therefore, highly polished metals can be used and the need for subsequent polishing and cleanup of the finished screen plate is minimized or even eliminated.
In operation, as illustrated in FIGS. 1 and 2, a series of cylindrical screen sections 16 and 17 are provided, each with perforations therethrough, such as illustrated in the forms of FIGS. 3 and 4. The sections used in any screen may be identical, or the openings and/or profiles of the sections may be different. The circumferential sections are supported by end rings 20 and 20a and intermediate rings 21 which have tapered grooves such as 23 and 24 for receiving the ends of the screens. The screen plate is assembled by positioning the individual sections in the appropriate rings and inserting the axial rods 22 through the rings. Tightening the nuts 22a compresses the assembly and secures the rings and screen sections in place. The completed assembly is mounted in the screen apparatus 8 in conventional manner.
Replacement of any of the screen sections can be quickly accomplished by removing the screen plate assembly 10 from the apparatus 8 and loosening the nuts 22a from the axial through rods 22. After freeing the sections form the rings, replacing, or exchanging the screen sections and reconnecting and tightening the rods can be completed quickly. Even if all the screen plate sections are replaced, the cost for doing it is substantially less than for replacing a conventional screen plate in that the rings and through rods of the present invention can be reused for substantial periods of time.
The relatively thin material used for the present screen plates can be formed into a variety of undulated patterns by simple bending and forming techniques. FIGS. 18 through 21 show a four step forming process within a forming machine. The forming machine includes top and bottom forming units 80 and 82, respectively, each having some discrete and individually operating portions thereof, to be described subsequently. The individual portions advance independently by means of pneumatic, hydraulic, or other actuators which will be well known to those versed in the art.
As shown in FIG. 18, the forming machine has a bottom support member 84 and upwardly extending interlocking male members 86 and 88. As will be apparent from the following description, the interlocking members 86 and 88 may be stationarily mounted in the supporting member 84. The shape being formed by the apparatus depicted in FIGS. 18 through 21 includes a relatively narrow, generally U-shaped section 90 and a relatively wider modified W-shaped section 92. The interlocking member 86 extends into the last completely formed narrow section 90. A first forming section 94 from the upper unit 80 is advanced into the last completely formed wider section 92, and interlocks the material therein between it and the interlocking members 86 and 88. In some aspects, it can be stated that the upwardly extending interlocking male members 86 and 88 define between them a female member for receiving the first forming section 94.
As shown in FIG. 19, a second forming section 96 from the upper unit 80 advances downwardly towards the lower unit, and completes the formation of a second generally narrow shaped section 90a. Thus, the forming sections 94 and 96 define between them a female section for receiving the interlocking member 88 of the lower unit. At the same time, the bottom portion of the next generally wider section 92a is formed. Clearance between adjacent surfaces of the upper and lower units when positioned as in FIG. 19, is not substantially greater than the thickness of the material being formed.
As shown in FIG. 20, after the formation shown in FIG. 19 is completed, a preformer including an upper section 100, a bottom section 102, and a side section 104 is advanced to generally shape the material into a predetermined pattern which aids the subsequent forming process, and ensures that the material being formed is shaped into the desired undulating pattern, rather than being pulled or stretched, thereby minimizing the generation of built-in stresses.
After the preforming is completed, all forming sections are retracted, and the material is advanced through the machine such that the forming process depicted in FIG. 18 can be repeated. That is, the last formed section 90a is advanced to the position previously occupied by the section 90, generally covering the interlocking piece 86.
An alternate forming process and apparatus therefore is shown in FIGS. 22 through 27. The forming apparatus again includes a top section 120 and a bottom section 122 for creating a contoured pattern similar to that shown in FIGS. 18 through 21. The various parts of the upper and lower sections do not move individually. Each section moves as a unit.
The top forming unit 120 includes generally wider male forming fixtures 124, 126, 128, and 130. Disposed between the male fixtures are the generally narrower shaped female fixtures 132, 134, and 136. The bottom forming unit includes complimentary fixtures, including generally wider female fixtures 140, 142, 144, and 146; and generally narrower male fixtures 148, 150, and 152.
In FIG. 25, the top and bottom forming units have again moved apart vertically. In FIG. 26, the top forming unit has moved one pattern back to the right. In FIG. 27, the top and bottom units have again closed, thereby forming yet another of the undulating patterns.
For sake of clarity, several of the patterns have been numbered in the drawings, and the movement of the patterns is readily apparent. Thus, the patterns previously formed, prior to the operation shown in FIG. 22, have been designated with numerals 160a, b, and c in FIG. 22. In FIG. 24, a new pattern 160d has been formed, and in FIG. 27, yet another pattern 160e has been formed.
In the operation of a forming apparatus and method as described for FIGS. 22 through 27, the material being formed will alternately stay with the top and bottom forming units as the patterns are formed. Thus, in FIG. 22, the material has remained on the top unit as the bottom unit is retracted, and as the top unit advances to the left. In FIG. 25, the material is shown to have stayed with the bottom unit as the top unit is retracted and moved to the right, prior to the formation shown in FIG. 27. At completion of the step shown in FIG. 27, the procedure repeats again with the step as shown in FIG. 22.
By changing the shape of the forming tools used, any number of different shapes or patterns may be formed, which may enhance the hydraulic capacity or throughput of a given screen plate, depending upon its application. For example, the patterns shown in FIGS. 5 through 10, as well as a variety of other patterns, can easily be formed in the relatively thin material through the press forming techniques shown generally in FIGS. 18 through 27.
Another advantage obtained from using the relatively thin material that can be employed advantageously in screen plates of the present invention is that the hole or slot forming process can be incorporated with the undulating pattern forming process. For example, in FIG. 28, a press forming operation is shown for forming the pattern generally shown in FIG. 11, and incorporation a punch dye 170 for forming the louvered openings shown in FIGS. 15 and 16. Such a formation process greatly simplifies and reduces the cost for forming the screen plate sections, thereby obtaining even greater financial advantages for screen plate manufacture.
The manufacturing and assembly methods of the present invention make possible other modification for specific applications. For example, when the slurry being screened is high in abrasive contaminants, such as metals, sand, plastic, and glass often found in recycling wastepaper, conventional screen plates wear out rapidly. The modular design of the current screen plates permits the use of highly abrasive-resistant inserts in the screen plate. In FIG. 29, inserts 180 and 182 are shown disposed in the corrugations or undulations 184 and 186 of the inlet side of the screen plate. The modular design incorporating clamping rings will also clamp the abrasive-resistant inserts in place, along with the screen plate sections. Further, the modular design also permits replacement of worn or damaged inserts as needed. Therefore, if one or several inserts become severely damaged due to a large contaminant, only those inserts need to be replaced. Alternatively, the entire set of abrasive resistant inserts can be replaced without replacing the rings, tie rods, or even the screen plate; which may be reused.
Additionally, by varying the shape of the top of the insert which is exposed to the material to be screened, a secondary aggressive profile or shape can be produced. It is possible to further increase the hydraulic capacity or throughput of a given screen plate by the use of inserts, whether or not the inserts are used for abrasion resistance. FIGS. 30 through 35 illustrate a variety of different tip shapes, indicated by numerals 190, 192, 194, 196, 198, and 200 that can be useful in screening different materials. FIG. 36 further illustrates the mounting or screen plate sections 204 and 206 with inserts 180 and 208 in the central mounting ring 202. Each insert is similarly secured at its opposite end in the end ring or support member.
The screen plate assembly of the present invention is capable of even further modification for particular applications. For example, in FIG. 2, the rings shown project inwardly from the inner surface of the screen plate sections. This geometry limits the minimum gap that can be provided between the screen plate surface and the rotating foil. In some situations, this limitation may deter flow performance and screen output. Therefore, when minimal screen to rotor gap is required, the mounting means for the screen can be modified. FIG. 37 through 39 illustrate modifications for use with minimal clearance screens. The openings to the grooves of the rings are at least partly radially inward from part of the groove bottom, and inner most surfaces of the screen plate are substantially in line with the inner most surfaces of the rings. A secondary forming operation to the corrugation formation, wherein the edges are crimped, can be utilized, thereby allowing the screen plate's inner contour to blend with the mounting rings, and allowing closer plate to rotor gap settings.
In FIG. 37, the mounting ring 210 includes grooves having bottoms 212, straight sides 214 and angular surfaces 216. The screen plate sections at their edges have angular shapes complementary to the mounting ring grooves.
In FIG. 38, the ring 220 includes grooves having radially inward wall sections 222 opposite and parallel to the outer wall sides 214 and an angular section 224 extending from the section 222 to the opening of the groove. The edge of the screen plate sections are crimped correspondingly.
In FIG. 39, the mounting ring 230 includes grooves having generally arcuate shaped sections 232, and again the edge of the screen plate sections are crimped correspondingly.
It can be seen that any of the shapes illustrated in FIGS. 37, 38, and 39; as well as a variety of other shapes can be utilized to maintain the rigid and stationary mounting within the mounting rings, while offsetting the screen plates so that the inner surface of the rings and the inner surface of the plates correspond, thereby not limiting the minimum gap allowable between the rotor and the screen plate inner surfaces.
The present invention achieves many desirable objectives for screen plate design. The modular construction permits wide flexibility in screen plate shape, hole or slot formation, and screen plate utilization. Manufacturing and maintenance costs are significantly reduced in that the manufacturing techniques which can be used are less expense than those previously used for the necessary thick-walled screen plate material for previous designs. Replacement due to damage, failure, or alternate operation can be limited to those parts actually requiring replacement. The screen can readily be adapted to different uses by adapting the shape of slot opening, and by the use of inserts for wear resistance or increased aggressiveness of the surface contour.
While the present invention has been broadly described herein, including a wide variety of modified embodiments, it should be recognized that additional embodiments may be made without departing from the scope of the present invention.
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A paper pulp screening apparatus wherein a modular cylindrically-shaped screen plate is formed of a thin material of uniform thickness bent to form an undulating shape to increase the screening area, and the screen plate is supported by cylindrical-backing members to give the plate strength, with the plate being formed into various complex shapes. Manufacturing methods for forming the undulating shapes are disclosed.
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BACKGROUND OF THE INVENTION
[0001] The present invention is directed to control devices for bicycles and, more particularly, to a twist-grip shift control device for shifting a bicycle transmission.
[0002] An example of a twist-grip shift control device is shown in U.S. Pat. No. 5,921,139. That shift control device comprises a fixed member that is nonrotatably fixed to the bicycle handlebar, a handgrip operating member rotatably supported relative to the fixed member for rotating in first and second directions, a takeup member rotatably mounted relative to the fixed member for controlling the pulling and releasing of a transmission control element, and an intermediate (position setting) member coupled for rotation with the takeup member. Ratchet teeth are formed on the fixed member and the intermediate member for holding the intermediate member, and hence the takeup member, in a plurality of fixed positions. Additional ratchet teeth are formed on the intermediate member and the handgrip operating member for rotating the intermediate member and the takeup member for pulling and releasing the transmission control element.
[0003] Twist-grip shift control devices have long been used to control bicycle transmissions such as derailleurs and internal hub transmissions. In derailleur transmissions, it is sometimes desirable to provide an overshift function when shifting from one sprocket to an adjacent sprocket. When performing this function, the derailleur chain guide temporarily moves the chain beyond the destination sprocket to ensure that the chain has engaged the destination sprocket and then returns the chain into proper alignment with the destination sprocket. JP 1969-26571 and U.S. Pat. No. 5,102,372 both disclose twist grip shifting devices that perform this function. In JP 1969-26571 a spring-biased ball moves within a space to provide the overshift function, whereas in U.S. Pat. No. 5,102,372 a leaf spring moves within a space to provide the overshift function.
SUMMARY OF THE INVENTION
[0004] The present invention is directed to a twist-grip shift control device that provides the overshift function in a novel way. In one embodiment of the present invention, a bicycle shift control device comprises a base member; an operating member structured to be mounted around a handlebar so as to rotate in first and second directions around the handlebar; a transmission control member coupled to the operating member and rotatably mounted relative to the base member for pulling and releasing a transmission control element; a first position setting member; a second position setting member structured to rotate with the operating member and to move axially, wherein the second position setting member moves between an engagement position in which the second position setting member engages the first position setting member and a disengagement position in which the second position setting member is disengaged from the first position setting member; a first coupling member that moves in response to rotation of the operating member; and a second coupling member coupled to the second position setting member for engaging the first coupling member so that rotation of the operating member causes rotation of the second position setting member. The first coupling member and the second coupling member are structured so that rotation of the operating member rotates the transmission control member for a selected rotational distance without moving the second position setting member toward the disengagement position.
[0005] In another embodiment of the present invention, a bicycle shift control device comprises a first base member having a first coupling member; a second base member having a second coupling member; an operating member structured to be mounted around a handlebar so as to rotate in first and second directions around the handlebar; wherein the first base member and the second base member are structured to move relative to each other in response to rotation of the operating member; a transmission control member coupled to the operating member and rotatably mounted relative to the first base member for pulling and releasing a transmission control element; a first position setting member; second position setting member structured to rotate with the operating member and to move axially, wherein the second position setting member moves between an engagement position in which the second position setting member engages the first position setting member and a disengagement position in which the second position setting member is disengaged from the first position setting member; a third coupling member that moves in response to rotation of the operating member; and a fourth coupling member coupled to the second position setting member for engaging the operating member so that rotation of the operating member causes rotation of the second position setting member. The first coupling member and the second coupling member are structured so that rotation of the operating member rotates the transmission control member and moves the first base member and the second base member relative to each other for a selected distance without moving the second position setting member toward the disengagement position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a side view of a bicycle which incorporates a particular embodiment of a twist-grip shift control device according to the present invention;
[0007] [0007]FIG. 2 is an oblique view of a particular embodiment of a twist-grip shift control device according to the present invention;
[0008] [0008]FIG. 3 is an exploded view of the twist-grip shift control device shown in FIG. 2;
[0009] [0009]FIG. 4 is a cross sectional view of the twist-grip shift control device shown in FIG. 2;
[0010] [0010]FIG. 5 is a partial cross sectional view of the base member shown in FIG. 3;
[0011] [0011]FIG. 6 is a view taken along line VI-VI in FIG. 4;
[0012] [0012]FIGS. 7A and 7B are cross sectional views depicting the shapes of the ratchet teeth of the position setting member, the base member, and the operating member;
[0013] FIGS. 8 A- 8 G are schematic views showing the operation of the twist-grip shift control device when the operating member is rotated in a wire pulling direction;
[0014] [0014]FIG. 9 illustrates an overshift operation according to the present invention;
[0015] [0015]FIG. 10 is a cross sectional view of an alternative embodiment of a twist grip shifting device according to the present invention; and
[0016] FIGS. 11 A- 11 G are schematic views showing the operation of the twist-grip shift control device when the operating member is rotated in a first direction.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] [0017]FIG. 1 shows a bicycle 1 provided with a twist-grip shift control device 10 according to the present invention. Bicycle 1 is equipped with a front wheel 2 , pedals 4 , a derailleur 6 for moving a chain 5 over a sprocket cassette 7 attached to a rear wheel 3 , a brake mechanism 9 , and the like. Twist-grip shift control device 10 is attached to a handlebar 8 and operates the derailleur 6 via a Bowden-type control cable 11 . As used herein, the terms “front direction,” “back direction,” “transverse direction,” and the like refer to the directions with respect to the bicycle. For example, “right” means to the right of the rider sitting on the saddle.
[0018] [0018]FIG. 2 is an oblique view of a particular embodiment of shift control device 10 according to the present invention, FIG. 3 is an exploded view of shift control device 10 , and FIG. 4 is a cross-sectional view of shift control device 10 . In general, rotating an operating member 16 around an axis X that runs along the handlebar 8 rotates a transmission control member in the form of a wire takeup member 18 which, in turn, pulls and releases an inner wire 11 a of control cable 11 to operate derailleur 6 . In this embodiment, seven-step shifting can be accomplished with shift control device 10 , but the number of steps can be varied depending upon the application.
[0019] More specifically, shift control device 10 includes a clamping band 22 that is fastened to handlebar 8 with a screw 26 in a conventional manner. Clamping band 22 includes a connecting arm 30 that is fixed to a portion 34 of a housing 38 by a screw (not shown). Housing 38 includes a side wall 42 that defines an opening 46 such that side wall 42 circumferentially fits within a fixing groove 50 formed in one end of a tubular base member 54 that also fits around handlebar 8 .
[0020] Wire takeup member 18 is rotatably supported on base member 54 , and it includes a wire winding groove 58 for winding and releasing inner wire 11 a and another wire winding groove 62 for winding and releasing an auxiliary wire 66 that may be used for controlling some other bicycle device such as a remotely located gear indicator. Inner wire 11 a is guided within a channel 70 formed in housing 38 , and auxiliary wire 66 is guided within a channel 74 formed in housing 38 . Wire takeup member 18 is formed as one piece with a planet gear carrier 78 . A shown in FIGS. 3, 4 and 6 , planet gear carrier 78 includes a plurality of (e.g., five) pivot shafts 82 for rotatably supporting a corresponding plurality of planet gears 86 . Planet gear carrier 78 also includes a plurality of mounting bases 90 , wherein each mounting base 90 includes a mounting shaft 94 . A cover plate 98 is fitted to planet gear carrier 78 such that cover plate 98 rests against the plurality of mounting bases 90 and each pivot shaft 82 and mounting shaft 94 is press fit within a corresponding opening 102 formed in cover plate 98 . Each planet gear 86 meshes with the teeth 105 of a sun gear 106 formed as one piece with the outer peripheral surface of base member 54 . Each planet gear 86 also meshes with ring gear teeth 110 formed on the inner peripheral surface of a ring gear 114 . It should be readily recognized that sun gear 106 , planet gear carrier 78 (and cover plate 98 ), planet gears 86 and ring gear 114 form a planetary gear mechanism.
[0021] An annular position setting member 118 is rotatably supported on base member 54 , and it includes a plurality of circumferentially disposed position setting (ratchet) teeth 122 for selectively engaging three position setting teeth 126 evenly spaced circumferentially on a flange 130 that extends radially outwardly from and one piece with base member 54 , a plurality of circumferentially disposed coupling (ratchet) teeth 134 for selectively engaging a corresponding plurality of coupling (ratchet) teeth 138 circumferentially disposed on an operating member body 142 of operating member 16 , and an axially extending coupling tab 146 forming an abutment 150 . Abutment 150 contacts an abutment 154 formed on a coupling tab 158 that extends axially from ring gear 114 so that position setting member 118 and ring gear 114 can rotate as a unit. A fixing washer 162 is mounted to base member 54 by coupling tabs 166 that are fitted in L-shaped coupling grooves 170 formed in base member 54 (only one such coupling groove is shown in FIG. 3). A spring washer 174 is disposed between fixing washer 162 and position setting member 118 for biasing position setting member 118 toward flange 130 so that the plurality of position setting teeth 122 firmly engage the position setting teeth 126 formed on flange 130 , and the plurality of coupling teeth 134 firmly engage the plurality of coupling teeth 138 formed on operating member body 142 .
[0022] Operating member 16 includes operating member body 142 and a gripping cover 174 . Gripping cover 174 is formed from an elastic material, and it includes gripping projections 178 circumferentially formed over its outer peripheral surface to facilitate gripping. Gripping cover 174 includes a plurality coupling grooves 182 formed on its inner peripheral surface for engaging a corresponding plurality of coupling projections 186 formed on the outer peripheral surface of operating member body 142 to securely mount gripping cover 174 to operating member body 142 . Operating member body 142 is rotatably mounted on base member 54 and axially held in place against flange 130 by fixing tabs 190 on base member 54 , each of which includes a radially extending locking projection 194 . A circumferential recess (not shown) formed on the inner peripheral surface of operating member body 142 cooperates with a stop projection 196 (FIG. 5) formed on the side of flange 130 opposite position setting teeth 126 to set the range of motion of operating member body 142 and hence operating member 16 .
[0023] As noted above, operating member body 142 includes a plurality of circumferentially disposed coupling teeth 138 that engage a corresponding plurality of coupling teeth 134 formed on position setting member 118 . Operating body 142 further includes an axially extending first drive tab 200 forming an abutment 204 and an axially extending second drive tab 208 forming an abutment 212 . Abutment 204 contacts an abutment 216 formed on an axially extending coupling tab 220 on ring gear 114 for rotating ring gear 114 in the direction A shown in FIG. 3. A return spring 224 has a first spring leg 228 contacting abutment 212 on second drive tab 208 and a second spring leg 230 contacting a second abutment 234 formed on coupling tab 220 for biasing ring gear 114 in the direction B shown in FIG. 3.
[0024] As shown in FIG. 7(A), the plurality of coupling teeth 138 on operating member body 142 are provided in a reference plane 142 s facing the position setting member 118 . The plurality of coupling teeth 138 extend along the axis X away from the reference plane 142 s, and the height of each coupling tooth 138 in relation to the reference plane 142 s is indicated as 138 h. In this embodiment, each coupling tooth 138 is formed as a ratchet tooth having a first ratchet tooth surface 138 a and a second ratchet tooth surface 138 b that functions as a cam surface in a manner described below. Similarly, the plurality of coupling teeth 134 on position setting member 118 are provided in a reference plane 118 s facing the operating member body 142 . The plurality of coupling teeth 134 extend along the axis X away from the reference plane 118 s, and the height of each coupling tooth 134 in relation to the reference plane 118 s is indicated as 134 h. In this embodiment, each coupling tooth 134 is formed as a ratchet tooth having a first ratchet tooth surface 134 a facing a corresponding first ratchet tooth surface 138 a on operating member body 142 and a second ratchet tooth surface 134 b that functions as a cam surface in a manner described below. When position setting member 118 is in the position shown in FIG. 4, a space S is formed between first ratchet tooth surface 134 a of each coupling tooth 134 and first ratchet tooth surface 138 a of each coupling tooth 138 . This space S provides the overshift function described below. In this embodiment, space S has a distance of between approximately 1.0 millimeter and 2.0 millimeters. However, since the winding radius of wire takeup member 18 and the gear reduction of the planetary gear mechanism determine the amount of pull of the inner wire 11 a, this space will differ for different applications. The width W represents the distance position setting member 118 moves when inner wire 11 a is pulled to move derailleur 6 the distance between adjacent sprockets on sprocket cassette 7 . Thus, the distance between each coupling tooth 134 corresponds to one speed step.
[0025] As shown in FIG. 7(B), the position setting teeth 126 on flange 130 are provided in a reference plane 130 s facing the position setting member 118 . The position setting teeth 126 extend along the axis X away from the reference plane 130 s, and the height of the position setting teeth 126 in relation to the reference plane 130 s is indicated as 126 h. In this embodiment, position setting teeth 126 each are formed as a ratchet tooth having a first ratchet tooth surface 126 a and a second ratchet tooth surface 126 b that functions as a cam surface in a manner described below. Similarly, the plurality of position setting teeth 122 on position setting member 118 are provided in a reference plane 118 t facing the flange 130 . The plurality of position setting teeth 122 extend along the axis X away from the reference plane 118 t, and the height of each position setting tooth 122 in relation to the reference plane 118 t is indicated as 122 h. In this embodiment, each position setting tooth 122 is formed as a ratchet tooth having a first ratchet tooth surface 122 a and a second ratchet tooth surface 122 b that functions as a cam surface in a manner described below.
[0026] The operation of shift control device 10 when actuating member 16 is rotated in the direction A will now be described with reference to FIGS. 8 (A)- 8 (G). For the sake of simplicity, the shape of the coupling and position setting teeth will be shown in simplified form. FIGS. 8 (A)- 8 (G) show the teeth disposed in the rear of shift control device 10 when viewed from the front. Thus, the teeth move upwardly when operating member 16 rotates in the direction A.
[0027] [0027]FIG. 8(A) shows operating member body 142 and position setting member 118 in an idle state before rotation of operating member 16 . In this state, the plurality of coupling teeth 134 on position setting member 118 mesh with the plurality of coupling teeth 138 on operating member body 142 such that there is the space S between each first ratchet tooth surface 134 a and each first ratchet tooth surface 138 a. Position setting teeth 126 similarly mesh with a pair of the plurality of position setting teeth 122 on position setting member 118 .
[0028] [0028]FIG. 8(B) shows the state upon initial rotation of operating member 16 . In this state, operating member body 142 has rotated the distance of the space S so that each first ratchet tooth surface 134 a contacts its associated first ratchet tooth surface 138 a while position setting member 118 has remained stationary. During this time, abutment 204 of first drive tab 200 of operating member body 142 contacts abutment 216 of coupling tab 220 of ring gear 114 to rotate ring gear 114 by the same distance. The rotation of ring gear 114 is communicated to the plurality of planet gears 83 , which rotate around the stationary sun gear 106 to cause a corresponding rotation of planet gear carrier 78 and wire takeup member 18 to wind the inner wire 11 a.
[0029] As shown in FIGS. 8 (C) and 8 (D), upon further rotation of operating member body 142 the first ratchet tooth surfaces 138 a continue to press against the corresponding plurality of second ratchet tooth surfaces 134 a, but now position setting member 118 rotates around the axis X. At the same time, a cam surface 122 b on a position setting tooth 122 and cam surface 126 b on a position setting tooth 126 displace position setting member 118 axially away from flange 130 . Further rotation of operating member body 142 in the direction A causes the position setting teeth 122 of position setting member 118 to jump over the position setting teeth of the flange 130 as shown in FIG. 8(E). At this time, the position setting member 118 is again fixed by the position setting teeth 126 of base member 54 . However, it should be recalled that because of the original space S between ratchet tooth surface 134 a and ratchet tooth surface 138 a, operating member body 142 and hence wire takeup member 18 have rotated by more than the amount (W) corresponding to movement of the derailleur from one sprocket to another, so the chain is in the automatic overshift position shown in FIG. 9. If further overshifting is desired, operating member body 142 may be further rotated as shown in FIG. 8(F) to produce additional manual overshift as shown in FIG. 9 without causing a double shift to the next sprocket. That is a benefit of the inclined cam surfaces 122 b and 126 b in this embodiment.
[0030] Because the height 134 h of the coupling teeth 134 of position setting member 118 is greater than the height 122 h of the position setting teeth 122 of position setting member 118 , the coupling teeth 134 of position setting member 118 do not move over the coupling teeth 138 of operating member body 142 and remain captured by the same teeth even when the position setting teeth 122 of position setting member 118 has moved over the position setting teeth 126 of the flange 130 . In other words, the meshing relationship of the position setting member 118 relative to the operating member body 142 remains the same throughout the wire pulling operation.
[0031] When the rider ceases to rotate operating member 16 in the direction A, operating member body 142 rotates in the direction B as a result of wire tension from derailleur 6 to the position shown in FIG. 8(G) without moving position setting member 118 . This, in turn, causes a corresponding rotation of ring gear 114 , planet gears 86 and planet gear carrier 18 , and wire takeup member 78 , thus releasing inner wire 11 a enough to remove the automatic and any manual overshift and return the derailleur 6 to a position such that chain 5 is located beneath the destination sprocket as shown in FIG. 9.
[0032] When operating member 16 is rotated in the direction B to release inner wire 11 a, the ratchet tooth surfaces 138 b of operating member body 142 press against the ratchet tooth surfaces 134 b of position setting member 118 . Since position setting member 118 cannot rotate because of the contact between the ratchet tooth surfaces 122 a of position setting teeth 122 of position setting member 118 and the ratchet tooth surfaces 126 a of position setting teeth 126 on flange 130 , position setting member 118 moves axially away from flange 130 until the position setting teeth 122 jump over position setting teeth 126 (since, as noted above, the height 134 h of the coupling teeth 134 of position setting member 118 is greater than the height 122 h of the position setting teeth 122 of position setting member 118 ), and position setting member 118 rotates by one speed step (W). The operation of operating member 16 and position setting member 118 in this direction is the same as disclosed in U.S. Pat. No. 5,921,139. At the same time, second drive tab 208 of operating member body 142 causes return spring 224 to press against abutment 234 on coupling tab 220 of ring gear 114 to rotate ring gear 114 in the direction B. Ring gear 114 , planet gears 82 , planet gear carrier 78 and wire takeup member 18 rotate accordingly to release inner wire 11 a by one speed step.
[0033] [0033]FIG. 10 is a cross sectional view of a twist grip shifting device 10 ′ illustrating an alternative embodiment of the present invention. Many components are the same as in the first embodiment and are likewise numbered the same. Thus, only the differences will be described.
[0034] In this embodiment, the coupling teeth 138 ′ on operating member body 142 ′ are formed such that there is no space between the ratchet tooth surfaces 138 a ′ and the ratchet tooth surfaces 134 a on the corresponding coupling teeth 134 on position setting member 118 . Instead, base member 54 in the first embodiment is converted into a first base member 54 a and a second base member 54 b. First base member 54 a has a tubular body 300 with radially outwardly extending locking projections 304 for engaging the side wall 42 of housing 38 , radially outwardly extending locking projections 308 for axially retaining second base member 54 b and operating member body 142 ′ (similar to locking projections 194 in the first embodiment), and a radially outwardly extending coupling member in the form of a projection 310 . Second base member 54 b is constructed substantially the same as base member 54 in the first embodiment, except that it is rotatably supported by first base member 54 a, and it includes coupling members in the form of abutments 314 and 318 (FIG. 11(A)) disposed on opposite sides of projection 310 to form a space S similar to space S between ratchet tooth surfaces 134 a and 138 a in the first embodiment. Second base member 54 b is axially retained on first base member 54 a by abutting against side wall 42 of housing 38 and by abutting against locking projections 308 .
[0035] The operation of shift control device 10 ′ when actuating member 16 ′ is rotated in the direction A will now be described with reference to FIGS. 11 (A)- 11 (G). FIG. 11(A) shows operating member body 142 ′, position setting member 118 , first base member 54 a and second base member 54 b in an idle state before rotation of operating member 16 ′. In this state the plurality of coupling teeth 134 on position setting member 118 mesh with the plurality of coupling teeth 138 ′ on operating member body 142 ′ so that first ratchet tooth surfaces 138 a ′ press against the corresponding plurality of first ratchet tooth surfaces 134 a, and position setting teeth 126 similarly mesh with corresponding pairs of the plurality of position setting teeth 122 on position setting member 118 . Projection 310 of first base member 54 a contacts abutment 318 on second base member 54 b so that space S is located between projection 310 and first abutment 314 .
[0036] [0036]FIG. 11( 13 ) shows the state upon initial rotation of operating member 16 ′. In this state, operating member body 142 ′ and second base member 54 b have rotated the distance S to close the space between projection 310 and abutment 314 while position setting member 118 has remained stationary. During this time, abutment 204 of first drive tab 200 on operating member body 142 ′ contacts abutment 216 of coupling tab 220 on ring gear 114 to rotate ring gear 114 by the same distance in the same manner as in the first embodiment. The rotation of ring gear 114 is communicated to the plurality of planet gears 83 , which rotate around the stationary sun gear 106 to cause a corresponding rotation of planet gear carrier 78 and wire takeup member 18 to wind the inner wire 11 a.
[0037] As shown in FIGS. 11 (C) and 11 (D), upon further rotation of operating member body 142 ′, the first ratchet tooth surfaces 138 a ′ continue to press against first ratchet tooth surfaces 134 a, but now position setting member 118 rotates around the axis X. At the same time, cam surfaces 122 b on a position setting teeth 122 of position setting member 118 and cam surfaces 126 b on position setting teeth 126 of flange 130 displace position setting member 118 axially away from flange 130 . Further rotation of the operating member body 142 ′ in the direction A causes the position setting tooth 122 of position setting member 118 to jump over the position setting tooth 126 of the flange 130 as shown in FIG. 11(E). At this time, position setting member 118 is again fixed by position setting teeth 126 on flange 130 of base member 54 b. However, it should be recalled that because of the original space S between projection 310 and abutment 314 , operating member body 142 ′, and hence wire takeup member 18 , has rotated by more than the amount (W) corresponding to movement of the derailleur from one sprocket to another, so the chain is in the automatic overshift position shown in FIG. 9. If further overshifting is desired, operating member body 142 ′ may be further rotated as shown in FIG. 11(F) to produce the additional manual overshift shown in FIG. 9.
[0038] When the rider ceases to rotate operating member 16 ′ in the direction A, operating member body 142 ′ and second base member 54 b rotate in the direction B to the position shown in FIG. 11(G) so that projection 310 on first base member 54 a abuts against abutment 318 without moving position setting member 118 . This, in turn, causes a corresponding rotation of ring gear 114 , planet gears 86 , planet gear carrier 18 and takeup member 78 , thus releasing inner wire 11 a enough to remove the overshift and return the derailleur 6 to a position such that chain 5 is located beneath the destination sprocket as shown in FIG. 9.
[0039] Operation of shift control device 10 ′ when operating member 16 is rotated in the direction B is substantially the same as in the first embodiment. In this case projection 310 on first base member 54 a contacts abutment 318 on second base member 54 b for the duration of the shifting operation.
[0040] While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. For example, the size, shape, location or orientation of the various components may be changed as desired. Components that are shown directly connected or contacting each other may have intermediate structures disposed between them. The functions of one element may be performed by two, and vice versa. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the scope of the invention should not be limited by the specific structures disclosed or the apparent initial focus on a particular structure.
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A bicycle shift control device comprises a base member; an operating member structured to be mounted around a handlebar so as to rotate in first and second directions around the handlebar; a transmission control member coupled to the operating member and rotatably mounted relative to the base member for pulling and releasing a transmission control element; a first position setting member; a second position setting member structured to rotate with the operating member and to move axially, wherein the second position setting member moves between an engagement position in which the second position setting member engages the first position setting member and a disengagement position in which the second position setting member is disengaged from the first position setting member; a first coupling member that moves in response to rotation of the operating member; a second coupling member coupled to the second position setting member for engaging the first coupling member so that rotation of the operating member causes rotation of the second position setting member; and wherein the first coupling member and the second coupling member are structured so that rotation of the operating member rotates the transmission control member for a selected rotational distance without moving the second position setting member toward the disengagement position.
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BACKGROUND OF THE INVENTION
Diaphragm pumps have found wide application because of the fact that they work essentially leak free, as compared to conventional piston pumps, and do not contain parts as susceptible to wear, which may also contribute to contaminating the pumping medium. In diaphragm pumps, the diaphragm is not directly driven by a mechanical component, but rather is driven through a hydraulic pressure medium, usually oil, and hereinafter referred to as oil, which in turn is activated by a mechanical piston. This piston is not particularly susceptible to sealing problems since leakage oil, if any, may be supplied to an oil reservoir from which the oil volume between the piston and the diaphragm is automatically refilled. In this type of pump, the diaphragm forms the boundary between the pumping medium to be delivered and the working oil.
High pressure liquid chromatography (HPLC) is one of the fields of application of diaphragm pumps of the type described above. Growth in this technology has been toward increasing pressures at ever decreasing flow rates. Here, a disadvantage inherent in the design of diaphragm pumps makes itself felt, namely the pulsating flow of the liquid delivered. When a diaphragm pump is used in liquid chromatography, it is necessary that this pulsation be damped enough to ensure that it will not vitiate the analysis. To effect this damping, one generally employs damping elements containing the medium delivered which are adapted to increase their volume as the pressure rises and to reduce it again when the pressure drops. Thus, a "capacitor effect" is achieved meaning that part of the medium delivered by the pump is stored during the pressure phase and released again via a flow resistance during the other phase of the pump when its pressure drops at the high pressure end. In this manner, a certain uniformity of flow is achieved.
A damper of this type is described by Achener, U.S. Pat. No. 4,222,414, issued Sept. 16, 1980 wherein delivered fluid is caused to pass through a sealed expandable plastic tube immersed in a sealed chamber of a compressible liquid. A pressure pulse in the delivered fluid is damped by the radial expansion of the plastic tube into the compressible liquid. Bourdon tubes and compressible liquid or spring loaded diaphragms also are typical of the above described damping technique. The function of these prior art dampers is similar to that of RC elements in an electrical circuit; namely the damping behavior is a function of the pumping frequency. In addition, the equilibrium volume of the damping element increases as the absolute pressure of the delivered medium rises creating dead volume which is undesirable in modern high pressure liquid chromatography. For example, in light of the present tendency to ever smaller flow quantities and ever higher pressures, a dead volume of even 1 ml is unacceptable, since it would appreciably widen the peak in an HPLC chromatogram.
Ernst, et al., U.S. Pat. No. 3,984,315 issued Oct. 5, 1976 describes a damping device which predominatly overcomes the limited performance range of prior art RC type dampers. Here, a manually adjustable spring is coupled to the diaphragm of a diaphragm damper to provide adjustable stiffness to the damping chamber. When used at high absolute fluid pressures the spring is manually compressed to raise the effective stiffness of the diaphragm and restrict the dead volume expansion of the damper chamber. At low fluid pressures the stiffness is adjusted accordingly lower. In this manner, an appropriate balance between damping and dead volume can be adjusted for a given pump operating pressure condition. The primary shortcoming of this technique is the inconvenience of the manual set point adjustment and the fact that in liquid chromatography operating pressures are not always constant; a loss in absolute pressure would cause diminished damping, whilst a gain in absolute pressure would cause a rise in dead volume for a given spring preload.
A second disadvantage of diaphragm pumps concerns the need to provide a means for regulating the oil pressure developed between the piston and diaphragm. Once the diaphragm has reached its full deflection with hydraulic pressure, any residual stroke of the diaphragm pump piston will incur a rapid pressure increase of the oil over the diaphragm pressure which could be damaging to the diaphragm, pump seals and valves. In the prior art measures to limit excessive oil pressure development have consisted of the placement of a pressure regulating valve in the oil chamber between the piston and diaphragm to vent the high pressure oil back to the pump oil reservoir, or the placement of a preloaded spring between the piston and its drive mechanism to restrict piston displacmeent beyond an oil pressure set point. In either case, the oil override set point must be set at an oil pressure greater than the maximum downstream delivered fluid pressure to insure sufficient oil pressure to cause proper deflection of the diaphragm with each stroke of the piston over all operating conditions and delivery pressures. Since in liquid chromatography the analysis is most often obtained at average pump pressures substantially below the maximum operating point of the pump, the prior art diaphragm pump is usually substantially overworked, causing premature wear of seals, valves, and other parts in each pump.
SUMMARY OF THE INVENTION
In accordance with the illustrated preferred embodiment the present invention provides a damping system which achieves efficient damping of the pulsations of a diaphragm pump of the delivered medium over a range from high to extremely low delivery volumes over a broad range of low to high pressures, without giving rise to any significant dead volume. Simultaneously, with the delivery of the medium to be delivered, the diaphragm pump of the invention delivers a flow of the pressure medium, e.g., oil, into a damper vessel. The pressure in the damper vessel builds up with a certain delay relative to the pressure in the damper chamber because the flow resistance that must be overcome by the pressure agent is somewhat higher than that which must be overcome by the liquid to be delivered. The damper vessel is equipped with a pressure medium outlet which communicates with atmospheric pressure via a valve with variable flow resistance. When the pressure in the damper vessel is lower than the pressure in the damper chamber, this flow resistance is increased so that the pressure in the damper vessel rises until an equilibrium is reached between the mean pressure in the damper chamber and the pressure in the damper vessel. When the pressure in the damper vessel is higher than the pressure in the damper chamber, the flow resistance of the valve decreases so that again a pressure equilibrium is reached between the damper chamber and the damper vessel. Because of the delay with which the pressure is balanced between the pressure medium reservoir of the pump and the damper vessel, the pressure pulsations occurring in the pressure medium reservoir are not transmitted to the damper vessel. In contrast, the pressure encountered in the damper vessel is always equal to the mean value of the pulsating pressure in the damper chamber, irrespective of the absolute pressure level. This means that the resilient partition wall between the damper chamber and the damper vessel moves invariably about a constant mean position so that the mean volume of the damper chamber remains constant, irrespective of the absolute pressure existing at any time. Accordingly, the dead volume does not change as the absolute pressure changes.
According to the invention, the volume of the damper chamber of the pump of the invention may have a size small enough (on the order of 0.1 ml) to make it suited also for use in modern highpressure liquid chromatography with minimum flow quantities. Thus, since the volume of the damper chamber can be made small and the average volume can be kept constant as the absolute pressure is varied, the present invention is well suited for use over a broad range of operating pressures. In addition, since the damper chamber serves as a constant averaging load for the pump, the pumping chamber of the pump need only be pressurized to a pressure just exceeding the desired output pressure for the medium to be delivered. The result is that the pump itself is subjected to less wear and tear than pumps in the prior art which must operate continuously at the maximum operational pump pressure.
In particular, the resilient partition wall (diaphragm) between the damper chamber and the damper vessel may be an integral part of the valve with variable flow resistance. To this end, the output opening of the damper vessel is arranged near the partition wall in a manner such that it will be covered up by the latter to a greater or lesser extent, depending on the differential pressure between the damper chamber and the damper vessel.
The invention will now be described with reference to certain embodiments and to the pertinent drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a basic diagram of a diaphragm pump and damper system of the invention.
FIG. 2 is a diagrammatic representation of a practical embodiment of the diaphragm pump and damper system of the type shown in FIG. 1.
FIG. 3 is a part-sectioned longitudinal view of the damper chamber and the damper vessel.
FIG. 4 shows the details of the output opening of the damper vessel in the arrangement shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, reference number 11 designates the pumping section of a diaphragm pump. The pumping section 11 includes a pumping chamber 13 for a liquid to be delivered, such as a solvent in an LC system, from a solvent reservoir 5 to a load 7 such as an LC column. The pumping chamber 13 is separated by a diaphragm 15 from a pressure medium chamber 17 filled with a hydraulic pressure medium such as oil, or other suitable medium. A piston 19 is actuated by a crank mechanism 21 to perform a reciprocating movement in the oil chamber 17.
The pumping chamber 13 is connected via an input valve 23 and a suction line 25 to solvent reservoir 5 for the fluid to be delivered, and via an output valve 27 to a high-pressure line 29. The oil chamber 17 communicates with an oil reservoir 35 via an input valve 31 and a suction line 33, and with an oil line 41 via an output valve 37; a resistance element 39 provides a specific flow resistance. The design of the output valve 37 is such that it will open only at a pressure substantially higher than that causing the output valve 27 to open.
A damper arrangement 43 includes a damper vessel 45 and a damper chamber 47 separated from each other by a flexible diaphragm 49. The damper chamber 47 communicates with the solvent high pressure line 29, while the damper vessel 45 communicates with the oil pressure medium line 41. Connection lines 51 and 53 connect the damper chamber 47 and the damper vessel 45, respectively, with a differential-pressure controlled valve 55.
The differential pressure controlled valve 55 has two pressure chambers 57 and 59 separated from each other by a flexible diaphragm 61. The pressure chamber 57 communicates with the solvent connection line 51, while the pressure chamber 59 communicates with the oil connection line 53. Also connected to the pressure chamber 57 is an output line 63 for the liquid to be delivered to load 7. An oil vent 65 leads from the pressure chamber 59 back to the oil reservoir 35.
The oil vent 65 terminates in an opening 67 located in the pressure chamber 59 near the diaphragm 61. When the solvent pressure in the chamber 57 exceeds the oil pressure in the chamber 59, the diaphragm 61 is deformed towards the opening 67. Conversely, the diaphragm 61 is deformed away from the opening 67 when the oil pressure in the chamber 59 exceeds the solvent pressure in chamber 57. The diaphragm 61 and the opening 67 coact to ensure that the flow resistance for the oil flowing through the pressure medium vent 65 increases continuously as the diaphragm 61 approaches the opening 67.
The function of the arrangement described above is as follows:
The reciprocating movement of the piston 19 causes the oil in the pressure medium chamber 17, and consequently, the diaphragm 15 to move to and fro. As a result, the input valve 23 and the output valve 27 open and close respectively so that solvent is delivered from the suction line 25 to the highpressure line 29. It is an inherent feature of the design that the solvent delivery takes place in a pulsating manner. To eliminate or greatly reduce pulsations the solvent is initially supplied into the damper chamber 47 of the damper arrangement 43. Together with the input valve 31 and the output valve 37, the oil chamber 17 coacts with the piston 19 to operate as a normal piston pump by means of which oil is delivered from the pressure medium reservoir 35 to the damper vessel 45 of the damper arrangement 43. However, because the output valve 37 requires a higher pressure to respond than the output valve 27, this latter operation will start only upon completion of the delivery phase of the solvent. And given the fact that the oil flow must pass the flow resistance 39, it must overcome a much higher flow resistance than the liquid in the high pressure line 29. Accordingly, the pressure in the damper vessel 45 follows the pressure in the damper chamber 47 with a certain delay.
The volume of the damper vessel 45 is large enough so that under operating pressure conditions (in high pressure liquid chromatography up to 500 bars) the compressibility of the oil in the damper vessel 45 is high enough to permit the volume of the damper chamber 47 to vary sufficiently to obtain the desired damping of pulsations in the high pressure line 29. For example, damper vessel 45 may have a volume of 15-35 ml, containing oil of compressibility 65×10 -6 bar -1 .
The pressure in the oil damper vessel 45 adapts itself continuously to the mean pressure in the solvent damper chamber 47. This results from deformation of diaphragm 61 toward the opening 67 when the pressure in the solvent pressure chamber 57 exceeds the pressure existing in the oil pressure chamber 59. Flow of oil out of opening 67 is reduced, thereby causing the pressure in the oil pressure chamber 59 to rise until an equilibrium is achieved. Similarly, when the pressure in the oil pressure chamber 59 exceeds the pressure in the solvent pressure chamber 57 oil flow from opening 67 is increased, reducing the pressure in chamber 59. The flow resistance 39 and the flow resistance in the opening 67 cause the pressure in the damper vessel 45 to change only slowly, as compared to the pressure in the damper chamber 47. Thus, a quasi-static counter pressure is obtained for the damper chamber 47. Since this counter pressure is always equal to the mean pressure in the damper chamber 47, the diaphragm 49 moves constantly about its neutral central position, irrespective of the absolute pressure existing at any time in the system. If, however, the damper vessel 45 were closed, the increasing mean pressure in the damper chamber 47 would cause the diaphragm 49 to bulge further and further into the damper vessel 45, and as a result thereof the dead volume of the damper chamber 47 would increase with rising pressure. This situation is prevented by the arrangement described above.
FIG. 2 is a diagrammatic representation of a practical embodiment of the diaphragm pump shown in FIG. 1. A pumping chamber 113 is separated by a diaphragm 115 from a pressure medium (oil) chamber 117 in which a piston 119 reciprocates. The piston 119 is driven by a motor 122 via a crank mechanism 121.
The pumping chamber 113 communicates via an input valve 123 with a suction line 125 and via an output valve 127 with a highpressure line 129. The oil chamber 117 communicates via an input valve 131 with an oil reservoir 135. An output valve 137 and a flow resistance loop 139 connect the oil chamber 117 to a damper vessel 145 provided in a damper arrangement 143. Between the output valve 137 and the flow resistance loop 139 there is connected to the connection line 141 a pressure relief valve 142 which serves to prevent damage to the individual elements of the diaphragm pump in the event the flow of pumped liquid should be blocked for any reason whatever.
The damper arrangement 143 includes a damper vessel 145 with a diaphragm 149. The damper chamber 147 communicates, on the one hand, with the solvent high pressure line 129 and, on the other hand, with a solvent output line 163. The damper vessel 145 communicates with a valve chamber 152 via channels 148 and 150. The diaphragm 149 is firmly held about its periphery between the damper chamber 147 and the valve chamber 152. The shape of the damper chamber 147 and the valve chamber 152 is preferrably such that the diaphragm 149 may abut against the wall on either side without damage.
A pressure medium vent 165 opens into the valve chamber 152 through an opening 167 which is closed to a greater or lesser extent in response to the pressure difference between the damper chamber 147 and the damper vessel 145 or the valve chamber 152, respectively, the function being substantially the same as that of valve 55 in FIG. 1.
The diaphragm pump arrangement shown in FIG. 2 may be constructed of such a small size that the dead volume of the liquid delivered may be kept as low as 50 ul, while a hydrostatic pressure of 450 bars can be achieved. The damping arrangement permits the restriction of the pressure variations in output line 163 to 10 bars. A conventional passive damping arrangement would have a dead volume of 1 ml at 450 bars.
FIG. 3 shows the detail of a damper arrangement 243 of a design similar to that of damping arrangement 143 in FIG. 2. A damper vessel 245 communicates with a valve chamber 252 via channels 248 and 250. The valve chamber 252 is separated by a diaphragm 249 from a damper chamber 247 into which open a high pressure line 229 arriving from the pumping chamber and an output line 263.
The damper vessel 245 communicates via a flow resistance loop 239 and a connection line 240 with an output valve 237 from the oil chamber of the pumping arrangement (not shown in FIG. 3). As in the arrangement shown in FIG. 2, a pressure relief valve 242 is connected to the connection line 240. An oil vent 265 opens through an opening 267 into the valve chamber 252. The opening 267 is provided in a protrusion 268, whose detailed shape will be described in more detail below.
The damper arrangement 243 includes two housing portions 271 and 273 clamped together by screws 275, of which only one is shown in FIG. 3. Between the housing portions 271 and 273, an insert 277 includes two channels 248 and 250 and the opening 267. The individual components may be constructed of a pressure and corrosion resistant material suited for the liquid to be delivered. For example, the lines shown in FIG. 3 may be capillary tubes of corrosion resistant steel and connected in sealing relationship to the respective portions of the damper arrangement 243 by means of commercial attachment fittings 279.
As in the arrangement shown in FIG. 2, the surfaces of the housing portion 273 and the insert 277 facing the diaphraph 249 are only slightly rounded so that the diaphragm 249 may abut against them without being damaged. In order to ensure that the diaphragm 249 will not adhere to said surfaces, the surfaces are finished with sufficient roughness to prevent suction between the diaphragm 249 and the surfaces. Grooves may also be applied to said surfaces to achieve the same purpose.
FIG. 4 shows a preferred embodiment of the opening 267 and its surroundings in a somewhat enlarged scale. The circular line 270 defines the outline of the spherical protrusion 268 at the center of which the opening 267 can be seen. On the spherical protrusion 268 grooves 281 and 283 are provided emerging radially from the opening 267, the grooves 283 being somewhat shorter than the grooves 281. For example, grooves 283 may be 2 mm in length, while grooves 281 are 3 mm long. The grooves 281 and 283 are triangular in cross-section and become flatter with increasing distance from the opening 267. Now, when the diaphragm 249 is in full contact with the spherical protrusion 268, the opening 267 is fully closed. When the diaphragm 249 begins to lift off the spherical protrusion 268, the ends of the grooves 281 will be released first so that a small flow of pressure medium will be permitted to flow from the damper vessel 245 into the opening 267. As the diaphragm continues to lift off of spherical protrusion 268, the cross-section through which the pressure medium can flow off increases, especially since the grooves 283 also become active. Finally, when the diaphragm 249 has fully come off the spherical protrusion, the flow resistance is solely determined by the distance between the diaphragm 249 and the opening 267.
The grooves 281 and 283 guarantee a smooth flow resistance characteristic for the pressure medium flow, in response to the position of the diaphragm. Grooves 281 and 283 also provide a means to match the oil flow rate from the pump to the specific flow resistance needed to obtain damper stability. Thus the grooves 281 and 283 would be enlarged for higher oil flow rates or visa versa.
The embodiments described herein do not limit the teachings of this invention. For example, it would be obvious to one skilled in the art that the pressure control valve 55 of FIG. 1 could consist of a differential pressure transducer and a motor or electrically operated valve. The differential pressure transducer would electrically sense average pressure changes between the solvent and oil in pulse damper 43 and provide thereby feedback for electronically controlling the flow resistance of oil through the electrically operated valve and the oil pressure in damper chamber 47. Such a system could include electrical filtering to limit transient response and hence further stabilize damper operation. It would also be obvious to one skilled in the art that the diaphragm 49 and damper chamber 47 could consist of a sealed expandable plastic tube immersed in the damper vessel 45.
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A new mechanism for pulsation damping in a reciprocating diaphragm pump system is disclosed which is especially suitable for solvent delivery in modern high pressure liquid chromatography requiring a wide range of solvent flow rates and pressures. The disclosed damper has good overall performance over the full range of liquid chromatographic conditions, a dead volume independent of solvent pressure, and largely eliminates the necessity for continuously pumping the working oil of the diaphragm pump to a maximum operating pressure.
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This is a divisional of copending application Ser. No. 08/220,274 filed on Mar. 30, 1994.
TECHNICAL FIELD
The invention relates to the analysis of an oil sample to determine metal additive content and other organic content, and more particularly, to a self-contained analyzer for on-site use and analysis.
BACKGROUND OF THE INVENTION
Oil is generally utilized to lubricate moving parts in mechanical systems, such as engines, transmissions, and hydraulics in vehicles. Contaminants are not originally present in the oil but are by-products of wear and corrosion in these systems. Metal particulates are formed through abrasion or chemical corrosion and cause further deterioration of internal parts. Normal operation causes oxidation, nitration, and sulfation, but the introduction of additional elements or compounds into the oil accelerates the accumulation of metal particles from abrasion and corrosion. The lubricant filters are designed to remove larger size particulates from oil. However, this leaves the majority of smaller contaminants free to further affect the equipment, especially the nonmetallic components such as pump diaphrams, gaskets and seals, fluid lines, etc.
Concentrations of water in oil affect systems differently, i.e., some systems are of little concern unless above a certain concentration while other systems may be effected with the slightest trace of water. Small amounts of water come from primarily water vapor in the atmosphere, and larger amounts may be due to water leaks, which could damage equipment.
Ethylene glycol is the main component used in anti-freeze products. A significant leak could also damage equipment. Thus, contaminants in oil such as ethylene glycol, fuel, silicon, and soot and other chemicals are also concerns.
Oil analysis provides a method of monitoring wear trends on moving parts of virtually any system or mechanical device. This allows identifying changes from normal wear patterns and thereby predicts progressive damage-type failures. The composition of foreign materials in oil can be determined by a variety of techniques, such as infrared spectrometry, optical emission spectrometry, x-ray fluorescence, etc.
Accurate oil analysis has been provided mainly in a laboratory setting. A system utilized in a laboratory is disclosed in U.S. Pat. No. 3,526,127, issued to Sarkis on Sep. 1, 1970. Sarkis is a semi-automated oil analysis system for a laboratory which utilizes a metal content testing device, a viscometer and an infrared absorbing device. These testing devices transmit their results to a computer which stores reference limits, compares the tested values to the reference limits, and provides evaluation, reporting and trending of oil for various types of engines. An oil sample is separated into three different containers; one container of oil is read by the metal electrometer to determine the concentration of metals; a second container of oil is measured by the viscometer; and a third container of oil is measured by the infrared analyzer to determine contents of water and glycol, and determine oil degradation. The results are sent to a computer which stores the reference information of viscosity, metal content, and infrared characteristics.
It is desirable to have a shop-level or on-site machine that can comprehensively evaluate the condition of an engine, transmission, gear box, or other oil source through the measurement of microscopic wear debris and dissolved contaminants in the equipment's lubricating oil.
SUMMARY OF THE INVENTION
The invention includes an oil analysis system for analyzing the contents of oil. The system comprises a plurality of isolated and remote oil test assemblies each including an oil spectrometer for automatically testing contents of the oil and for storage of test results from the oil spectrometer with associated identification information of the oil. A plurality of communicators transfer the test results with the associated identification information from the plurality of oil test assemblies. A centralized computer assembly is connected to each of the communicators for receiving the test results with the associated identification information and for evaluating the test results based on the identification information to determine characteristics of the test results from a plurality of the remote oil test assemblies.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is a perspective view of the test assembly with internal components indicated in phantom lines;
FIG. 2 is a schematic diagram of the analysis system;
FIG. 3 is a schematic diagram of the computer controller;
FIGS. 4a and 4b are a flow chart of the operation of the computer controller; and
FIG. 5a is a table of events stored in the event table memory of the computer controller and FIGS. 5b and 5d are tables of rules stored in the rules memory of the computer controller.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A test assembly 10 for testing a sample 12 of oil to determine additives and contents thereof is generally illustrated in FIG. 1. The test assembly 10 allows a sample of oil to be tested to determine wear from analysis of contaminants, additive elements, oxidation, nitration, etc., as subsequently discussed. The test assembly 10 automatically performs non-destructive and destructive testing of the sample, analysis and data evaluation, and diagnoses and reports the results and remedial action required based on the analyzed sample 12.
As illustrated in FIG. 2, the test assembly 10 is optionally part of an oil analyzing system 100 which includes and incorporates information from a plurality of test assemblies 10 for trend reporting and general data base information and update. The test assembly 10 may operate independent and separate from the remainder of the oil analyzing system 100. The system 100 is subsequently discussed.
The test assembly 10 includes a housing 14 for containing the test equipment to automatically test the sample 12. The housing 14 is generally comprised of a rectangular rigid, supporting structure 15 having wheels 16 attached thereto for allowing mobility of the housing 14 and therefore test assembly 10. The housing 14 provides a self-contained analysis assembly 10.
The test assembly 10 includes an infrared spectrometer 18 within the housing 14 for optically testing the sample 12 and producing first test results. The infrared spectrometer 18 generally provides for testing organic materials in the sample 12, such as oxidation, nitration, sulfation, fuel, water, glycol and soot. The infrared spectrometer 18 is generally known in the art, such as that provided by Thermo Nicholet. The infrared spectrometer 18 produces a spectrograph of the sample 12 indicative of light absorption by the sample 12 at different frequencies, as generally known in the art. Empirical correlations translate the wave peak information to physical parameter values.
The infrared spectrometer 18 generally includes an infrared source 20 for generating a plurality of wave lengths which pass through the sample 12 contained in a flow cell 21, and to a detector 22 which detects absorption of the wave lengths. The infrared spectrometer 18 produces data in the form of peak values from the generated spectrum.
The test assembly 10 also includes an optical emission spectrometer 24 for receiving the sample 12 from the infrared spectrometer 18 and for destructively testing the sample 12 to produce second test results. The optical emission spectrometer 24 generally tests for and measures wear, contaminants, and additive elements found in oil samples 12, such as metals and sand. Optical emission spectrometers 24 are commonly known in the art and are available from Thermo Jarrell Ash. The emission spectrometer 24 produces raw data or test results in "parts per million".
The optical emission spectrometer 24 physically breaks down the fluid sample between and produces a report on the amount of certain metals in the sample 12 based on the optical emissions occurring during breakdown. The optical emission spectrometer 24 generally includes a source electrode 26 and a sample platform electrode 28 for electrical excitation therebetween. Photocells 30 optically monitor the excitation to determine additives based on the produced light spectrum.
The sample 12 of oil is communicated in series through the infrared spectrometer 18 and then through the optical emission spectrometer 24. A channeling means or channelling assembly 32 communicates the sample 12 to the flow cell 21 of the infrared spectrometer 18 and thereafter to the optical emission spectrometer 24. The channelling means 32 generally includes a conduit which includes a first end 34 for receiving the sample 12 of oil to transfer the oil into the conduit 32, and a second end 36 for disposing of the sample of oil 12. The first end 34 of the conduit 32 includes a nozzle 38 connected thereto for submerging within the sample 12 of oil to draw the sample 12 into the conduit 32. The flow cell 21 is connected within the conduit 32 to allow testing by the infrared spectrometer 18.
Also included is pump means 40 operatively connected to the conduit 32 for drawing the sample 12 into the first end 34 and for transferring the sample 12 through the conduit 32 to the second end 36 thereof. The pump means 40 comprises a liquid pump as commonly known in the art. The pump 40 may be controlled to selectively draw the sample 12 into the conduit 32 and initially to the infrared spectrometer 18 for testing, and subsequently to the optical emission spectrometer 24.
The assembly 10 may optionally include a heater 42 operatively connected to the conduit 32 for heating the sample 12 of oil prior to being tested. It is desirable to first heat the sample of oil to lower the viscosity thereof to facilitate the transfer of the oil through the conduit 32. The heater 42 is connected about the conduit 32 between the nozzle 38 and the infrared spectrometer 18 to heat the sample 12.
The assembly 10 also includes a computer controller 50 connected to the pump 40, heater 42, the infrared spectrometer 18 and the optical emission spectrometer 24 for controlling the transfer of the sample 12 to the infrared spectrometer 18 and the optical emission spectrometer 24, and for initiating testing to receive and evaluate the first and second test results. The computer controller 50 may be any type of commonly available computer based system with memory for analyzing the results and controlling the remainder of the assembly 10. The computer controller 50 operates under the flow chart of FIGS. 4a and 4b, as subsequently discussed. The computer controller 50 includes a processor 51 and sample memory 52 for storing working parameters, the test results and identification information associated with the sample 12. The computer controller 50 is of the type able to operate in a Windows® format and run the software of the invention coded in Foxpro and Visual Basic in a DOS shell.
The assembly 10 includes a keyboard 54 connected to the computer controller 50 for allowing input of identification information and data of the sample 12 for reception by the computer controller 50. The information is stored in the memory 52 to distinguish the sample 12 and associated test results, from other samples 12. The keyboard 54 also allows editing functions of the identification information, software program, and variables or parameters as commonly known in the art.
The assembly 10 also includes a display screen 56 connected to the computer controller 50 for displaying the input of identification information and the output of the test results, or any other analysis or results provided by the computer controller 50. Such a display screen 56 is commonly known in the art.
The assembly 10 also includes a printer 58 connected to the computer controller 50 for printing test and analysis results. The computer controller 50 may dump the analysis information and any trending or diagnosis onto the printer 58.
The assembly 10 includes a bar code reader 60 connected to the computer controller 50 for reading an identification code from a bar code label 61 on a container 62 holding the sample 12. Each of the containers 62 generally include a different identification code thereon for reading by the bar code reader 60. This code is input into the computer controller 50 and then stored in memory 52 with the sample information input from the key board 54 for a sample 12. Typical bar code readers 60 are commonly known in the art. The identification code may alternatively be input by the operator via the keyboard 54 from the code on the container 62.
The test assembly 10 includes a modem 66 to allow external communication with a remote, central computer 70 which accumulates results from each of the remote test assemblies 10. The central accumulating computer 70 is part of the analyzing system 100, and is located at a remote area to receive information from each of the test assemblies 10. The function of the remote central computer 70 will be subsequently discussed.
A discard container 68 is located below the second end 36 of the conduit 32 to collect the unused portion of the sample 12 of oil which flows out of the optical emission spectrometer 24.
The housing 14 on its exterior of the structure 15 supports the keyboard 54, display screen 56, printer 58, and bar code reader 60 along with the first end 34 of the conduit 32 protruding from the housing 14 with the nozzle 38 extending therefrom. A container holder 64 is positioned beneath the flexible nozzle 38 to receive the container 62 so that the nozzle 38 can be directed and moved into the sample 12 of oil.
Enclosed within the housing 14 on its interior for protection thereof is the infrared spectrometer 18, optical emission spectrometer 24, remainder of the conduit 32, discard container 68, the pump 40, optional heater 42, and the computer controller 50.
The computer controller 50 is schematically illustrated in FIG. 3. The results from the infrared spectrometer 18 includes peak values from the generated spectrum, polled from the infrared spectrometer 18 dynamically by the computer controller 50. The results from the optical emission spectrometer 24 consists of various metal quantities in the samples. This data is passed to the computer controller 50 in the form of a text file. In general, the computer controller 50 controls the infrared spectrometer 18, optical emission spectrometer 24, pump 40, heater 42, display screen 56, printer 58. The computer controller 50 manages and provides the timing for the components.
The controller 50 includes identification memory 73 for storing used identification numbers. The controller includes an identification comparator 72 for receiving the identification code input either by the bar code reader 60 or the keyboard 54 to ensure that the identification number has not been previously utilized and is unique by comparing it to the numbers in the identification memory 70. If the identification number has been utilized, an alert message is displayed on the display screen 56 and the computer controller 50 awaits input of a unique identification number.
The computer controller 50 also includes sample data memory 74 for storing information regarding tested samples. For each sample, the sample data memory 74 includes the information of ("samp -- osa"): identification number, assembly number, customer name, unit code, system, unit type, make, model, time units (hours or miles), total time (total time on unit), fluid time (time on oil), fluid type (type of oil), oil brand, oil capacity, oil capacity units, all of which are initially set up for a sample prior to testing. The identification, assembly number, date and time are filled in automatically by the processor 51. The system information may be selected from a check list which includes pump, industrial, gear box, engine-diesel, engine-gasoline, engine-natural gas, turbine, new oil.
Other information which is input into the sample data memory 74 by the processor 51 for each sample includes the following: diagnostic codes, diagnostic text, enter date, enter time, aluminum, chromium, copper, iron, lead, tin, nickel, silver, silicone, sodium, potassium, boron, magnesium, zinc, water, fuel, nitrogen fixation, oxidation, pentane/toluene and solubles and resins, total base number (TBN), total acid number (tan), and viscosity.
Also included is an event table memory 76 for storing information utilized by the controller 50 to control the timing sequence and rates of the pump 40, and the infrared spectrometer 18 and emission spectrometer 24. FIG. 5a is illustrative of an event table which includes the start time and rate information.
IR memory 78 stores the received spectrograph from the infrared spectrometer 18, and includes values and parameters which enables the controller 50 through peak analysis means 80 to determine soot, oxidation, nitration, water and glycol. Such calculations and fourier transform analysis are commonly known which are based on the location of the peak value in the spectrum and the height thereof.
The peak analysis means 80 analyzes the stored spectrograph to obtain "parts per million" values and stores the resultant calculations in the sample data means 74 for the specified sample. Typical values may include the following: glycol equals 4.3, V100C equals 15.8, V40C equals 32.1, V100F equals 32.0, V210F equals 15.7, TAN equals 12, and TBN equals 9.8. The V values indicate viscosity at the indicated temperatures, either in units of C° or F°, which are standard industry measurements.
The controller 50 receives the data from the emission spectrometer 24 as a text file and is received in emission memory 82. The information is then stored with the sample data in the sample data memory 74. Indicative of the emission memory 82 for a specified sample is as follows: AL=75.0, CU=50.4, FE=51.2, PB=321.1, SI=1.15, ZN=2.2, K=456, CR=54.2, and SN=45.1.
The controller 50 also includes a rules memory 84 for comparison with the data in the data sample memory 74 by diagnosis means 86 upon complete testing thereof, to determine condition and diagnosis of the test results. Different rules may be utilized for different types of engines, models, makes, etc. Depending on this type information depends on the rules utilized. Different rules are for diagnosis at a refinery, standard used oil diagnosis, special used oil diagnosis to accommodate unusual climate, standard industrial diagnosis, etc.
The rules memory 84 is partitioned to include a list of rule bases 90, list of rule definitions 92, and rule call table 94. The list of rule bases 90 includes a rule base identification and description. The rules base identification is unique and identifies the system type which is the source of the oil. For example, the table shown in FIG. 5b may be utilized.
The prefix "QSAD" rule bases are utilized for automatic diagnosis, and the "QC" rule bases are utilized to check and verify the data provided by the spectrometers 18, 24, i.e., provides windows of acceptable values.
The list of rule definitions 92 include a rule identification, rule expression and comments. The rule expression is any Foxpro compatible code (or other software system code) that, when evaluated at run-time, returns a Boolean value (true/false). Any fields in the data memory 74 are available for use in the rules. The RR() function allows rules to call other rules. Example of typical rules are shown in FIG. 5c.
The rule call table 94 specifies which rule definitions to process for which bases in what order, and what action to take in the event of a "true" rule. The rule base identification identifies one in the list of rules 90 and the rule identification identifies a rule in the list of rule definitions 92. The sequence number indicates the order in which rule calls within a particular rule base are processed, and may be repeated. The custom function CREPLACE includes memory table (test data), key (expression of value to seek on within table to identify proper record), field (in the test data to act on), value (value to add to field), concatenate/overwrite value flag (whether to replace existing contents of table-value or add to existing contents) and append new record if not found flag (whether to append a new record if the seek on key fails). FIG. 5d is exemplary of the rule call table 94.
In general, the computer controller 50 operates according to the flow chart illustrated in FIGS. 4a and 4b. The controller 50 first displays the following selections: A-analyze a sample, P-print a report, C-check/calibrate. The "A" selection allows the assembly 10 to automatically test and diagnose a sample, the "P" selection prints the report of resulting diagnosis, and the "C" selection provides automatic calibration of the assembly 10.
If the "A" selection is made, the following occurs. The identification number is input by the operator on the keyboard 54 or by the bar code reader 60. The identification comparator 72 compares the input identification number to the used identification numbers stored in identification memory 73. If the number exists in the memory 73, an alert message is displayed on the screen 56 indicating prior use thereof and unavailability, and the program awaits a new identification number. If the number does not exist in memory 73, the input identification number is written into the memory 73 and the program continues.
Thereafter, the controller 50 requests equipment or unit data which identifies the oil or fluid and source thereof. The controller 50 lists equipment and oil type as follows: pump, industrial, gear box, engine-diesel, engine-gasoline, engine-natural gas, turbine, new oil. Upon selection of one of the former, the controller 50 stores in sample data memory 74 the identification number and selection, and thereafter displays a data entry screen for entry of further data relating to the sample 12. A different data entry screen may be displayed for each different type of equipment/oil type, depending on the data variables desired. This information includes data about the engine and the oil being analyzed so that the test results may be properly categorized and analyzed by the appropriate rule bases. The data provides information to the computer controller 50 for diagnosis and is included on the report for reference. Such information includes the automatic display of identification number, date and time, and requests entry of information of customer name, unit identification, unit make, unit model, time units (hours and miles), total number of units oil in service, total number of units unit in service, oil type, oil brand, gross oil capacity and units thereof. This sample information is stored in the sample data memory 74 with its associated identification number.
Thereafter, the controller 50 displays on the display screen 56 messages of the execution of each test until completion of the test such messages may include: insert nozzle in sample, processing sample, conducting infrared test, conducting emission test, processing results, tests completed.
In order for the controller 50 to automatically test the sample 12, the event table 76 is read for the type of sample based on the equipment/oil type. The table 76 allows the controller 50 through driver means 53 to drive the operation of the pump 40, infrared spectrometer 18, and optical emission spectrometer 24. The timing and sequence of each of these components is specified in this event table 76, as previously illustrated.
The computer controller 50 starts the pump 40 to draw the sample 12 through the nozzle 38 and into the conduit 32. This sample 12 is moved to the flow cell 21 of the infrared spectrometer 18 and is drawn therepast to ensure a clean sample is tested, i.e., no residue from the previous sample. The pump 40 is then stopped. The controller 50 instructs the infrared spectrometer 18 to start testing. The controller 50 awaits to receive the test information from the infrared spectrometer 18, i.e., spectrograph.
The IR spectrograph is received by the controller 50 and stored in the IR memory 78, and then analyzed by peak analysis means 80. The peak analysis means 80 isolates peaks at various locations on the spectrograph and the magnitude thereof to obtain a standardized value for glycol, soot, fuel, water, viscosity, TAN, TBN. The results are stored in the sample data memory 74 with the associated identification number.
The controller 50 reinitates the pump 40 to pump the sample 12 to the optical emission spectrometer 24 based on the event table 76. A specified amount of the sample 12 is pumped through the optical emission spectrometer 24 to ensure a clean sample 12. The controller 50 instructs the electric emission spectrometer 24 to begin testing. Thereafter, the controller 50 waits for the text file to be produced by the optical emission spectrometer 24 and received in emission memory 82. The text file is stored in the sample data memory 74 with the associated identification number.
Thereafter, the controller 50 pumps the remainder of the sample 12 through the conduit 32 to the discard container 68. The test information is stored in memory 52 with the associated identification number and data.
Optionally, the test results are checked by running the appropriate rule base for QC (quality control). The quality means 87 utilizes the QC rules in rules memory 84 to ensure all test results are feasible, and may adjust or modify results if out of acceptable range. An alert message will be indicated if some tests are too inaccurate. For example, a test result may be impossible for the type of oil being tested. This will ensure that the test results are valid and feasible. The QC rule base exists to test each test result value.
Diagnosis of the sample data and test results occurs in the diagnosis means 86 with the rule memory 84. As previously discussed, the sample data is compared to the relevant rules of the rules memory 84, and a numerical and textual diagnosis is developed. The resultant diagnosis codes and text are stored in the sample data memory 74.
The diagnosis means 86 first looks to the equipment and oil type to determine which of the rule bases 90 is to be utilized. The new oil selection could designate the refinery, i.e., USAD-R rule base. The engine selections could designate the standard used oil diagnosis, i.e., USAD-U rule base. Further development of the rule bases may occur based on the equipment type, make, model, etc. However, for purpose of illustration, rules and bases of a generic engine is utilized.
Once the rule base is selected based on the input sample information, the diagnosis means 86 may act on the rule call table 94 to utilize the rules associated with the selected rule base to diagnose the sample 12. The rules and boolean results are determined for each rule and are stored in the diagnostic fields in the data memory 74. The controller 50 indicates to the operator that testing and diagnosis is completed.
When the operator selects "P" to print a report, the controller 50 prompts the operator to input an identification number. The identification number of the most recently analyzed sample 12 appears and can be edited if another number is desired. After the operator confirms the identification number displayed or enters a new one, the controller 50 displays possible forms of reporting, such as a diagnosis report with raw data, or a diagnosis report without raw data. The operator selects one of the types of reports, and the controller 50 gets the data from sample data memory 74 and formats the information in report means 88 and sends same to the printer 58. The report means 88 includes the possible reporting formats such that the data is patterned therein.
With regard to "C" or the check/calibrate section, the controller 50 drives the infrared spectrometer 18 and emission spectrometer 24 according to a selected calibration event scheduled for internal and automatic calibrations of the spectrometers 18, 24.
Wear metals are the key metals worn from the friction surfaces in an oil-lubricated unit. As the unit runs, bacteria-size particles are produced and the oil holds them in suspension. The measurement of these particles in the oil can identify where the wear is occurring. For example, aluminum occurs from pistons, blocks and pumps. Chromium occurs in piston rings, roller-taper bearings, and coolant additives. Copper occurs from bearings, oil cooler, clutches, trust washers and trust plates. Iron occurs from crank shaft, valve train, cylinders, gears and bearings. Lead occurs from bearings, additives in some fuels and oil additives. Tin occurs from bearings and pistons. Nickel occurs from exhaust valves. Silver occurs from bearings and wrist-pin bushings. Silicone may indicate the presence of dirt, which is the most common cause of system wear. It may also be a sealant or an indicator of the presence of a silicone based additive in the lube oil and/or coolant. Sodium is found as an additive in engine coolant, but is frequently used as a lube oil additive. Potassium and boron are also common coolant additives. Additives such as magnesium, molybdenum, calcium, phosphorus, and zinc are ingredients that can be blended into the oil to improve its life and performance. Water and light concentrations can be condensation due to a cold running system. High concentrations may be from cooling system or outside the environmental contamination. Glycol is in the formulation of most commercial anti-freezes and is present indicates a serious coolant leak. Soot is an indication of the build up of dispersed carbon that has occurred due to excessive below-by in the engine. Fuel in the oil indicates faulty combustion, rich air-fuel mixture or poor injection.
All of these materials can be measured by the subject assembly 10, and diagnosed as to potential or future problems caused by these materials depending on the oil system. Quantities may be predetermined for each material to determine when harmful or normal. Such quantities may be accumulated over time from tests on several similar sources. Wear data is also accumulated in this manner to determine the quantities versus wear on the source, i.e., engine.
The remote central computer 70 receives data from each of the test assemblies 10 for evaluation, trending, and reporting. Remote central computer 70 also includes a modem 71 for communication with the modem 66 of the test assembly 10. Information which is transferred from each of the test assemblies 10 includes all data sample information in the sample data memory 74 relating to test results and analysis thereof. This information is accumulated within the central computer 70 and may be analyzed based on geographical location, type of vehicle, make and model, etc., to determine general trending of oil characteristics and wear based on a vast amount of data. This trending and evaluation at the remote central computer 70 incorporates significant amount of result from all the test assemblies 10. Furthermore, the central computer 70 can update the rules 92 or rule bases 90 or rule call 94 in the rules memory 84 at each test assembly 10 through the modems 66, 71 based on the new data or quantity thereof. Any other part of the programming of the controller 50 at the test assembly 10 may be modified from the remote central computer 70.
The remote central computer 70 may provide reporting based on any field in the sample data information and may provide evaluation on any of the fields. Wear pattern data may be analyzed and reported. This allows evaluation and reporting on a vast amount of data collected, to allow analysis based on source or engine type, etc. This can provide data to the manufacturers of general problems or trends in their particular engines, parts, etc.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
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 wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.
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The on-site analyzer (10) includes a housing (14). The housing (14) contains an infrared spectrometer (18) and an optical emission spectrometer (24) for testing a sample (12) of oil. A conduit (32) by operation of a pump (40) draws the sample (12) into the conduit (32), and controllably moves the sample (12) to an infrared spectrometer (18) for testing, and subsequently to an optical emission spectrometer (24) for testing. The pump (40) and spectrometers (18, 24) are controlled by a computer (50) for complete automation of testing. The computer (50) performs analysis and diagnosis of the test results from the spectrometers (18, 24) based on sets of known and standard information. The computer (50) may communicate with a central, remote computer (70). Remote computer (70) accumulates results from a plurality of on-site analyzers (10) to obtain trend and wear evaluations, and to update the standard information in each of the on-site analyzers (10).
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CROSS REFERENCE TO RELATED APPLICATION(S)
This application is a continuation of U.S. application Ser. No. 12/731,404 filed Mar. 25, 2010, which issued on Jun. 19, 2012 as U.S. Pat. No. 8,201,293, which in turn is a continuation of U.S. application Ser. No. 11/504,406, filed Aug. 15, 2006, which issued on May 11, 2010 as U.S. Pat. No. 7,712,172.
FIELD OF THE INVENTION
The present invention relates to a massaging bed and more particularly to a massaging bed having a mattress configured to accommodate a moving portion of a massaging, apparatus without substantially compromising the compressive resistive properties of the mattress.
BACKGROUND OF THE INVENTION
Sleeping mattress and design are typically of three forms: foam and batting, water bladders, or air bladders. A traditional mattress and foundation combination utilizes a box spring having a series of vertical springs arranged along the entire width and length of the box spring. These provide support for the mattress that is placed on top. The mattress may have various internal components such as vertical springs, wiring, cording, and soft batting materials such as cotton and foam. The firmness of the mattress is a function of the combination of compressive properties of each material. A firm mattress may utilize stiff vertical springs and a dense foam and cotton batting on top to form a “pillow-top”. One limitation of these traditional mattress and box-spring combinations is that the firmness of the mattress system can only be achieved by replacing the components, likewise, the firmness of the mattress changes with age of the materials and worn areas or depressed areas may develop.
Water bladders, or more commonly known as waterbeds utilize a bladder, which is filled with water. The firmness of the bed is controlled by the amount of water in the bladder and resulting fluid pressure. Various bladder designs are also available which provide wave support to prevent the water in the bladder from creating a wave. Also multiple bladders may be used to provide various zones of firmness. Like the traditional mattress and box-spring design, adding or removing water may only change the firmness of the water bladder bed. Water has a disadvantage over conventional mattress in that when weight is applied to one location, the displaced water raises the bladder in another area. Another disadvantage of these mattresses is the fact that the bladder can be compromised resulting in the water leaking from the mattress.
The third most common bed configuration is the air mattress. Like a waterbed, the air mattress utilizes a bladder or multiple bladders filled with air. One type of airbed configuration allows two users to adjust each side of the bed independently. The user may adjust the firmness of the bed by pumping air into or removing air from the bladder. The most common types of airbeds typically do not allow the user to adjust the firmness along the length of the bladder such as firmer along the area of the user's lower back is positioned and softer at the head of the bed. A multiple bladder system, using more than one bladder per sleeping area could be used to provide adjustable comfort. However, bladder systems, both air and water, have a disadvantage over conventional mattress in that when weight is applied to one location, the displaced air or water raises the bladder in another area. Thus, if the bladder system is set as soft, a heavy person's mass displaces more air or water at the heaviest areas such as the hips, which raises the head or foot area.
Another alternative of conventional and air or water bladders, is the foam bed. These foam systems may be composed of polyurethane or urethane foams. These mattresses may be used with a conventional box spring and the mattress itself may utilize foam of different densities along the length of the mattress or even spring systems. A disadvantage of the foam bed is that firm of the mattress cannot be adjusted and the foam subject to fatigue and loss of its rigidity.
Recent developments in foam systems include those mattress pads of viscoelastic foams such as Contour-Foam™, Tempurpedic®, Isotonic™ and similar foams. These may be used on top of traditional, air or waterbed to increase the comfort of the bed. Also, new mattress systems use the visco-elastic as a top portion with various foam bases or conventional spring systems. These types of foams conform to the body and provide reduced pressure support. A disadvantage of these systems is that they are not adjustable. Like a traditional mattress, both the visco-elastic foam and urethane foam mattresses need to be flipped, and rotated to prevent localized fatigued areas.
Hospital style beds often use the visco-elastic foam to help prevent pressure sores (subcutaneous ulcers) on bed-confined patents. Most hospital beds have adjustable positions, however, they do not provide adjustable firmness along the length of the bed. Hospitals also utilize air mattress systems that may utilize an active air pump to maintain the pressure in the mattress. These air pumps are typically noisy and often disturbing to the patient.
Although the above bed systems provide various methods of support, they lack the ability to provide adjustability of firmness along the length of the bed (Le. from foot to head). Furthermore, the above bed systems provide only one function—a place to sleep. Thus, it is desirable to have a sleep system that provides for adjustable firmness at multiple locations along the mattress. Furthermore, it is desirable to have a system that provides alternate functions such as compressive massaging. Beside the relaxing properties of massage to aid sleep, massage is also beneficial to persons confined to bed for the relief of localized pressure and increase blood flow to the area of pressure. Likewise, it is desirable to have a bed system that provides an alternative means of wakening such as vibration or even a gentle massage. This type of awaking means is also desired by the hearing impaired.
Previous attempts have been made to provide for automatic massage on a table or bed like foundation. U.S. Pat. No. 3,503,524 by Wilson, utilizes a table platform with foam placed on top. Massaging rollers on a conveyor belt system is located beneath the surface of the table. To make contact with the person lying on the table, a slot having a width greater than the roller is cut into the table and foam and the massaging roller protrudes through the slot. The conveyor belt utilizes multiple rollers, but only provides massage in the area of the slot in the table. As disclosed, the table can take the form of a bed by placing a cushion insert in the slot. This requires the user to get up from the table, retrieve the cushion and place it into the slot. This step is often undesirable such as the case when the user desires the massage to help him or her to relax, reduce tension and assist the person in obtaining sleep. Likewise, if the user falls asleep on the table with the massaging roller intact, the person may roll onto the roller or respond to the roller by moving over. The location of the roller or element is very undesirable in a bed. The cushion for the slot would need a stiff backing to prevent the user's weight from compressing it to prevent the cushion from molding to the belt and roller below. Thus, a massaging bed that automatically converts into a bed without the user getting out or having to move over on the bed to replace a cushion in the bed is desired.
Advances have been made in massaging chairs and recliner models are available. These reclining chairs can provide a very comfortable massage, but also carry a warning that states that the chair is not for sleeping in. Besides the fact that these chairs do not have significant padding between the massaging rollers or massaging heads. This provides significant contact or force into the muscle of the user. Massage chairs are designed to support the user's weight at the seat pan or the chair, arm rests and leg rests. These areas will have more padding and substructure and the quality of the massage is typically less than those areas without the extra padding. These areas requiring padding present problems to the designer. The padding used in the chair must be able to withstand the repetitive action of the massagers that create friction, heat and wear of the padding. In fact, U.S. Pat. No. 7,004,916 to Dehli, recognizes that it is desirable to have chair massager “that preferably does not rattle with age, does not wear away the chair fabric at a considerable rate, and is safe to the user.” Likewise, U.S. Pat. No. 6,881,195 to Wu also discusses the need for a fabric for a chair massager that can withstand the wear of the massage rollers, especially in the hollow area of the chair that does not contain significant padding.
SUMMARY OF THE INVENTION
The present invention is directed to a massaging bed that can include a method and apparatus for a multifunctional and multidimensional adjustable firmness sleep system that provides multiple sleep modes, relaxation, sleep and gentle awakening.
One embodiment utilizes a foam mattress placed on a multimodal and powered foundation with a timing device having a user interface.
A second embodiment utilizes foam and powered foundation having pistons and rollers to provide adjustable firmness and massaging and vibration.
A third embodiment utilizes foam and air solenoids to achieve adjustable firmness and provide massaging and vibration.
A fourth embodiment utilizes foam and a powered foundation with pneumatically controlled actuators.
A fifth embodiment utilizes foam and alternative mechanical methods of achieving adjustable firmness and massaging and vibration.
A sixth embodiment utilizes an algorithm to progressively reduce the massaging action to assist in obtaining sleep. This embodiment may alternatively use air noise or other mechanically produced white noise to further assist in obtaining sleep.
Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-C each illustrates a side plan view respectively illustrating a prior art conventional, air, and water bladder mattress system.
FIG. 2 is a side plan view of a multimodal sleep system constructed in accordance with the present invention.
FIG. 3 is a plan view of a mattress of the sleep system of FIG. 2 along line A-A of FIG. 2 .
FIG. 4 is a bottom plan view of mattress having slots for receiving massagers.
FIG. 5 is a portion of a cross-sectional view of the side of the sleep system powered foundation illustrating one set of massagers and its drive system of one embodiment.
FIG. 6 is a top plan view of the sleep system powered foundation having mechanically and independently adjustable support members.
FIG. 7 is a side elevation view of the massager actuator shown in phantom in FIG. 3 .
FIGS. 8A and 8B are cutaway views of respective massaging member embodiments taken along line 8 A,B- 8 A,B of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
The invention may be embodied in various forms; however, the invention is described with respect to the following embodiments.
Prior art bed systems typically use a mattress having some type of foam or other foam and cotton batting materials which may not provide adequate support for the user. FIG. 1A illustrates a foam or foam and cotton batting mattress that does not provide adequate support. The heaviest areas of the user compresses the foam more than the lighter areas. As illustrated in FIG. 1A , the user's spine is out of alignment placing pressure the user's shoulder, neck and lower back. In contrast, a mattress that is too stiff provides inadequate support of the contours of the user's body and places pressure on the user's shoulder, hip, knee and ankle as illustrated in FIG. 1B . The best possible posture for sleep is shown in FIG. 1C . The user's spine is in natural alignment and the mattress evenly supports the user's body.
Turning to FIG. 2 , one embodiment of sleep system 10 utilizes a visco-elastic foam mattress 12 and a powered foundation 14 . In one embodiment, mattress 12 is composed of a mattress body 13 and mattress topper 15 . Foam mattress body 13 contains slits 16 that appear like a thin cut in the foam mattress body 13 . FIG. 3 illustrates the slits 16 that originate from the underside of mattress body 13 and mates with apparatus (not shown) contained in powered foundation 14 . Returning to FIG. 2 , restraining member 17 is utilized to maintain a nearly flat surface on the top of mattress 12 . Restraining member 17 may be composed of various cording material such nylon, wire, plastic, cotton or similar materials having rigidity. Mattress jacket (not shown) covers mattress 12 and encases mattress body 13 and mattress topper 15 . Alignment guides in the form of pins 18 are used to ensure that mattress 12 is aligned with powered foundation 14 and is received in a corresponding hole in powered foundation 14 .
Illustrated in FIG. 3 is a cutaway view along plane A-A of FIG. 2 of mattress 12 illustrating the slits 16 that transverse the thickness of foam mattress body 13 from the bottom of foam mattress body 13 . Slit 16 opens when the massaging apparatus 21 (not shown in FIG. 3 ) travels vertically from powered foundation 14 through slit 16 to mattress topper 15 . Slit 16 is substantially closed at all times and is made by cutting a slit in foam mattress 12 . In contrast, a slot, where foam is removed from the cut, cannot close and leave an interrupted surface. When force is applied to mattress topper 15 with a slotted submattress, that area of the mattress containing a cut, topper 15 sags in the areas above the slots. Therefore, slit 16 is a preferred method of cutting foam mattress 12 . Also shown is restraining member 17 . Multiple slits 16 may be used along foam mattress 12 to obtain the desired massaging travel pathways or similar function.
The bottom of foam mattress 12 is illustrated in FIG. 4 . The opening of slits 16 are shown and various numbers of slits 16 may be used. Also seen in FIG. 4 are loop and hook fasteners 19 , such as Velcro®. These provide an additional attachment point along with pins 18 to secure mattress 12 to powered foundation 14 . However, various fastener systems may be used to secure mattress 12 to powered foundation 14 . Slits 16 may be are lined with material containing polytetrafluoroethylene (Teflon®), silicon, tungsten disulfide or other low friction coating to allow the massaging members (not shown) to travel upward through slits 16 to mattress topper 15 .
An alternative sleep system 10 is shown in FIG. 5 . Mattress 12 sits on top of power foundation 14 as illustrated. Massage actuators 24 are received in mattress slits 16 (shown in FIG. 4 ) of foam mattress 12 . Massager 26 is also received in slit 16 of foam mattress 12 and provides compressive massage as they move along mattress 12 in slits 16 . As stated above, slits 16 may be are lined with a fabric containing a low friction coating or fabric impregnated with a low friction material. Foam mattress 12 is composed of open-cell, visco-elastic memory foam and may be composed of multiple layers such as 3 pound density foam submattress (the portion of mattress 12 containing slits 16 ) and a denser foam, 4 or 5 pound density, for mattress topper 15 . As massaging apparatus 21 travels upward from powered foundation 14 , massaging apparatus 21 splits open slit 16 . Slits 16 are substantially closed when massaging apparatus 21 is retracted in powered foundation 14 or is passed by and foam mattress 12 appears to be a solid mattress. Furthermore, when fully retracted, the resistive compressive properties the slitted submattress of foam mattress 12 remains virtually identical to that of a non-slitted foam mattress of identical foam type and density. Vibrating motors 29 provides vibrating action to massager 26 . Likewise, y-axis motor 27 provides massager actuator 24 with up and down massaging action. Mattress topper 15 is an uninterrupted surface and has sufficient foam above massager 26 to provide comfort to the user. Mattress topper 15 may also contain a low friction material or coating where slits 16 stop at mattress topper 15 to reduction wear of mattress topper 16 and reduce frictional heat.
FIG. 7 illustrates massaging apparatus 21 and FIGS. 8A and 8B show embodiments of a cross-sectional view of massage actuator 24 . Massage actuator 24 has an aerodynamic cross-sectional shape as such, as those shown in FIGS. 8A and 8B . These shapes help assist in the opening of slits 16 as the massage actuator 24 travels to massage locations and close slit 16 behind it. The cross sectional shape shown in FIG. 8B is shaped such that the leading and trailing edges are curved to open slit 16 and separates as the foam as it travels pasts the side of massage actuator 24 to progressively close. Low friction coatings may be added to massage actuator 24 to reduce friction and abrasion. Various designs of massage actuator 24 may be utilized. The section shown in FIG. 8B separates the slit with low friction and the side shapes, the angled and flat surfaces to minimize the high-pressure regions and therefore reduce the fatigue wear to slits 16 . Slits 16 must remain substantially closed to keep the uniformity of foam mattress 12 . If slits 16 are allowed to stay open, foam mattress 12 collapses.
In an embodiment shown in FIG. 6 , motor 22 and cam 28 can be used to provide actuation power to drive shaft 28 which provides longitudinal positioning for massage actuators 24 and massager 26 . Additional motors (not shown) perform other functions such driving massager 26 inboard or outboard or providing vibration. Motor (not shown) may be used to drive an elastic cable system (not shown) to drive mechanical actuator 24 and massager 26 , drive shaft 28 and associated motor 22 to hoist this assembly vertically upward to mattress topper 15 and user and provide various compressive forces (massage). Alternative, this elastic cable system (not shown) may be used to lower the massaging assembly away from user, to reduce either gradually or abruptly reduce the massaging pressure. This elastic cable system allows the massaging assembly to follow the counter the user's body. Alternative, air controlled actuators may be alternatively utilized in place of mechanical actuator 24 . Likewise, various massaging contacts may be utilized in lieu of massager 26 .
One embodiment of an actively adjustable firmness sleep system is shown in FIG. 6 that illustrates powered foundation 14 with support members 20 . A motor 22 actuates support members 20 via a camshaft 28 . To adjust the firmness of foam mattress 12 , a support member 20 is raised which locally compresses mattress body 13 . A variety of support members 20 can be utilized along the length of foam mattress 12 . Multiple motor 22 and cam systems may be utilized to provide support or softness along the foam mattress 12 . Support members 20 may be composed of various materials such as wood, plastic, metal, fiberglass, carbon epoxy and other materials.
While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques that fall within the spirit and scope of the invention as set forth in the appended claims.
While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques that fall within the spirit and scope of the invention as set forth in the appended claims.
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A method and apparatus for a sleep system is provided. More specifically, the invention provides a method and apparatus for an adjustable mattress that allows the user to increase or decrease the firmness of the mattress. Furthermore, the adjustable mattress has zones of adjustability thereby allowing two users to adjust the firmness of the mattress of each user's zone. The adjustable mattress is also multimodal. The motorized foundation contains adjustable massaging units that may be used for physical therapy and relaxation. Likewise, the motorized foundation may be used in relax mode to assist in obtaining sleep and awaken mode to gently awake the user by the stimulation of the adjustable mattress.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a surgical instrument and a method for treating female urinary incontinence.
2. Description of the Related Art
Urinary incontinence is a significant health concern worldwide. Incontinence may occur when the pelvic floor weakens. There are five basic types of incontinence: stress incontinence, urge incontinence, mixed incontinence, overflow incontinence and functional incontinence. There are a large number of surgical interventions and procedures for addressing incontinence.
A variety of surgical procedure options are currently available to treat incontinence. Depending on age, medical condition, and personal preference, surgical procedures can be used to completely restore continence. One type of procedure, found to be an especially successful treatment option for Stress Urinary Incontinence in both men and women, is a sling procedure.
A sling procedure is a surgical method involving the placement of a sling to stabilize or support the bladder neck or urethra. There are a variety of different sling procedures. Descriptions of different sling procedures are disclosed in U.S. Pat. Nos. 5,112,344; 5,611,515; 5,842,478; 5,860,425; 5,899,909; 6,039,686, 6,042,534 and 6,110,101.
Sling procedures differ in the type of material used for the sling, the method of anchoring the sling material in the body and how the sling material is inserted in the body. The time required for a surgical procedure varies, but is preferably as short as possible. This factor is frequently reported in urology and gynecology literature. See Atherton M. J., et al., A Comparison of Bladder Neck Movement and Elevation After Tension-free Vaginal Tape and Colposuspension, British Journal of Obstetrics and Gynecology, November 2000, Vol. 17, p. 366-1370, Nilsson et al, The Tension-free Vaginal Tape Procedure is Successful in the Majority of Women with Indications for Surgical Treatment of Urinary Stress Incontinence, British Journal of Obstetrics and Gynecology, April 2001, Vol. 108, P. 414-419; and Ulmsten et al., An Ambulatory Surgical Procedure Under Local Anesthesia For Treatment of Female Urinary Incontinence, Int. Urogynecol. J. (1996), v. 7, pps. 81-86.
Although serious complications associated with sling procedures are infrequent, they do occur. Complications include urethral obstruction, development of de novo urge incontinence, hemorrhage, prolonged urinary retention, infection, and damage to surrounding tissue and sling erosion. Infection may occur as a result of exposing contaminants from the vagina during the removal of prior art two piece overlapping sheath assemblies via either suprapubic incisions or groin incisions. A two piece overlapping sheath assembly is disclosed in published U.S. patent application No. 2002/0156487-A1.
Many slings include a protective sheath used during insertion of the sling. After the sling is implanted, the sheath is removed and discarded. The protective sheath is generally constructed of a material that affords visual examination of the implantable sling and that affords smooth passage of the sling assembly through tissue of the patient.
In many cases, the sheath is made of polyethylene. Other materials used to construct the sheath include polypropylene, nylon, polyester or Teflon. The sheath material should be flexible and provide sufficient structural integrity to withstand the various forces exerted on the sheath throughout the sling delivery procedure. Referring to FIG. 14 , the sheath 44 is configured to have sufficient flexibility to facilitate user manipulation and adequate structural strength to withstand the various forces applied to the sheath 44 during delivery and/or positioning of the sling assembly. It should also conveniently separate from the sling material after the sling is implanted without materially changing the position of the sling.
The sheath 44 may comprise two elongate, separable sections 86 . Portion S of the sheath 44 detachably and telescopically overlap near the middle portion of the sling. During sheath removal, the first section and the second section of the sheath are slid off the sling by pulling each end 86 of the sheath 44 away from the middle portion of the sling assembly. Removal of the sheath 44 causes separation of the overlapping sheath sections, thereby exposing the sling.
The problem with the telescoping configuration of the first and second sections of the sheath 44 is that there has been a tendency for the two telescoping sections to “stick” to one another during the removal process believed to be due to either friction caused by the respective telescoping sections of the sheath or use of a spacer such as a clamp under the urethra. In the latter, the spacer increases the friction between the two sheaths and causes them to stick. That is, the overlapping section of the first and second sections of the sheath is situated at the point of maximum curvature and hence the point of maximum interference/friction.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a sling assembly including a sheath assembly that is easily removed from a surgical sling after the sling assembly is situated under the patient's urethra, the sheath assembly including two upper sheaths and a lower sheath.
Further, it is an object of the present invention to provide a spacer configured to be placed between the surgical sling and the patient's urethra after the portion of the sheath assembly situated below the patient's urethra (i.e., the lower sheath) has been removed.
Further, it is an object of the present invention to reduce the amount of exposed material moved from the vaginal region to another part of the patient's body (e.g., the abdominal or groin region);
Finally, it is an object of the present invention to provide a method for removing the three piece sheath assembly after the sling assembly has been placed under the urethra.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a sling assembly having a three piece removable sheath according to the present invention;
FIG. 2 is a perspective view of the pubic area of a patient relative to a sling assembly including two needles, two dilators, a surgical sling, and a three piece sheath assembly according to the present invention prior to the surgical sling and the sheath assembly being placed under the patient's urethra using a suprapubic approach;
FIG. 3 illustrates the two needles as they are withdrawn through two suprapubic incisions in order to position the surgical sling and the protective sheath under the patient's urethra;
FIG. 4 illustrates a process of removing the lower sheath after the surgical sling has been positioned underneath the patient's urethra;
FIG. 5 illustrates the process of removing the two upper sheaths after the lower sheath has been removed;
FIG. 6 illustrates the placement of the surgical sling after the sheath assembly has been removed and the ends of the sling assembly have been cut-off at the suprapubic incisions;
FIG. 7 illustrates the sheath assembly of the present invention in conjunction with a trans-obturator sling assembly;
FIG. 8 illustrates the process of removing the lower sheath after the surgical sling has been positioned underneath the patient's urethra using the trans-obturator sling assembly system;
FIG. 9 illustrates the process of removing the two upper sheaths after the surgical sling has been positioned underneath the patient's urethra using the trans-obturator sling assembly system;
FIG. 10 is a magnified view of the pubic area illustrated in FIG. 9 ;
FIG. 11 is a cross-sectional view of the lower sheath and the surgical sling;
FIG. 12 is a perspective view of a spacer mechanism with jaws open;
FIG. 13 is a perspective view of a spacer mechanism with jaws closed; and
FIG. 14 is a perspective view of the prior art sheath assembly.
DETAILED 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 illustrates a sling assembly 10 including a surgical sling 11 and three sheaths, two upper sheaths 12 and 14 and a lower sheath 20 . The sling 11 and the three sheaths 12 , 14 , and 20 are made of biocompatible materials having sufficient strength and structural integrity to withstand the various forces exerted upon these components during an implant procedure and/or following implantation within a patient. Suitable implantable materials (i.e., slings) associated with the present invention include synthetic and non-synthetic materials. Suitable non-synthetic implantable materials include human fascia lata, treated animal (e.g. bovine or porcine or equine pericardium) tissue, autologous tissue, cadaver tissue, homografts, xenografts, heterografts, allografts and combinations of such materials. Suitable synthetic materials include knitted polypropylene slings alone, such slings with surrounding sheaths, or silicone coated polymer slings, such as those described in published U.S. patent application No. 2002/0072694-A1.
The sheaths 12 , 14 , and 20 are preferably made of polyethylene. Other materials including, without limitation, polypropylene, nylon, polyester, or Teflon can also be used. In a preferred embodiment, the sling comprises a mesh material. The mesh material may comprise one or more woven, knitted or inter-linked filaments or fibers that form multiple fiber junctions throughout the mesh. The filaments may comprise monofilaments or braided filament. The fiber junctions may be formed via weaving, knitting, braiding, bonding, ultrasonic welding or other junction forming techniques, including combinations thereof. In addition, the size of the resultant openings or pores of the mesh may be sufficient to allow tissue in-growth and fixation within surrounding tissue. As an example, not intended to be limiting, the holes may comprise polygonal shaped holes with diagonals of 0.132 inches and 0.076 inches.
The quantity and type of fiber junctions, fiber weave, pattern, and material type influence various sling properties or characteristics. As another example, not intended to be limiting, the mesh may be woven polypropylene monofilament, knitted with a warp tricot. The stitch count may be 27.5 courses/inch (+ or − 2 courses ) and 13 wales/inch (+ or − 2 wales). The thickness of this example is 0.024 inches. Non-mesh sling configurations are also included within the scope of the invention. In a one embodiment, a polypropylene sling mesh is constructed of polypropylene monofilament. The mesh may be precut to a predetermined size (e.g. about 1.1 cm width×35 cm length). An absorbable tensioning suture is preferably threaded into the length of the sling mesh to allow for tensioning adjustment of the sling mesh after placement in the patient is achieved.
In a preferred embodiment, the mesh is preferably an elastic, as opposed to a substantially inelastic mesh. A test for differentiating between elastic meshes and substantially inelastic meshes is disclosed in U.S. Pat. application Ser. No. 10/386,897, filed Mar. 11, 2003 (the entire contents of which are herein incorporated by reference).
Dilators 54 are optionally attached to the ends of the sling assembly 10 . The dilators 54 atraumatically create and/or expand the passageway through the tissues for sling assembly delivery.
Tab portion 24 is preferably connected to the lower sheath 20 via suture 22 . Tab portion 24 is designed and shaped to be pulled by the thumb and one of the fingers through a vaginal incision of the patient. A cross-sectional view is shown in FIG. 11 . As can be seen from FIG. 11 , a removal assembly including a tube 70 is situated within lower sheath 20 below sling 11 . The longitudinal length of the tube 70 is perpendicular to the longitudinal length of the lower sheath 20 . Further, the tube 70 is preferably situated at the mid-portion of the lower sheath 20 measured lengthwise. Through holes 74 are placed in the lower sheath 20 adjacent the ends of the tube 70 . Suture 22 is a closed loop threaded through holes 74 and a hole placed in tab 24 . Alternatively, the suture 22 is fastened to tab 24 using any biocompatible adhesive. In either case, the removal assembly should have sufficient strength and structural integrity to withstand the force necessary to remove the lower sheath 20 from the sling 11 by pulling on the tab 24 .
FIG. 11 further illustrates the relationship between upper sheath 12 and lower sheath 20 . The lower sheath 20 can be placed telescopically within upper sheath 12 as illustrated in FIG. 11 . Alternatively, the upper sheaths 12 and 14 can be placed telescopically within the lower sheath 20 . A slit 72 is placed along the longitudinal length of the lower sheath 20 in order to allow the lower sheath 20 to be removed from the sling 11 when the tab 24 is pulled. Alternatively, the slit can comprise a score or other weakening of the sheath material including a kiss cut.
FIG. 2 illustrates the sling assembly 10 of the present invention in conjunction with needles 60 and handles 64 used in a suprapubic approach. The sling assembly 10 may be implanted by a wide variety of surgical approaches such as transabdominal (i.e. suprapubic or from above), transvaginal (from below), or transobturator (e.g. with the sling anchored in the obturator foramen). Various surgical tools for implanting sling assemblies, sling assemblies and surgical approaches are disclosed in U.S. Pat. No. 6,612,977; published U.S. patent application Nos. 2002-0107430-A1, 2002-0147382, 2002-0099258-A1 and US-2002-0099259-A1; and U.S. pat. application Ser. No. 10/306,179 filed Nov. 27, 2002, all of the above incorporated herein by reference thereto. The dilators 54 dilate a needle track for ease of sling introduction and positioning within the patient. An end of the needle 60 is preferably keyed to allow for convenient, secure attachment of the needle 60 relative to the dilator 54 .
The dilator 54 atraumatically creates and/or expands the passageway through the tissues for sling assembly delivery. The dilator 54 is short relative to a needle 60 for ease of passage of the assembly and to reduce the overall amount of tissue that is deflected at one time. The dilator is less than 2.5 inches in length. The maximum radius of a dilator 54 is less than 10 mm. The tip of the dilator 54 is blunt, as the leading tip of the dilator 54 will pass through tissue that has already been pierced by a needle 60 . As shown in FIG. 2 , the needles 60 have been passed downward through a vaginal incision 404 and out the vagina 200 . The sling assembly has been associated with the needles 60 using dilators 54 . FIG. 3 further illustrates suprapubic incisions 400 . The suprapubic incisions 400 enable the needles to be passed downward through the vaginal incision 404 .
FIG. 4 illustrates the positioning of the sling assembly 10 underneath the urethra 16 . The lower sheath 20 has been removed by pulling the tab 24 through the vaginal incision 404 and the vagina 200 . Thus, exposing the sling 11 . Because the lower sheath 20 is situated adjacent the urethra 16 , the lower sheath 20 is the sheath most exposed to vaginal contaminants of the three sheaths including upper sheaths 12 and 14 . The position where lower sheath 20 is placed relative to the urethra 16 substantially corresponds to the position of the overlapping portion S of the prior art sheath relative to the urethra. Both the lower sheath 20 and the overlapping portion of the prior art sheath are the most exposed portions of their respective sling assemblies. That is, those portions are exposed to the contaminants of the vaginal region. However, because in the present invention, the lower sling 20 is removed through vaginal incision 404 as opposed to a suprapubic incision, the lower sling 20 is not exposed to the body during removal thereof. FIG. 4 further shows the sling after the dilators 54 have been cut off, but prior to final trimming.
In another embodiment, a spacer is inserted between the exposed sling and the patient's urethra until final positioning and tensioning adjustments are made to the sling 11 . The spacer can be for example a Hegar dilator, scissors, or Metzenbaum clamps, etc. Alternatively, the spacer can be a device as shown in FIGS. 12 and 13 . See also U.S. patent application Ser. No. 10/646,082 entitled Surgical Article and filed on Aug. 22, 2003. FIGS. 12 and 13 illustrate a spacer 90 including jaws 92 and 94 . FIG. 12 illustrates the jaws 92 and 94 in an open state. The jaws 92 and 94 are positioned over and below the sling assembly 10 in a position where the jaws would clamp the lower sheath 20 when closed. FIG. 13 illustrates the jaws 92 and 94 clamped on the sheath assembly 10 . Since the lower sheath 20 and the upper sheaths 10 and 12 do not overlap in the center of the sling underneath the urethra 16 and the assembly 10 is not tensioned against a spacer, the lower sheath 20 is easily removed. The upper sheaths 12 and 14 remain associated with the sling 11 at this time. According to one embodiment, a spacer (e.g., spacer 90 ) remains between the exposed sling and the urethra while the upper sheaths 12 and 14 are removed. Because the upper sheaths 12 and 14 do not overlap the lower sheath 20 at the center of the sling 11 underneath the urethra and the sling assembly 10 is not tensioned against a spacer, the upper sheaths 12 and 14 can be removed easily.
In another embodiment, the upper sheaths 12 and 14 are removed prior to removing the lower sheath 20 (no spacer is used). Because sheaths are designed to aid in passing the sling into the body with little resistance, if the upper sheaths are not removed prior to removing the lower sheath, the sling may slide up when the upper sheaths are pulled and could cause over tensioning of the sling, placing the patient in retention. By removing the upper sheaths first, the sling is exposed to the patient's tissue anchoring the sling in place for the removal of the lower sheath.
According to another embodiment, a time advantage may be obtained by using a spacing mechanism (e.g., spacer 90 ) and by removing the upper sheaths first. This is due to the fact that if the upper sheaths 12 and 14 are removed prior to removing the lower sheath, the sling will become anchored into the body. If this is done with a spacing mechanism in place, the sling is anchored at the right tension. The spacing mechanism can then be removed and the lower sheath 20 removed vaginally without affecting the tension. By allowing the spacer mechanism to be placed over the lower sheath 20 , the surgical method does not require the step of attaching the spacing mechanism to the sling after insertion of the sling and removal of the lower sheath 20 . According to another embodiment, the sling assembly could be provided with the spacer integrated thereto. Another advantage would be that the sling can be pulled to the proper tension when removing the needles and the attached sling assembly rather than having to leave the sling initially loose to allow placement of the spacer between the urethra and sling after removing the lower sheath.
FIG. 5 illustrates removing the upper sheaths 12 and 14 through the suprapubic incisions 400 . The final placement of the sling assembly using a suprapubic approach is illustrated in FIG. 6 . The ends of the sling 11 are cut off and anchored in the abdominal region at the suprapubic incisions 400 . FIG. 6 further shows tensioning suture 66 . Tensioning suture 66 may be used to center and properly position the sling assembly 10 under the midurethra after the dilators 54 have been removed.
FIG. 7 illustrates the sling assembly according to the present invention as it would be used in conjunction with a trans-obturator sling assembly. U.S. patent applications Ser. No. 10/306,179 filed Nov. 27, 2002 and No. 10/386,897 filed Mar. 11, 2003 describe a trans-obturator sling assembly and a method of use and are hereby incorporated herein by reference. The trans-obturator sling assembly includes a handle 100 , a helical needle 62 , and a sling assembly 10 according to the present invention. A Foley catheter 2 with a balloon is used to move the urethra 16 out of harms way in order to allow, among other things, a vaginal incision to be made. More precisely, a mediane paraurethral incision is made in the region of the middle third of the urethra. A finger is slipped in the vaginal incision and is guided to one side of the urethra in order to locate an obturator foramen. An incision 600 B is made adjacent thereto in the groin region. Handle 100 is used to guide helical needle 62 through the incision 600 B and out the vaginal incision. Dilator 54 B is then attached to the needle 62 and the sling assembly is pulled through the vagina and out of the skin.
A finger is slipped in the vaginal incision and is guided to the opposite side of the urethra 16 in order to locate the second obturator foramen. An incision 600 A is made adjacent thereto. A second helical needle shaped and sized to be used on the opposite side of the urethra is then passed through the skin incision 600 A using handle 100 and out the vaginal incision. Dilator 54 A is then attached to the second helical needle and the sling assembly is pulled through the vagina and out of the groin incision 600 A. The sling assembly 10 is consequently positioned underneath the urethra. More particularly, the lower sheath 20 is positioned underneath the urethra 16 .
FIG. 8 illustrates the placement of the sling assembly 10 after the lower sheath 20 A has been removed there from via the vaginal incision. As described above regarding the suprapubic approach, suture 22 A is pulled by pulling tab 24 A in order to remove the lower sheath 20 A via the vaginal incision. FIG. 8 further illustrates that one of the dilators 54 has been cut-off. After the second dilator 54 is removed, as shown in FIG. 9 , the upper sheaths 12 A and 14 A can be removed. As discussed above with regard to the suprapubic approach, a spacer (e.g., spacer 90 ) can be placed between the sling 11 and the urethra 16 after the lower sling 20 A has been removed. As can be further seen from FIG. 9 , the end of the sling 42 is anchored outside of the obturator foramen 3 . FIG. 10 is a magnified view of the pubic region illustrated in FIG. 9 .
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. For example, the sheath assembly of the present invention can be used during a transvaginal approach. After a sling and the sheath assembly of the present invention is situated under the urethra, the lower sheath can be removed via the vaginal incision and the upper sheaths can be removed via the suprapubic incisions. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A sling assembly including a surgical sling configured to be implanted during a surgical sling procedure. The sling includes first and second regions and a central portion. The sling assembly further includes a removable sheath assembly situated about the surgical sling. The removable sheath assembly includes first and second upper sheaths. The first upper sheath is configured to be situated about the first region of the surgical sling, and the second upper sheath is configured to be situated about the second region of the surgical sling. The removable sheath assembly further includes a lower sheath. The lower sheath is configured to be situated about the central portion of the surgical sling and to be in cooperative association with both the first and second upper sheaths.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 10/935,032, filed Sep. 7, 2004, now U.S. Pat. No. 7,135,449 which is a Continuation-in-Part of U.S. patent application Ser. No. 10/783,071, filed Feb. 20, 2004, now abandoned, said Applications being incorporated by reference herein.
TECHNICAL FIELD
The present disclosure relates to compositions useful for maintaining the clean impression of a textile product (that is, its scent and appearance) over an extended time despite occurrences that might damage the textile surface. The composition is especially useful for textile floor covering products. The composition, which includes an antimicrobial agent, an enzyme inhibitor, and an odor-reacting compound, can be used by a consumer to remove contaminants from the textile and to prevent the odor associated with the decomposition of present and future contamination. Specifically, the composition has been shown effective in controlling odors associated with the decomposition of organic materials (such as urine or food spills) by absorbing and/or removing the odor-generating source. A pre-treatment composition and methods for using are also disclosed.
BACKGROUND
“Contamination”, as defined herein, means the unintentional introduction of undesirable and potentially damaging materials onto a textile surface, specifically including contaminants such as human or animal waste, food spills, and vomit. “Textile”, as used herein, refers to fibrous materials, including, without limitation, floor coverings such as carpet, area rugs, mats, and the like; upholstery and pet bed fabrics; interior fabrics, such as wall covering fabrics, bed covers, and mattress covers; and apparel fabrics, such as sportswear and undergarments. “Carpet”, as used herein, refers to a textile floor covering having a plurality of pile fibers and a backing surface, and specifically includes broadloom carpeting, area rugs, and mats.
People tasked with maintaining carpet in commercial and/or residential settings have often experienced problems with removal of odors associated with organic contamination. Such contamination may occur, for example, when food or drink is spilled onto a carpet surface. Contamination also occurs if an individual or pet vomits on the carpet. Yet a third source of contamination is from human or animal urine, as may occur in homes with indoor pets or in health care or nursing facilities that care for patients suffering from incontinence.
In situations such as those described above, the contamination reaches the carpet surface and either remains on the surface or is absorbed by the pile fibers. The contaminant, which may or may not have foul odors inherent in the contaminant, will begin to decompose over time, if not removed. The decomposition process, in most instances, generates odor molecules as the organic contaminant breaks down. Clearly, this odor generation is problematic for maintaining an odor-free environment having a healthy indoor air quality. Urine odors, for example, are particularly difficult to mask or neutralize.
There are several approaches used by those tasked with maintaining clean-appearing carpet. One approach is to clean the affected area with water and/or detergent. Another approach is to clean the affected area and then apply a fragrance-carrying compound to the surface or the air to mask the odor. These approaches have not been wholly sufficient or successful.
One reason that these approaches fail is that the cleaning technique is ineffective at removing the contaminant. Because the cleaning technique is ineffective at removing all of the contaminant, some source material remains in the carpet. As this source material decomposes, odor molecules emanate from the source, resulting in an undesirable situation for those in proximity to the contamination. Furthermore, the cleaning process leaves a residual amount of cleaning compositions in the carpet. Conventional wisdom holds that any remaining detergent or surfactant left in the carpet pile will “attract” dirt, resulting in a dirty or dingy-looking appearance over time.
A second reason that these approaches fail is because, rather than eliminating odors, they only mask the odors with fragrance. When an individual has completed his cleaning efforts, he may choose to use a scented powder or spray to restore the fresh scent of the carpet. Fragrances associated with scented powders or sprays provide temporary pleasant smells to the room in which they are used, but the malodors are again noticeable when the fragrance disperses. One common and widely recognized problem with scented powders or sprays is that their high fragrance or perfume content may aggravate the allergies of some users. Perfumes can also adversely affect indoor air quality. Therefore, the use of a perfume or fragrance alone to provide a freshening impression does not solve the odor problem, and add to problems for sensitive users who are exposed to ingredients in the product that are likely to cause an allergic reaction.
Finally, using hot water or steam extraction to clean the carpet raises several issues. One issue is the availability, efficiency, and expense of the cleaning equipment. In some instances, individuals turn to professional cleaning services to perform this type of carpet maintenance. Another issue is the amount of water that is in contact with the carpet and how long it takes to dry. Water can seep through the carpet pile and into the carpet padding and/or sub-flooring, which then becomes susceptible to damage from mildew. Deterioration of the padding and sub-flooring can also be an issue. Hot water or steam extraction also leaves residual amounts of detergent or surfactant in the carpet pile, leading to problems that have been previously discussed.
The present disclosure addresses the shortcomings of the previous approaches. The present composition provides a cleaning composition that allows the contaminant to be removed before it breaks down and generates odor. The residual amount of composition that remains after cleaning is useful in preventing deterioration of future contaminants that contact the carpet and in aiding removal of future contaminants.
SUMMARY
The cleaning composition described herein includes (a) an antimicrobial agent, (b) an enzyme inhibitor, and (c) a perfume-free compound that reacts with odorous amines and thiol compounds, thereby reducing or eliminating the resulting foul odors (hereinafter referred to as an “odor-reacting compound”). The present composition is applied as a liquid, preferably in conjunction with a powder cleaning composition. More preferably, the pile of the carpet has also been treated during the manufacturing process with a treatment composition comprising an antimicrobial agent, an enzyme inhibitor, and, optionally, an odor-absorbing compound. Most preferably, the carpet to which the composition is applied has a liquid barrier layer between the pile and the backing.
DETAILED DESCRIPTION
The cleaning composition is used to maintain the fresh appearance and scent of clean carpet or other textile products. The composition is preferably used on a periodic frequency, such as once a month or, more preferably, once every two weeks, to prevent the generation of odor from decomposition of organic contaminants by enzymes in the environment. The cleaning composition can be used in a spray, in a carpet shampoo, as a liquid charge to a powder cleaning composition, and as a cleaning solution for water or steam extracting equipment.
The treatment composition used in manufacturing the carpet is preferably applied to the pile layer of the carpet, by application techniques such as impregnation, coating, foam coating, spraying, or the like. The treatment composition could also be incorporated in the barrier layer or backing layer of the carpet. The treatment composition includes an antimicrobial agent, an enzyme inhibitor, and, optionally, an odor-absorbing compound and/or an odor-reacting compound.
In one spray embodiment of the cleaning composition, an exemplary relative proportion of components is as follows:
(a) from between 0.01% to about 10% by weight of an antimicrobial agent; (b) from between 0.01% to about 10% by weight of an enzyme inhibitor; (c) from between 0.01% to about 10% by weight of odor-reacting compound; and (d) the percentage by weight of water is such that the total is 100%.
In one powder-like embodiment of the cleaning composition, an exemplary relative proportion of components is as follows:
(a) from between 0.01% to about 10% by weight of an antimicrobial agent; (b) from between 0.01% to about 10% by weight of an enzyme inhibitor; (c) from between 0% to about 10% by weight of odor-reacting compound; (d) from between 0% to about 7% by weight of an aldehyde-containing aroma; (e) from between 10% to about 50% by weight of water; and (f) the percentage by weight of powder is such that the total is 100%.
It should also be noted that some compounds as are useful herein may perform dual functions. For example, some antimicrobial agents (such as 2-bromo-2-nitro-1,3 propanediol) also act as enzyme inhibitors. Likewise, some odor-absorbing compounds (such as zinc ricinoleate) also act as enzyme inhibitors. It should also be noted that, although one compound may perform two functions, a synergistic effect is observed from the use of different compounds and, therefore, at least two different compounds are preferably used as the antimicrobial agent and the enzyme inhibitor.
Antimicrobial Agents
The cleaning composition and the treatment composition contain an antimicrobial agent. The antimicrobial agent mainly acts as a preservative to prevent the cleaning composition from spoiling. The antimicrobial agent can also allow the contaminant to be removed (for example, during regular cleaning or maintenance) before the contaminant decomposes and generates odor. The antimicrobial component includes any organic or inorganic compound that effectively controls or inhibits the growth of odor-causing microorganisms, such as bacteria and fungus. Examples of such materials include silver zirconium phosphate, zinc oxide, imidazolidinyl urea, cationic quaternary ammonium salt, sodium sorbate, potassium sorbate, sorbic acid, grapefruit seed extract, and polyhexamethylene biguanide. Certain alcohols, such as benzyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, and amyl alcohols, also are useful for this purpose.
Preferably, the antimicrobial agent is a formaldehyde-donor antimicrobial, such as N,N′-dimethylol 5,5-dimethyl hydantoin or N-methylol 5,5-dimethyl hydantoin. Aldehyde-based antimicrobial agents, such as glutaraldehyde, may also be used. It has been found that aldehyde-donor antimicrobials are most effective at eliminating microbes and preventing contaminant decomposition that leads to unpleasant odors, especially those odors associated with urine decomposition. It is believed that the aldehyde functionality of this class of antimicrobial agents reacts with amines and thiols of the odor source to form imine and thioacetal, respectively.
Formaldehyde-donor and aldehyde-containing antimicrobial compounds, therefore, can provide odor-controlling and odor-reducing properties in addition to preservation of the composition. When formaldehyde-donating antimicrobial compounds are used, it is preferable to minimize the free formaldehyde level to prevent potential irritation effects. The type of antimicrobial agent and the usage level should be chosen such that the free formaldehyde content in the final composition is less than 50 ppm, and preferably less than 5 ppm.
Salts of transitional metals (e.g., zinc, copper, and silver) are also effective as antimicrobial agents, but are less preferred because of their potential to adversely affect the carpet color and their deleterious environmental effects.
Enzyme Inhibitors
The cleaning composition and the treatment composition also include an enzyme inhibitor, typically present at no more than about 1% by weight of the cleaning composition. Enzyme inhibitors, such as urease inhibitors useful for controlling odorous ammonia generation from urine contamination due to urease-catalyzed decomposition of urea in human and animal urines, are desirable. Enzyme inhibitors include organic and inorganic salts of zinc, copper, zirconium, aluminum, silver, and tin, as well as organic compounds such as certain aldehydes (e.g., p-hydroxybenzyl aldehyde) and quaternary ammonium compounds.
Although there are many urease inhibitors reported, many of them either do not provide adequate urease-inhibiting performance on carpet or they discolor the textile material. For example, violuric acid is effective in inhibiting urease when incorporated in the present composition. However, because it discolors carpet and other textile materials, it would not be suitable for use herein. Acetohydroxamic acid is a well-known urease inhibitor in the biological field, but it failed to exhibit urease-inhibiting properties when tested on carpet as part of the present compositions.
Suitable non-discoloring urease inhibitors include (a) salts or complexes containing silver ions, zinc ions, or copper ions; (b) the acid and salt forms of boric acid, citric acid, sorbic acid, salicylic acid, and acetylsalicylic acid; (c) aldehydes, such as glutaraldehyde, p-hydroxybenzaldehyde, phthalic dicarboxaldehyde, and benzaldehyde; (d) bromo-nitro organic compounds, such as 2-bromo-2-nitro-1,3-propanediol; (e) phosphoamide compounds, such as phenyl phosphorodiamidate (PPDA); and (f) quinones, such as hydroquinone. At concentrations of greater than 1% by weight, phenyl phosphorodiamidate and hydroquinone discolor most carpet substrates; however, these compounds are effective urease inhibitors at concentrations of 0.1% or less.
Because of concern over the potential toxicity and environmental effect of transitional metal salts, bromo-nitro compounds and organic acid compounds are preferably used as enzyme inhibitors. Specifically, 2-bromo-2-nitro-1,3-propanediol, sodium sorbate, and p-hydroxybenzaldehyde are preferred due to their effectiveness, low toxicity, and non-discoloring properties.
Odor-Reacting Compounds
Odor-reacting compounds are an important feature of the compositions described herein. Ammonia, amines, and thiol compounds are common odorants found in urine, vomit, and other organic contaminants. Odor-reacting compounds are those that are capable of chemically reacting with one or more of these odorants, thereby reducing or eliminating these odors. Preferably, odor-reacting compounds are selected from those compounds that do not inherently have strong odors or aromas and those that are not used as perfumes, fragrances, or aromas. Odor-reacting compounds suitable for use in the liquid or powder compositions described herein include aldehyde compounds, formaldehyde-donating compounds, ketones, and oxidizing agents.
Aldehyde compounds can react with odorous amine compounds to form an imine structure. Aldehyde compounds can also react with thiol compounds to form a thioacetal structure. Formaldehyde-donor compounds, which have similar reactivity with amines and thiols, can be used in combination or interchangeably with aldehyde compounds. The reaction of odorous amines and thiols with either the aldehyde compound or the formaldehyde-donor compound results in the products of imine and thioacetal, both of which are larger molecules than their odorous substituents. As such, these resulting structures are less volatile than their predecessors and have little to no smell.
Examples of suitable aldehyde compounds include benzyl aldehyde, formaldehyde, p-hydroxybenzaldehyde, glyoxal, glutaraldehyde, formylbutanoic acid, formylcyclopentane, phenylacetaldehyde, octanal, m-tolualdehyde, o-tolualdehyde, p-tolualdehyde, salicylaldehyde, and isobutyraldehyde.
Examples of suitable formaldehyde-donor compounds include methylol acrylamide, N,N-dimethylol-5,5-dimethylhydantoin, N-methylol derivatives of amino acids, trihydroxymethyl melamine, and dimethylol dihydroxyethylene urea.
Ketones react with odorous amines to form enamines and with thiols to form thioacetals. Examples of ketones include 3,3-dimethyl-2-butanone, 2-heptanone, 5-methyl-2-hexanone, 2-octanone, diacetone alcohol, diethylketone, dipropylketone, diisobutylketone, isophorone, 2-3 butanedione, 2,5-hexanedione, benzophenone, hydroxybenzophenones, phenylacetone, phenyl ethylketones, 1,4-cyclohexanedione, and acetylacetone.
Oxidizing agents are those that are capable of oxidizing amines to amine oxide and thiols to a sulfur salt such as sulfate, thiosulfate, and the like. When using an oxidizing agent in the present composition, care must be taken to ensure that the oxidizing agent is compatible with the antimicrobial agent and the enzyme inhibitor and that it is used at suitably low concentrations. Otherwise, discoloration and/or a reaction between components may occur, adversely affecting the substrate to be cleaned or the efficacy of the cleaning composition.
Examples of oxidizing agents are hydrogen peroxide; non-transitional metal salts of perborate, percarbonate, persulfate, perophosphorate, peroxyacetic acid, and their salts; m-chloroperoxybenoic acid; dibenzoyl peroxide; chloramines; bromamines; chlorine oxide; and hypochloride compounds. By way of example, if hydrogen peroxide is used as the oxidizing agent, the active hydrogen content of the solution should be less than 2% by weight and, more preferably, less than 0.5% by weight.
Odor-Absorbing Compounds
An odor-absorbing compound may be included in the treatment composition. The odor-absorbing compound is selected from activated carbon, zeolites, zinc oxide, cyclodextrin, and zinc ricinoleate. The preferred odor-absorbing compounds are zinc ricinoleate and cyclodextrin.
Application of Composition During Manufacturing
In the treatment composition, the antimicrobial agent, the enzyme inhibitor, the optional odor-reacting compound, and the odor-absorbing compound are prepared for application to the carpet by combining the components with an amount of water appropriate for the application method. The treatment composition may be applied onto the carpet surface by spraying, by coating, by foam coating, by impregnation or the like. In cases where the treatment composition is applied as a foam, a foam stabilizing agent may also be used. The treatment composition can be applied to a carpet as part of the finishing process at the manufacturing location or as a post-treatment after the carpet has been installed.
Preferably, the treatment composition is applied to a textile during manufacturing, where an elevated temperature in the range of 60° C. to about 220° C. is used to remove water and provide durable bonding to, and penetration of, the carpet structure. The treatment composition is applied to a textile (particularly a carpet or an upholstery fabric) at an add-on level of about 5 oz/yd 2 to about 100 oz/yd 2 , depending on the weight and construction of the textile material, such that the treated textile will exhibit durable antimicrobial and urease inhibiting properties without noticeable discoloration. It is believed that antimicrobial and enzyme-inhibiting properties are inherent to the finished carpet, because of the incorporation of these components into the fibers and/or the backing of the carpet.
Optionally, but preferably, a resin binder and a cross-linking agent may be further included in the composition to provide more durability. The optional odor-reacting compounds should be chosen such that the composition will not cause adverse discoloration, when applied at the elevated temperatures mentioned above.
Application of Composition During Spot or Routine Cleaning
The cleaning composition, as used by persons tasked with carpet cleaning and/or maintenance, can be sprayed directly onto the carpet surface in a concentrated form. This method of use is particularly desirable when the contaminants have created a stubborn stain. In this instance, the concentrated cleaning composition is applied to the area of the stain. The composition is allowed to penetrate the stain before being removed by blotting with an absorbent material (such as a paper towel or towel).
Alternatively, where cleaning of a larger area is necessary or desired, the composition can be applied across the surface of the carpet. In this instance, the user may prefer to employ the cleaning composition as part of a water- or steam-extraction process. The cleaning composition is then applied to the carpeting. After a few minutes, an extraction machine is used to remove the majority of the composition from the carpet.
Whereas residual amounts of conventional surfactant-based cleaners tend to attract dirt that is subsequently applied, causing stains and odors to seemingly reappear, an opposite effect is observed with the present cleaning composition. Residual amounts of the present cleaning composition have been found to aid in maintaining the fresh appearance of the carpet. It is believed that this phenomenon results from the tendency of the antimicrobial and the enzyme inhibitor to actually prevent the decay of contaminants (especially the chemical break-down of urea). By preserving the contaminants until they can be removed with a subsequent routine cleaning, the present composition prevents their decomposition and the foul odors associated with decomposition.
Alternatively, and perhaps more preferred, a smaller, but more concentrated, amount of liquid cleaning composition is charged onto a powder composition (that is, sprayed onto the powder composition until the powder composition is damp). One particularly suitable powder composition for this purpose is described in U.S. Pat. No. 4,434,067 to Malone, assigned to Milliken Research Corporation and incorporated herein by reference.
The preferred, patented powder composition contains an absorbent and/or adsorbent particulate polymeric material, an inorganic salt adjuvant, and an aqueous or organic fluid component. The powder-like cleaning composition has liquid absorbing properties and the ability to adhere to dirt and contaminant particles.
Specifically, the powdered cleaning composition is provided consisting essentially of:
(a) about 100 parts by weight particulate polymeric material having an average particle size of from about 37 to about 105 microns in diameter, an oil absorption value of no less than about 90, and a bulk density of at least about 0.2 g/cc; (b) from about 5 to about 400 parts by weight of an inorganic salt adjuvant having an average particle size of from about 45 to about 60 microns in diameter; and (c) from about 5 to about 400 parts by weight of a fluid consisting essentially of 0 to 100 percent water containing sufficient surfactant to give a surface tension of less than about 40 dynes per centimeter and 100 to 0 percent of organic liquid selected from high boiling hydrocarbon solvents, tetrachloroethylene, methylchloroform, 1,1,2-trichloro-1,2,2,-trifluoroethane, an aliphatic alcohol containing from 1 to about 4 carbon atoms, and mixtures thereof.
It has been found that this particular compound is highly effective at removing a variety of contaminants from carpet, without creating any of the problems associated with wet cleaning techniques in which the carpet is saturated.
In use, the powder-like composition (as described above to which the present liquid composition is incorporated) is applied to a textile substrate, by hand or by using a sieve-like material. Typically, between 0.1 inches and 1.0 inches of powder-like material is used to cover the contaminated area. A brush is then used to rub the powder-like material into the carpet (or other textile material, such as upholstery fabric) to allow the powder-like material to absorb and adhere to contaminants. The powder-like material is then removed by vacuuming the area, usually between one and two hours after the application of the powder.
When the powder-like cleaning composition is removed by vacuuming, the contaminants (and their associated odors) are also removed. Because the majority of the composition does not remain on the textile article being cleaned, odor-reacting compounds are not necessary, although preferred, to provide odor-removing performance. Antimicrobial and non-discoloring enzyme inhibitors, and optionally odor-absorbing compounds and aldehyde aroma compounds, are suitable for incorporation in the powder-like cleaning composition described above. Further, the residual amounts of the powder-like cleaning composition to which an antimicrobial and an enzyme inhibitor have been added provide the same benefits as were described above in preventing the decay (and subsequent odor generation) of contaminants.
Other Additives
An aldehyde-containing aroma is preferred as an optional fragrance component in the powder-like cleaning composition, when a certain aroma characteristic is desired. Examples of preferred fragrances include citral, cinnamic aldehyde, hexyl cinnamic aldehyde, benzyl aldehyde, benzyl salicylate, amyl cinnamic aldehyde, and vanillin. The most preferred of these is hexyl cinnamic aldehyde, which is commonly used to create a “fresh” scent in many consumer products, such as fabric softeners.
Also optionally included in either the aqueous or powder-like cleaning composition are surfactants that enhance cleaning properties. Useful surfactants are ones that do not discolor the carpet, but that provide emulsifying properties for the other components in the cleaning composition.
It is also preferred that the final pH of the cleaning composition (whether liquid or powder-like form) is less than 8 and, more preferably, in the range of 3 to 7. pH values of higher than 8 can cause potential discoloration of some of the components in the composition, and particularly discoloration of the carpet. Low pH values (that is, less than 3) are corrosive to many metals and are potential skin irritants. Acids, such as citric acid, acetic acid, oxalic acid, formic acid, sulfuric acid, phosphoric acid, and nitric acid, can be used to adjust the final pH of the composition.
Even though the compositions disclosed herein are effective in cleaning and controlling malodors on textile materials, it is also contemplated that these compositions may be used for cleaning and controlling odors on hard surfaces, such as vinyl, ceramic tile, concrete, hardwood, and laminated composites surfaces.
The following examples, and testing thereof, are intended to be representative of various embodiments of the present invention.
TESTING OF EXEMPLARY EMBODIMENTS
The following tests were conducted to demonstrate the effectiveness of the present cleaning composition at controlling human urine odor.
Test 1
Odor Prevention Test
The test procedure is described as follows. For each sample, 40 ml of fresh human urine was applied to the carpet pile that had been cleaned with a cleaning composition. Each sample was sealed inside a 2 mil thick plastic bag to prevent evaporation of moisture and odors. The samples were stored inside the sealed bags for ten days, after which human judges were asked to evaluate, on a scale of 1 to 10, the odor in the headspace of the bag. Using this scale, 1 indicated the worst odor and 10 indicated the most pleasant odor.
After being assessed by the judges, the carpet samples were removed from the bags and cleaned with the same cleaning composition. Another 40 mL of fresh human urine was applied to each carpet sample. Each sample was then placed in a clean 2 mil thick plastic bag, where the sample remained for a total of 5 days. At the end of the 5 days, the human judges again evaluated the odor in the headspace of the bags using the same 1 to 10 scale. The pH of the headspace was also evaluated, using a pH indicator strip moist with distilled water, to detect the presence of ammonia (pH values higher than 7 indicate the presence of ammonia).
Test 2
Odor Removal Test
In this experiment, human urine was collected and stored for 10 days in a sealed bottle. Strong ammonia and other odors developed. 10 mL of the aged urine was applied to an 8″×8″ carpet sample, and the carpet was allowed to sit for 2 hours before being cleaned with the present liquid cleaning composition as used with the powder cleaning composition described herein. The powder cleaning composition was dampened with the present liquid cleaning composition and then sprinkled onto the carpet. The cleaning composition was brushed into the carpet and then removed by vacuuming.
The odor of the carpet sample was evaluated following cleaning and two weeks after cleaning to determine whether the cleaning composition was effective at removing odor. No ammonia or other offensive odors were detected at either time.
Having been evaluated, the recently cleaned sample was subjected to another round of testing, in which an additional 10 mL of human urine were added to the carpet. The carpet sample was then placed into a sealed plastic bag to prevent evaporation of the moisture and dispersion of any generated odors.
After ten days storage at room temperature, the sample was evaluated to determine whether the residual cleaning composition remaining in the carpet was effective at preventing the generation of odors from later-applied contaminants. No ammonia or other odors were detected, proving that the cleaning composition was effective in preventing the generation of odors.
Example 1
Manufacturing Treatment Composition
This example was created as a comparative example for the compositions described in EXAMPLES 2 and 3. In this composition, the antimicrobial component was purposely omitted. The comparative treatment composition comprised:
(a) as an odor-absorbing agent (and also as enzyme inhibitor), 3% by weight of zinc ricinoleate, available as 30% active ingredient from Degussa sold under the trade name “TEGO SORB 30”; (b) as an pH adjuster, 0.3% by weight of citric acid; (c) as solvent, water such that the total percentage equaled 100%.
Example 2
Manufacturing Treatment Composition
This example describes a first embodiment of a treatment composition useful for application to the carpet surface during manufacturing or after installation. The treatment composition comprises:
(a) as antimicrobial compound (and also an enzyme inhibitor), 2-bromo-2-nitro-1,3 propanedial; (b) as a pH adjuster, 0.3% by weight of citric acid; (c) as solvent, water such that the total percentage equaled 100%.
Example 3
Manufacturing Treatment Composition
This example describes a second embodiment of a treatment composition useful for application to the carpet surface during manufacturing or after installation. The treatment composition comprises:
(a) as an enzyme inhibitor, 0.02% by weight of 2-bromo-2-nitro-1,3 propanediol; (b) as an odor-reacting compound and preservative, 0.5% by weight of monomethylol dimethyl hydantoin, a formaldehyde-donor antimicrobial agent sold as a 55% active solution under the trade name “DANTOGARD 2000” by Lonza Corporation of Fair Lawn, N.J.; (c) as a pH adjuster, 0.3% by weight of citric acid; and (d) as solvent, water such that the total percentage equaled 100%.
Evaluation of Examples 1, 2, and 3
20 mL of EXAMPLES 1, 2, and 3 were allowed to soak into 4″×4″ square carpet samples. The carpet samples were dried at about 110° C. for 20 minutes to evaporate the water, leaving (on EXAMPLES 2 and 3) a thin coating of antimicrobial compound and enzyme inhibitor on the yarns and base of the carpet pile. Other trials in which samples were dried at about 300° F. and at about 370° F. showed decreased efficacy, but the samples were still functional.
When tested using Test 1, as described above, the three carpet treatments prevented the generation of detectable amounts of ammonia.
When tested using Test 2, only EXAMPLES 2 and 3 were successful at preventing the generation of odor for one month, thus supporting the hypothesis that the combination of an antimicrobial component and an enzyme-inhibiting component is most effective.
Further, five cycles of cold water extraction were performed on Example 3, using a commercially available carpet extractor. The odor-control performance did not change noticeably after the extractions, thereby indicating the durable nature of the treatments achieved by penetration of the treatment solution into the carpet and bonding of the components to the carpet.
Example 4
Liquid Cleaning Composition
One embodiment of the liquid cleaning composition was created comprising the following ingredients:
(a) as an antimicrobial agent, 0.5% by weight of monomethylol dimethyl hydantoin, a formaldehyde-donor antimicrobial solution sold as a 55% active aqueous solution under the trade name “DANTOGARD 2000” by Lonza Corporation of Fair Lawn, N.J.; (b) as a urease inhibitor and preservative, 1% by weight of sodium sorbate (formed by mixing equivalent amounts of sorbic acid and sodium hydroxide solution); (c) as a urease inhibitor, 0.1% by weight of hydroquinone; (d) as an odor-reacting compound, 0.2% by weight of p-hydroxybenzaldehyde; (e) as a pH-adjuster, 0.2% by weight of citric acid, to adjust the pH of the solution to about 6; and (f) as solvent, water such that the total percentage by weight equaled 100%.
Test 3
Urease Inhibition Test
The ingredients were combined and used to saturate a 2″ circle of carpet. The carpet was then blotted dry with paper towel such that the carpet circle retained about one gram of the solution. Then, 4 milliliters (mL) of 10% urea and 3 drops of 0.005% urease (type III, purchased from Sigma) were added separately to the treated carpet and to an untreated “control” carpet. Urease is an enzyme that causes urea to decompose and release ammonia, which is responsible for the characteristic pungent smell of urine odor.
Each carpet samples was sealed in a 250 mL plastic beaker. A small piece of nonwoven fabric impregnated with bromothymol blue indicator water solution was then used to monitor the presence of ammonia in the headspace of each beaker. This indicator solution is light yellow in the absence of ammonia, but turns to dark blue in the presence of ammonia.
Observations were made 1 hour, 2 hours, and 4 hours after the addition of the urea and urease solutions. After approximately only 10 minutes, the control carpet sample (untreated) showed the presence of ammonia. At no time during the observation period did the treated sample indicate the presence of ammonia. This result indicates that the chemical cleaning compound described above is capable of inhibiting urease activity and preventing ammonia generation from the decomposition of urea.
Also worth noting, the untreated control sample generated significant ammonia odor in the headspace of the beaker after 2 hours.
In comparison, commercially available products, such as Febreeze (from Proctor & Gamble of Cincinnati, Ohio); Syon 5 (from Collins & Aikman Floorcoverings of Dalton, Ga.); and Woolite Pet Stain & Upholstery Cleaner (from Platex, Inc.?), mask the odor of ammonia, but the presence of ammonia is detectable by this method after less than half an hour on average.
Example 5
Liquid Cleaning Composition
An alternate embodiment of the liquid cleaning composition was created comprising the following ingredients:
(a) as an antimicrobial agent and enzyme inhibitor, 3% by weight of sodium sorbate; (b) as an antimcrobial agent, 0.5% by weight of monomethylol dimethyl hydantoin, a formaldehyde-donor antimicrobial solution sold as a 55% active aqueous solution under the trade name “DANTOGARD 2000” by Lonza Corporation of Fair Lawn, N.J.; (c) as a pH adjustment, 0.3% by weight of citric acid; (d) as an odor-reacting compound, 0.1% by weight of N,N′-dimethylol 5,5-dimethylhydantoin; (e) as an odor-absorbing agent (and also as enzyme inhibitor), 3% by weight of zinc ricinoleate, available as 30% active ingredient from Degussa sold under the trade name “TEGO SORB 30”; and (f) as solvent, water such that the total percentage equaled 100%.
The addition of zinc ricinoleate was found to be effective at absorbing some of the odor associated with urine as a contaminant.
Example 6
Liquid Cleaning Composition
Yet another embodiment of the liquid cleaning composition was created comprising the following ingredients:
(a) as an antimicrobial agent and urease inhibitor, 1% by weight of sodium sorbate; (b) as an enzyme inhibitor, 0.05% by weight of 2-bromo-2-nitro-1,3-propanediol; (c) as an odor-reacting compound, 0.2% by weight of N,N′-dimethylol-5,5-dimethylhydantoin; (d) as a pH adjuster, 0.3% by weight of citric acid, such that the pH of the solution was about 6; (e) as surfactants to aid in suspending the components in solution and to aid in cleaning, 1% by weight of “Tween 40” sold by Uniqema of New Castle, N.J., and 1% by weight of “Pluronic L62LF” sold by BASF Corporation; and (f) as solvent, water such that the total percentage equaled 100%.
This composition completely prevented the generation of detectable ammonia odors when tested according to Test 1 and Test 2. The composition also inhibited ammonia generation in the Urease Inhibition Test.
Example 7
Powder-Like Cleaning Composition
A liquid cleaning composition was created similar to that of EXAMPLE 5, which was added to a urea formaldehyde resin powder having 30% moisture content, thereby creating a damp powder-like cleaning composition comprising the following ingredients:
(a) as an antimicrobial agent and a urease inhibitor, 3% by weight of sodium sorbate; (b) as an antimicrobial agent, 0.5% of monomethylol dimethyl hydantoin, a formaldehyde-donor antimicrobial agent sold as a 55% active aqueous solution under the trade name “DANTOGARD 2000” by Lonza Corporation of Fair Lawn, N.J.; (c) as a pH adjustment, 0.3% of citric acid; (d) as an odor-absorbing agent (and also as enzyme inhibitor), 3% by weight of zinc ricinoleate, available as 30% active ingredient from Degussa sold under the trade name “TEGO SORB 30”; (e) as an odor-reacting aroma compound, 1% by weight of hexyl cinnamic aldehyde, 1% by weight of a fragrance blend sold as “Green Downy-type Fragrance H20-type” from Berge'; (f) 5% by weight of water; and (g) as carrier, urea formaldehyde resin powder such that the total percentage equaled 100%.
Examples 4 through 7 are effective in urease inhibition and odor prevention when tested using Test 1.
Comparative Test
Three carpet samples, having been cleaned using different methods, were used in this test. All of the samples were 15″×15″ carpet squares, constructed with a liquid barrier layer between the pile face yarns and the foam backing and a silver zirconium phosphate antimicrobial agent in the back-coating.
Test Sample A was cleaned using the composition of Examples 5 and 7 described above. The carpet was sprayed with in a fine mist of the composition of Example 5. The powder composition of Example 7 was then brushed into the carpet. Then, the carpet was vacuumed, using a commercially available vacuum cleaner.
Test Sample B was cleaned using a commercially available liquid cleaning solution for carpet, which includes as its active ingredient an Australian tea tree extract. The carpet was saturated with the cleaning solution and then subjected to cleaning with an extraction-type vacuum cleaner.
Test Sample C was cleaned using only water with an extraction-type vacuum cleaner. No cleaning compositions were used.
The three samples were tested according to the procedure described above for Test 1. TABLE 1 shows the results of COMPARATIVE TEST.
TABLE 1
Results of COMPARATIVE TEST
(Odor Prevention)
Headspace pH
Odor Rating
(lower =
(higher =
Sample ID
Cleaning Method
good)
good)
Test Sample
Cleaning Compositions of
5
8
A
Examples 5 & 7 + Vaccum
Test Sample
Commercially Available
9
2
B
Cleaning Liquid +
Extraction
Test Sample
Water + Extraction
10
1
C
The results above indicate that the present cleaning composition and composition are effective in controlling human urine odors on carpet and in preventing ammonia generation.
CONCLUSIONS
The tests conducted indicate that the compositions described herein, which comprise an antimicrobial compound and an enzyme inhibitor, are effective at removing existing contaminants and their odors from carpet, at preventing recurrence of odors from degeneration of later applied contaminants, and at maintaining the desired appearance and smell of carpet cleaned according to the teachings herein. For these reasons, the present compositions represent a useful advance over the prior art.
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The present disclosure relates to compositions useful for maintaining the clean impression of a carpet (that is, its scent and appearance) over an extended time despite occurrences that might damage the carpet surface. The composition, which includes an antimicrobial agent, an enzyme inhibitor, and an odor-reacting compound, can be used by a consumer to remove contaminants from the carpet and to prevent the odor associated with the decomposition of future contamination. Specifically, the composition has been shown effective in neutralizing odors associated with the decomposition of organic materials (such as urine or food spills) by absorbing and/or removing the odor-generating source. A manufacturing treatment composition and methods for using are also disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a cowling, and in particular, to a cowling for a wind power generator.
[0003] 2. Description of the Related Art
[0004] An impeller of a conventional wind power generator is driven by wind to generate electric power. Wind, however, blows in all directions. If the wind does not blow directly on the impeller, the wind power generator can not operate at optimum efficiency. Another impeller of a conventional wind power generator changes direction corresponding to wind direction. When the turbulence occurs, the impeller loads wind force in all directions, the potential damage causes to the wind power generator.
[0005] The invention provides a cowling applicable to any kind of impeller for wind power generators, capable of effectively solving the described problems.
BRIEF SUMMARY OF INVENTION
[0006] The invention provides a cowling for a wind power generator. The cowling rotates to face the wind according to wind direction, avoiding impeller load due to multidirectional wind force thus protecting the impeller.
[0007] The cowling of the invention includes a cover body and an empennage connected with the cover body. The cover body includes an accommodating space for receiving an impeller, and a first opening serving as an air inlet for the impeller. According to the wind direction, the empennage will adjust the first opening to the proper position to face the wind.
[0008] If the wind is a multidirectional and turbulent, the cowling can be positioned to provide a single direction for channeling the multidirectional turbulence through the impeller from the first opening and drive to the impeller. The cover body blocks turbulence from entering the cowling from a direction interfering with the impeller. Thus, the impeller works efficiently and the lifespan of the impeller is prolonged.
[0009] A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0010] The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0011] FIG. 1 shows an embodiment of a cowling of the invention;
[0012] FIG. 2 is a schematic view in a different view angle of the cowling shown in FIG. 1 ;
[0013] FIG. 3 is a front view of a cowling applied to a wind power generator of the invention;
[0014] FIG. 4 is a cross-sectional view of the cowling shown in FIG. 3 ;
[0015] FIGS. 5 to 7 are schematic views to show all kinds of empennages;
[0016] FIG. 8 is a schematic view of another embodiment of a cowling of the invention;
[0017] FIG. 9 is a schematic view of another embodiment of a cowling of the invention;
[0018] FIG. 10 is a schematic view to show a first opening of a cowling facing side of an impeller;
[0019] FIG. 11 is a front view the cowling shown in FIG. 10 .
DETAILED DESCRIPTION OF INVENTION
[0020] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope df the invention is best determined by reference to the appended claims.
[0021] Referring to FIGS. 1 to 3 , a cowling 1 of the invention comprises a cover body 10 and an empennage 12 connected to the cover body 10 . The cover body 10 comprises an accommodating space 101 and a first opening 103 . The accommodating space 101 is communicated to the first opening 103 . An impeller 2 for generating electric power is disposed in the accommodating space 101 . The first opening 103 is located at one side of the cover body 10 and has an air inlet for transmission of the wind. The position of the empennage 12 is located at the side of the cover body 10 opposite to the first opening 103 . The empennage 12 can be adjusted by the wind so the first opening 103 faces the blowing wind. In this embodiment, the first opening 103 is a rectangle and an end 121 of the empennage 12 is a circle.
[0022] Referring to FIG. 4 , in detail, the impeller 2 further comprises a shaft 21 passing through the center of the impeller 2 . The cowling 1 is supported by the shaft 21 via two bearings 22 , thus, when the impeller 2 rotates, the cowling 1 can simultaneously rotate without interference.
[0023] Note that an end shape of the empennage 12 is not limited. The end of the empennage 12 may be rhombus, polygon, T-shape of fin shape shown in FIGS. 5 to 7 . The end of the empennage 12 can be any other shape enabling the cowling 1 to change direction.
[0024] The cover body 10 of the cowling 1 further comprises a second opening 105 shown in FIG. 2 opposite to the first opening 103 . After the wind passes through the impeller 2 , airflow exits from an air outlet, e.g. the second opening 105 , to prevent interference between the wind and the airflow.
[0025] If the wind is multidirectional turbulence, the empennage 12 rotates along one direction of the multidirectional turbulence. Thus, the first opening 103 of the cowling 1 is adjusted to a stable position so that the first opening 103 faces the wind. One direction of the multidirectional turbulence can pass through the impeller 2 from the first opening 103 to drive the impeller 2 . The cover body 10 blocks turbulent wind from other directions entering the cowling 1 and interfering with the impeller 2 . Thus, the impeller 2 works efficiently and the lifespan of the impeller 2 is prolonged.
[0026] FIG. 8 shows another embodiment of the invention. Compared with FIG. 1 , the first opening 303 of the cowling 3 is a bell shape for enlarging the area of the air inlet and concentrating the wind to drive the impeller.
[0027] Referring to FIG. 9 , the cowling 3 further comprises a plurality of air-guiding elements 305 installed in the first opening 303 shown in FIG. 8 for adjusting the wind. Thus, the impeller 2 works efficiently.
[0028] Moreover, the first openings can be located corresponding to one side of the impeller shown in FIGS. 10 to 11 . Compared with FIG. 1 , the first opening 403 of the cowling 4 does not correspondingly face the impeller 2 , but faces the side of the impeller 2 . In another word, the first opening 403 faces one side of the blades of the impeller 2 . Thus, after entering the first opening, the wind directly drives the blades, thus increasing efficiency.
[0029] While the invention has been described by way of example and in terms of the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A cowling of the invention includes a cover body and an empennage connected with the cover body. The cover body includes an accommodating space for receiving an impeller, and a first opening serving as an air inlet for the impeller. According to the wind direction, the empennage will adjust the first opening to the proper position to face the wind.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the national stage of International Application No. PCT/EP2007/004563, filed May 23, 2007, which claims priority to German Application No. DE 102006024319.6, filed May 24, 2006.
TECHNICAL FIELD
[0002] The present invention relates to a hair care appliance having at least one ionization device.
BACKGROUND
[0003] When brushing, combing or drying hair, there is an unwanted build up of electrostatic charge on the hair, making it difficult to shape and set hair in a targeted manner in particular. Apart from unpleasantness for the person affected, dust particles collect to a greater extent on electrostatically charged hair, which may also result in the hair becoming dirty more rapidly.
[0004] Some hair care appliances, designed with an ionization device, use a carrier medium, e.g., a stream of air, to convey ions onto the hair to be neutralized. But this necessarily means that the ionization device must be set up in a stream of air and/or in the immediate vicinity of a stream of air. First, this restricts the design freedom of the hair care appliance, and secondly, the scope of use of such ionization devices is limited to such hair care appliances which generate a stream of air.
[0005] In addition, because of the eddy currents which are unavoidably present in the stream of air, this allows targeted and controlled application of ions to the hair in an inadequate manner. In particular due to the unavoidable and difficult-to-control air eddies in an air outlet, a substantial portion of the ions do not even reach the hair that is to be neutralized.
[0006] In addition, with the ionization devices known from the state of the art, the ionization tips are mostly produced from needles or curved sheet metal, having tips not only in the direction of flow of the ions but also in other directions, which have the effect of concentrating the electric field.
[0007] Parallel capacitances and resistances develop due to an electric connection between the ionization tip and the high-voltage-carrying high-voltage cable and due to the mounting of the tip, and these lead to parallel currents during operation of the ionization device; this greatly reduces the voltage achievable at the ionization tip.
[0008] However, if a high voltage sufficient for ionization is to be made available at the ionization tip, the high-voltage source must be designed with large dimensions accordingly.
SUMMARY
[0009] One aspect of the invention features an ionizing hair-care appliance having a voltage source coupled to the hair-care appliance, an electrical conductor electrically connected to the voltage source, an ionization electrode comprising a tip and electrically connected to the voltage source by the electrical conductor. In certain implementations, the electrode is disposed within an ionization chamber defined by the hair-care appliance and defining an unobstructed opening through which the electrode tip is exposed.
[0010] Another aspect of the invention features an ionizing hair-care appliance having a voltage source and an electrical conductor that is electrically connected to the voltage source. In some embodiments, the electrical conductor includes a wire that has an insulated base section and an exposed tip section. The exposed tip section may form an ionization electrode positioned within the hair-care appliance so as to impede build up of electrostatic charge while grooming hair.
[0011] Another aspect of the invention features a method of providing a hair-care device with an ionization electrode. The method may include removing insulation from a distal portion of an insulated electrical conductor to form an exposed portion of the electrical conductor, forming one or more tips from the exposed portion of the electrical conductor, positioning the exposed portion of the electrical conductor within an ionization chamber of a hair care device, such that the one or more tips point toward an opening of the ionization chamber, and coupling the electrical conductor to a voltage source of the hair-care device.
[0012] The hair care appliance has, in some embodiments, at least one ionization device for generating an ionization of air and a high-voltage source, which is connected by at least one electric line to the ionization device. The free end of the conductor is designed as an ionization electrode and has at least one area designed in the form of a tip for this purpose.
[0013] In certain embodiments, the ionization electrode is arranged inside an ionization chamber designed like a sleeve open at one end.
[0014] The open end of the area designed as an opening of the ionization chamber allows ions formed inside the ionization chamber on the ionization electrode to emerge unhindered. In some implementations, there are no objects such as an ionization grid or a protective grid to cover the opening of the ionization chamber.
[0015] Thus, during operation of the hair care appliance and/or the ionization device, the ions formed on the ionization electrode emerge from the ionization chamber merely due to the electrostatically induced effects and spread preferentially forming a large-volume ion cloud.
[0016] Some embodiments of the invention facilitate independent spreading of the ion cloud over a large area, so an air stream as a carrier medium for the ions thereby generated becomes unnecessary, so that the ionization device can be used in a greater variety of ways on the whole and more universally.
[0017] In some embodiments, the hair care appliance thus can include all hair care appliances and hair styling appliances such as straighteners or curlers and is not limited to such appliances that create a stream of air.
[0018] According to a first embodiment, a counter-electrode is provided at a distance from the ionization electrode. By means of this counter-electrode, the ion cloud emerging from the ionization chamber can be controlled and influenced in a targeted manner. The quantity, direction of propagation and rate of propagation of the ions generated inside the ionization chamber can be controlled by a predefined potential gradient between the ionization electrode and the counter-electrode.
[0019] The counter-electrode is also arranged outside of the ionization chamber. The counter-electrode here is preferably installed on the open end of the ionization chamber, so that the ions that can be generated by the ionization tip move in the direction of the counter-electrode on emerging from the ionization chamber.
[0020] In some embodiments, the counter-electrode has an essentially plate-like geometry or an essentially linear shape. The two electrodes, the counter-electrode and the ionization electrode are designed to be asymmetrical in particular. The ionization electrode preferably has a radius of curvature of less than 3 mm and is designed to be somewhat round or cylindrical in cross section in particular. On the other hand, the counter-electrode is designed to be plate-like, flat and/or having a radius of curvature greater than 1 cm. Due to this arrangement of the two electrodes, corona discharges should be created in particular, preferably resulting in a continuous air flow between the two electrodes with the ions thereby created as the charge carriers.
[0021] According to another embodiment, the counter-electrode is arranged radially and/or axially offset relative to the ionization electrode, based on the geometry of the ionization chamber. The relative positioning, the mutual alignment and the spacing of the two electrodes—the ionization electrode and the counter-electrode—may facilitate creating the ion cloud and achieving the efficiency of the ionization device as a whole.
[0022] The parameters which pertain to the geometry of the ionization chamber, the relative alignment and the arrangement of electrodes are preferably optimized and coordinated so that at a predefined voltage level between the ionization electrode and the counter-electrode, a maximum of ions can be generated.
[0023] According to another embodiment, the ionization electrode is arranged inside the ionization chamber approximately at the center.
[0024] In addition, the tip area of the ionization electrode runs essentially in the axial direction of the ionization chamber. The ionization electrode and/or its free end, tapering to a point in at least one area, is preferably aligned in parallel with the direction of the resulting ion stream or the direction of propagation of the ion cloud.
[0025] According to another preferred embodiment, the ionization electrode comes to lie in the area of the opening of the ionization chamber in the axial direction of the ionization chamber. According to another embodiment, an arrangement of the ionization electrode such that its free end also extends beyond the edge of the ionization chamber may be considered as the axial area for the positioning of the ionization electrode.
[0026] According to another embodiment, the free end of the ionization electrode is arranged inside the ionization chamber and is set back from the edge of the ionization chamber. Additional embodiments in between, such as a flush arrangement of the ionization electrode with the edge of the ionization chamber, are also conceivable.
[0027] The axial positioning of the ionization electrode with respect to the geometry of the ionization chamber is of great importance for the development of the largest possible ion cloud.
[0028] The ionization chamber is also designed to be cylindrical according to some embodiments.
[0029] An alternative embodiment of the ionization chamber has an elliptical cross section with two axes of symmetry. Such symmetrical geometries of the ionization chamber, like the cylindrical design, are advantageous for the development of a homogeneous cloud of ionized molecules of air.
[0030] According to another preferred embodiment, the electric conductor between the high-voltage source and the ionization device and/or the ionization electrode is designed as an uninterrupted and insulated high-voltage cable.
[0031] If the hair care appliance has multiple ionization devices, e.g., arranged so they are separated from one another spatially, then a separate high-voltage cable may be provided for each ionization electrode so that, except for the branch, high-voltage cables between the high-voltage source and the ionization devices can be avoided.
[0032] The electrodes of the ionization devices may be electrically connected directly to the high-voltage source without interruption and without any other connection means. Edges, steps or the like which would occur in the transition from a separate metal electrode to the connecting cable are avoided due to the design of an uninterrupted connection. The field concentrations associated with such edges or steps and the related losses of efficiency in terms of ion output can thus be prevented in a simple and easy manner.
[0033] According to another preferred embodiment of the invention, the tip area of the ionization electrode is formed by cutting it off. An oblique cut of the free end of the electric conductor connected to the high-voltage source is provided for this purpose in particular. This makes it possible to create a sharp-edged area of the ionization electrode that tapers to a tip, where a high field concentration occurs, which is advantageous for efficient ion emission.
[0034] Obliquely cutting off the conductor is easily implemented and furthermore facilitates the emission of the ions formed on the electrode. In addition, the electric conductor is designed as a stranded cable and the ionization electrode has a plurality of tip areas spaced a distance apart from one another and/or fanned out. These are then designed as the ends of the strands or flexible cables. This makes it possible to increase the ion output. The ends of the strands or flexible cables may be arranged so they are offset both radially and axially to one another.
[0035] The oblique cut to form a tip on the ionization electrode is preferably made at an angle of 30° to 70°, preferably approximately 45° to 60° to the direction of the conductor, forming a tip of the ionization electrode of approx 20° to approx 60°, preferably approx 30° to 45° to the direction of the conductor.
[0036] According to another advantageous embodiment of the invention, the high-voltage source has an open-circuit voltage of 2 kV to 7 kV, with its internal resistance preferably amounting to 5 to 30 megaohm, in particular 10 megaohm. This high internal resistance ensures that a sufficiently low short-circuit current is achieved.
[0037] Furthermore, a high internal resistance of the high-voltage source is also advantageous for the design of the ionization chamber, which is open at one end, and the design of the exposed ionization electrode arranged therein, especially since the propagation of the ion cloud should not be impaired by any design safety measures such as a grid.
[0038] According to another embodiment of the invention, the high-voltage source, the electrode and the electric conductor are designed so that a negative high voltage of 2.5 kV to 6 kV, measured at 1 gigaohm of the measurement device, is applied to the electrode. This provides in particular for the electric conductor and the ionization electrode, which are connected to the high-voltage source, to form a high parallel impedance to the internal resistance of the high-voltage source.
[0039] A low parallel impedance would be a disadvantage because it would form a voltage divider together with the internal resistance of the high-voltage source. This would result in a great drop in voltage on the internal resistor of the high-voltage source which cannot be used for ionization. The usable voltage on the electrode is virtually the open-circuit voltage of the high-voltage source due to the inventive design of the electrode.
[0040] Open-circuit voltages below 6 kV are possible with a high efficiency and a high internal resistance of 10 megaohm, for example. The comparatively low voltage thus allows the use of an inexpensive transformer for the high-voltage source.
[0041] According to another preferred embodiment, the diameter of the ionization chamber is in the range between 3 mm and 10 mm. The ionization electrode can be arranged in an area where it protrudes up to 2 mm from the edge of the ionization chamber or is set back from the edge of the ionization chamber by up to 6 mm.
[0042] The strand diameter of the cable may range from 2.5 mm to 0.05 mm. It is preferably between 0.15 mm and 0.3 mm. The electric conductor itself may be made of copper, nickel silver or other comparable conductive alloys or metals. Furthermore, carbon fibers having a strand diameter in the range greater than 3 μm may also be used.
[0043] In addition, the counter-electrode is arranged a distance between 5 mm and 20 mm away from the ionization electrode in the axial direction.
[0044] All the absolute size information is given only as an example and should merely represent the distance and size ratios of the individual components but not an absolute dimensioning of the individual elements of the ionization device.
[0045] The embodiments are not limited to a single hair care appliance but instead may be applied universally to a plurality of different hair care appliances, e.g., hair curlers, curling rods, straighteners or curlers. Other areas for use include, for example, hair stylers, hairbrushes as well as drying hoods or hair-drying appliances. Use in climate control equipment, air conditioners, humidifiers, and the like is conceivable in principle.
[0046] The hair care appliance can provide improvements with regard to efficiency, performance, manufacturing cost and cost of materials. Furthermore, a wider area of use for such ionization sources is contemplated. In particular, an efficient and far-reaching dispersal of ions may be made possible even without a carrier medium or a stream of air, and furthermore, the use of high-voltage sources with small dimensions and a low energy consumption should also be made possible.
[0047] Additional goals, advantages, features and advantageous possible applications of the present invention are derived from the following description of one exemplary embodiment on the basis of the drawings. All the features described and/or presented here graphically form the subject matter of the invention, even independently of the patent claims or references back to the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIG. 1 shows a schematic diagram of the ionization device in a longitudinal cross section,
[0049] FIG. 2 shows a schematic diagram of the hair care appliance having an ionization device,
[0050] FIG. 3 shows a diagram of a hair care appliance according to FIG. 2 with an additional ionization device,
[0051] FIG. 4 shows a schematic diagram of the ionization device according to FIG. 1 in cross section,
[0052] FIG. 5 shows an ionization chamber designed with an elliptical cross section,
[0053] FIG. 6 shows a diagram of the electrode,
[0054] FIGS. 7-11 show variants of the electrode,
[0055] FIG. 12 shows a diagram of a cross-sectional area of the electrode, and
[0056] FIG. 13 shows a wiring diagram of the ionization device with a parallel capacitance and a parallel resistance, also showing an ineffective ion flow (arrow pointing upward).
DETAILED DESCRIPTION
[0057] FIG. 1 shows a schematic diagram of the ionization device 17 in a longitudinal cross section. The ionization chamber 34 , which is designed to be cylindrical, may be integrated into a housing of a hair care appliance 10 in any way. It is thus provided in particular that the ionization chamber 34 is integrated with its open area flush in a housing wall.
[0058] The electrode 12 , which is designed to taper to a tip due to an oblique cut of an electric conductor 15 , is arranged centrally inside the ionization chamber 34 . This high-voltage cable 13 is held in a mount 16 which may be designed as an aluminum sleeve or may be made of insulating material, e.g., in the form of a silicone tubing or a plastic sleeve. Plastic materials that may be used here include in particular PBT, polyamide, polyurethane, ABS and PC.
[0059] The counter-electrode 20 is designed to be asymmetrical with the ionization electrode 12 and therefore has a plate-shaped but essentially linear geometry. It is arranged outside of the ionization chamber 34 and is also arranged radially and axially offset relative to the ionization electrode 12 .
[0060] The dimensioning of the individual elements and their alignment and arrangement are of great importance for generating ions as efficiently as possible and/or producing a corona discharge between electrodes 20 and 12 . The diameter 28 of the outlet channel for the ions should be in a range between 3 mm and 10 mm.
[0061] The distance 22 between the free end of the counter-electrode 20 and the acutely tapered end of the ionization electrode 12 is to be selected in a range between 5 mm and 20 mm. Likewise, the extra measure 24 on the insulated area 13 of the electric conductor 15 from the support 16 should be in the range of 0.5 to 5 mm.
[0062] The axial extent of the stripped area 32 of the free end 13 of the conductor is in a range from 1 mm to 5 mm. The distance 30 between the tip of the ionization electrode and the edge of the ionization chamber 34 is in a range from −2 mm to 6 mm. The negative amount here means that the tip of the ionization electrode 12 may not only be inside the ionization chamber 34 but may also be arranged so that it protrudes slightly away from the edge of the chamber.
[0063] In this exemplary embodiment, the radial distance 26 between the ionization electrode 12 and the inside wall of the ionization chamber 34 is in the range of 0.5 to 6 mm.
[0064] The absolute sizes given here are by no means to be understood as absolute values but instead should serve only to give an accurate representation of the size ratios of the individual elements and their distances from one another. It is self-evident that the ionization device 17 may also be implemented on a larger or smaller scale accordingly.
[0065] According to the purely schematic diagram of the hair care appliance 10 according to FIG. 2 , the high-voltage source 11 is electrically connected by a continuous high-voltage cable 13 to the ionization device. The high-voltage source, which may be embodied as a transformer in particular, is designed to form a preferably negative high voltage of at least 2 kV and less than 6 kV, in particular less than 5 kV (each measured with 1 gigaohm of the measurement device at the electrode tip). Such dimensioning of the high-voltage source is made possible in particular by the one-piece design of the electrode 12 and the electric conductor 15 .
[0066] For example, if several ionization devices, as shown in FIG. 3 , are provided on the hair care appliance 10 , then they are preferably connected to the high-voltage source 11 by separate cables 13 in an electrically conducting manner or they are provided with a connection suitable for high-voltage purposes. This type of connection serves to avoid having other branches in the high-voltage cable 13 , so that the electric conductor ultimately does not have any soldered joints, rivet connections or similar connections which would lead to a field concentration due to edges or steps and thus would result in a reduction in the ion output.
[0067] FIGS. 4 and 5 each show one exemplary embodiment of an ionization chamber 34 , 38 in cross section. In the exemplary embodiment according to FIG. 4 , the ionization chamber 34 has a radially symmetrical cross section and thus has a cylindrical geometry, whereas in the exemplary embodiment according to FIG. 5 , the ionization chamber 38 has an elliptical cross-sectional profile. In both embodiment variants, the ionization electrode 12 is mounted centrally in the ionization chamber 34 , 38 , so that the most homogeneous possible propagation of the ion cloud that can be produced is to be achieved.
[0068] FIG. 6 illustrates the one-piece design of ionization electrode 12 and the electric conductor 15 . The free stripped end of the cable 13 is thus the electrode 12 itself The electrode 12 is held directly and preferably only by the cable 13 . According to FIG. 1 , it is attached with its insulated area to the retaining element 16 , which is designed in the form of a sleeve, inside the ionization chamber 34 .
[0069] To achieve a better ion output, the conductor 15 is cut off obliquely so that a tip 18 is formed preferably of approx. 20° to 60°, especially approx. 30° to 45°. The conductor may also be cut off obliquely several times from different sides, so that the tip 18 lies in the center of the conductor. The conductor cross section of the electrode 12 after stripping off the insulation is preferably approx. 0.8 to 2 mm.
[0070] The conductor 15 and/or the electrode 12 may comprise a single strand as shown in FIG. 7 or may consist of cables having multiple strands, as shown in FIG. 6 . A cable having multiple lines with several insulated conductors or even a stranded cable having multiple lines may also be used to form the electrode 12 (see FIGS. 9 to 11 ).
[0071] The end of the conductor may be fanned outward radially as shown in FIG. 9 or may be cut off obliquely, for example, and bent in a preferential direction as shown in FIG. 10 . The individual line ends, preferably designed as strands, are then arranged side by side and one after the other. It is advantageous that several tip areas 18 a , 18 b , 18 c , etc. are present. The tips are preferably arranged with the active direction toward the hair and in the direction of ion output.
[0072] Individual burrs 21 , which are formed when the lines are cut as illustrated in FIG. 12 , are especially advantageous. These in turn form additional tip areas 21 a , 21 b , etc. and/or a plurality of ionization tips and sharp edges. They thereby increase the effect of the electrode.
[0073] It is especially advantageous that not only the electrode tip 18 but also the entire electrode 12 is exposed and/or the tip 18 points directly toward the opening of the ionization chamber, as shown in FIG. 1 . The internal resistance Ri of the high-voltage source has hardly any effect on the voltage at the emitter of the electrode 12 . The voltage Uah corresponds approximately to the voltage Uaw shown in FIG. 13 .
[0074] This prevents the development of parallel impedances and/or parallel capacitances, which reduce the voltage Uaw by voltage splitting and thus have a negative effect on the ionization effect. The existence of such parallel impedances is noticed in particular at a high internal resistance of the generator Ri and also depends on the voltage shape. With steep pulses or high frequencies in particular, such a parallel capacitance acts like a short circuit, so that ion emission is prevented almost entirely.
[0075] Due to the one-piece electrode design, electrical and mechanical connections are prevented, at least in the area of the ionization electrode between the electrode and the cable; these could in turn lead to such unfavorable parallel impedances. Thus, no additional electric components are necessary in the tip area between the single branching tip and the ionization electrode.
[0076] Due to the arrangement having a low capacitance and the electrode provided here, a high-voltage generator with a lower power level and a lower voltage and/or lower current may be used. It is thus provided in particular that the internal resistance of the high-voltage source and/or the resistance of the arrangement as a whole meets the requirements for protective insulation according to IEC 335. To implement such a protective impedance, two independent resistors are provided in particular.
[0077] Furthermore, it is also possible for the tip 18 of the ionization electrode to be shaped by ultrasonic welding or formed by spark erosion. The end of the conductor and/or the electrode may also be pinched, pulled or formed from an intended breaking point, so that field concentration spots occur in the desired manner.
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An ionizing hair-care appliance includes a voltage source, an electrical conductor electrically connected to the voltage source, and an ionization electrode comprising a tip and electrically connected to the voltage source by the electrical conductor. The electrode is disposed within an ionization chamber defined by the hair-care appliance and defining an unobstructed opening through which the electrode tip is exposed.
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FIELD OF THE INVENTION
This invention relates generally to an apparatus and method for monitoring a surgical tourniquet system to detect a hazard. The invention relates more particularly, but not by way of limitation, to a hazard monitor having means to provide an alarm if a pneumatic cuff of a surgical tourniquet system is pressurized when electrical power required for operation of one or more components of the surgical tourniquet system is not supplied to the components.
BACKGROUND OF THE INVENTION
Surgical tourniquet systems are commonly used facilitate surgery by stopping the flow of arterial blood into a limb for a period of time sufficient for the performance of a surgical procedure, thereby allowing the surgical procedure to be performed in a dry and bloodless surgical field.
Published medical literature indicates that every usage of a surgical tourniquet necessarily causes some injury to the nerve, muscle and soft tissue in the limb beneath the cuff and distal to the cuff. To minimize the nature and extent of such injuries, tourniquet operators attempt to minimize the level of cuff pressure employed to establish and maintain a bloodless surgical field distal to the cuff. Also to minimize tourniquet-related injuries, tourniquet operators attempt to minimize the duration of tourniquet cuff pressurization. Cuff pressurization for an unnecessarily long period of time is hazardous because it is well established in the medical literature that the probability and severity of tourniquet-related injury to a patient's limb increase as the duration of tourniquet application increases.
Surgical tourniquet systems of the prior art generally include a pneumatic cuff for encircling a patient's limb at a location proximal to the surgical site, a source of pressurized gas and an instrument pneumatically connected to the cuff and the source for supplying gas to the cuff at a regulated pressure.
In some tourniquet systems of the prior art, the source of pressurized gas is a tank or hospital gas supply, while in other prior-art systems an electrically powered air pump is integrated into the instrument. Some surgical tourniquet instruments known in the prior art incorporate electrically powered components including electronic pressure transducers, microprocessors, displays and audiovisual alarms. Although a few types of prior-art surgical tourniquet instruments having no electrically powered components are still in use, most of the surgical tourniquet instruments in common use at present are electrically powered in whole or in part.
One type of tourniquet instrument known in the prior art that is partially powered by electricity is the Electromedics TCPM Tourniquet Cuff Pressure Monitor (Electromedics Inc., Englewood, Colo.). This instrument includes an electrically powered display component for displaying the cuff pressure set by an operator, an electrically powered elapsed time clock to allow an operator to monitor cuff inflation time, a non-electrical pneumatic switch component for allowing an operator to inflate and deflate the cuff, and a non-electrical pressure regulator for supplying gas to the cuff at a pressure near the set pressure. An electrical power switch on the instrument controls the supply of power to the electrical components from a battery within the instrument when an operator turns on an electrical power switch on the instrument. The Electromedics instrument does not incorporate an electrically powered pump and instead requires that either a gas tank or a centralized hospital gas supply be employed as the source of pressurized gas.
The prior-art Electromedics instrument is designed so that, when a pressurized tourniquet cuff is no longer required near the end of a surgical procedure, an operator can first deflate the cuff using the non-electrical pneumatic switch component and the operator can then turn off power to the electrical components by using the electrical power switch. However, if an operator erroneously turns off the electrical power at some point during a surgical procedure and does not depressurize the cuff by using the separate pneumatic switch, then the cuff remains pressurized near a pressure regulated by the non-electrical pressure regulator while the electrical pressure display is unpowered and blank. This error may create a serious hazard for the patient if an untrained or inexperienced operator erroneously assumes that the cuff has been deflated because the pressure display is blank, and as a result the cuff remains pressurized for an extended period of time. Cuff pressurization for an unnecessarily long period of time is hazardous because it is well established that the probability and severity of tourniquet-related injuries to a patient's limb increase as the duration of tourniquet application increases.
A tourniquet instrument known in the prior art that is completely powered by electricity is that of McEwen as described in U.S. Pat. No. B1 4,469,099, which is herein incorporated by reference. McEwen '099 describes a surgical tourniquet system that includes both an instrument that is electrically powered and an electrically powered air pump incorporated into the instrument as the source of pressurized gas. McEwen '099 is operable from power supplied by an external AC supply supplemented by an internal battery and includes the following electrically powered components: an operator interface for allowing an operator to set the tourniquet cuff pressure and the anticipated period of time of cuff pressurization; switches to allow the operator to initiate pressurization and depressurization of the cuff; a cuff pressure display for allowing the operator to set the cuff pressure and monitor the actual cuff pressure; a microprocessor-controlled pressure regulator for regulating the cuff pressure near the set pressure; and a time display for allowing the operator to specify a surgical time and monitor the elapsed time during which the cuff has been pressurized.
McEwen '099 also includes a variety of electrically powered audio-visual alarms for warning the operator of certain hazardous conditions that may exist during operation, including warning of any cuff over-pressurization, cuff under-pressurization or an excessive period of cuff pressurization. If the external AC power supply to McEwen '099 is unexpectedly interrupted while the cuff is pressurized, the internal battery continues to provide power to the displays and alarms but the pressure regulator ceases operation and pneumatic valves in the instrument seal off the pressurized cuff to retain the pressure in the cuff for as long as possible or until external AC power is restored and normal operation can resume. Thus in the event of an interruption of external AC power during use in surgery, McEwen '099 prevents hazards for the patient such as the unanticipated flow of arterial blood into the surgical field during a procedure, the loss of large amounts of blood, and in some cases the loss of intravenous anesthetic agent retained in the limb distal to the cuff. However, an unusual type of hazard may arise if the operator erroneously turns off the electrical power switch of the instrument without first deflating the tourniquet cuff, and then does not pneumatically disconnect the cuff from the instrument and remove the cuff from the patient's limb for an extended period of time. Turning off the electrical power switch of McEwen '099 interrupts the supply of electrical power from both the external AC supply and the internal battery. Thus in the event of such operator errors, without the supply of any electrical power, the cuff pressure display and the time display of McEwen '099 go blank and the audiovisual alarms are not functional, and an untrained or inexperienced operator may erroneously assume that the cuff has been deflated because the displays are blank. McEwen '099 does not produce an audiovisual alarm to alert the operator to the hazard that the tourniquet cuff might remain pressurized and apply pressure to the patient's limb for a prolonged period of time after interruption of the electrical power to the tourniquet instrument.
Other surgical tourniquet systems known in the prior art are entirely powered from an external AC power supply and have no internal supplementary battery as in McEwen '099. In the event of an interruption of power to these other prior-art systems during surgery, such as might arise from a disconnection of the AC supply or an operator error, any pressure and time displays included in such instruments go blank, any audio-visual alarms are non-functional, and the pressurized cuff is sealed off pneumatically to prevent the above-mentioned types of hazards that would otherwise arise for the patient if the cuff were to immediately depressurize upon power interruption. However, none of these prior-art systems produce an audio-visual alarm to alert the operator to the hazard that the tourniquet cuff might remain pressurized for a prolonged period of time after power interruption.
No surgical tourniquet system or monitoring apparatus is known in the prior art that can produce an alarm to indicate that a pneumatic cuff of a surgical tourniquet system is pressurized when electrical power required for proper operation of the surgical tourniquet system is not supplied to the system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial representation and block diagram of the preferred embodiment in a surgical application.
FIG. 2 is a circuit schematic of the preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The embodiment illustrated is not intended to be exhaustive or limit the invention to the precise form disclosed. It is chosen and described in order to explain the principles of the invention and its application and practical use, and thereby enable others skilled in the art to utilize the invention.
FIG. 1 depicts hazard monitor 2 configured to monitor the pressure in tourniquet cuff 4 positioned on limb 6 . Tourniquet instrument 8 is used to inflate and pressurize tourniquet cuff 4 , thereby occluding blood flow in limb 6 during surgical procedures. Tourniquet instrument 8 is connected pneumatically to tourniquet cuff 4 via pneumatic tubing 10 , pneumatic T-connector 12 , and pneumatic tubing 14 . Tourniquet instrument 8 has a number of components that are electrically powered during normal operation, including pressure transducer, pressure display, time display, alarms and indicators.
As shown in FIG. 1, hazard monitor 2 connects pneumatically to tourniquet cuff 4 via pneumatic tubing 16 , pneumatic T-connector 12 , and pneumatic tubing 14 . In addition, hazard monitor 2 connects electrically with tourniquet instrument 8 via electrical cable 18 , in order to permit hazard monitor 2 to monitor the voltage applied to an electrical component within tourniquet instrument 8 that requires electrical power for operation, as described below.
As shown in FIG. 1, tourniquet cuff 4 communicates pneumatically with pressure transducer 20 through pneumatic tubing 16 , pneumatic T-connector 12 , and pneumatic tubing 14 . In the preferred embodiment, pressure transducer 20 is a normally-closed single-pole single-throw pressure switch (MPL-600 Series, Micro Pneumatic Logic, Pompano Beach, Fla.); the contacts of this pressure switch open when the sensed pressure is greater than a predetermined pressure of 15 mmHg. Pressure transducer 20 is specified for operating pressures up to 2000 mmHg, well above the typical maximum pressure of 450 mmHg used in normal tourniquet cuff procedures. It will be apparent to those skilled in the art that, in place of the pressure switch employed in the preferred embodiment, pressure transducer 20 may be implemented by employing an analog pressure transducer which outputs a pressure signal proportional to the sensed pressure, and that the resulting pressure signal can be compared to a reference signal indicative of a predetermined reference pressure to detect when the sensed pressure in cuff 4 in is greater than the predetermined reference pressure level.
In the preferred embodiment, the supply of electrical power to a component of tourniquet instrument 8 requiring electricity for operation is monitored by monitoring the voltage level at the component; the preferred embodiment determines that power is not supplied to the component if the monitored voltage level at the component is below a predetermined voltage level. It will be appreciated that the supply of electrical power to the component could alternately be monitored by monitoring the level of current passing through the component. In the preferred embodiment, as can be seen in FIG. 1, voltage detector 22 connects via electrical cable 18 to an electrical component of tourniquet instrument 8 that requires electrical power in order for tourniquet instrument 8 to operate normally during a surgical procedure. Examples of such electrical components of tourniquet instrument 8 are: a pressure transducer used for sensing the pressure in tourniquet cuff 4 ; a display for producing an indication for an operator of the sensed pressure in cuff 4 ; a pressure regulator or individual electrically powered elements of the pressure regulator such as electro-pneumatic valves or microprocessors; an electrical pump for generating compressed air for use by a pressure regulator, and a display for providing an operator with an indication of the time during which pressurized gas has been supplied to cuff 4 by the tourniquet instrument 8 . In the preferred embodiment, voltage detector 22 monitors the voltage at any selected one of such electrical components via electrical cable 18 . When the voltage applied to the monitored electrical component is above a predetermined threshold, voltage detector 22 produces a signal and when the voltage is below the threshold no signal is produced.
As can be seen in FIG. 1, power supply 24 supplies the electrical power necessary for the electrically powered components in hazard monitor 2 . Power supply 24 is independent of any external sources of power, including the electrical power supply found in tourniquet instrument 8 . Power supply 24 is monitored by low power detector 26 which detects when the voltage produced by power supply 24 has fallen below a predetermined threshold, as described further below. In the preferred embodiment, power supply 24 is a 3 volt lithiumion battery capable of supplying power to hazard monitor 2 for up to 10 years before requiring replacement.
Low power detector 26 monitors the voltage output by power supply 24 . When the voltage output by power supply 24 drops below a predetermined threshold required for normal operation of hazard monitor 2 and requires replacement, low power detector 26 produces a signal.
Alarm control 28 responds to the signals produced by low power detector 26 and voltage detector 22 , and to the closed or open circuit provided by pressure transducer 20 , and produces an alarm signal when an alarm condition is present. An alarm condition exists when either: (a) pressure in tourniquet cuff 4 is above the predetermined pressure of 15 mmHg as sensed by pressure transducer 20 and the voltage applied to the monitored electrical component within tourniquet instrument 8 is below a predetermined threshold as sensed by voltage detector 22 ; (b) the voltage output of power supply 24 is below a predetermined threshold as sensed by low power detector 26 . In the preferred embodiment, the alarm condition logic is implemented via low-power CMOS logic gates. It is obvious to those skilled in the art that the alarm condition logic in alarm control 28 could be implemented in a number of ways, including the use of a microcontroller-based system, a network of diode and transistor logic gates, or the use of analog switches and relays.
When an alarm signal is produced by alarm control 28 the operator is alerted to the alarm condition by both audible and visual alarms via visual indicator 30 and audible indicator 32 . In the preferred embodiment, audible indicator 32 is a low-power piezoelectric pulse-tone generator, while visual indicator 30 is a low-power electromagnetically-actuated status indicator (Status Indicator Model 30-ND, Mark IV Industries, Mississauga, Ontario, Canada). Visual indicator 30 is a bi-stable indicator which requires no power during steady-state and minimal power when changing state from inactive (reset—alarm condition not indicated) to active (set—alarm condition indicated). In the preferred embodiment, visual indicator 30 remains in its last state indefinitely after power supply 24 has been depleted. By operating in this way, visual indicator 30 alerts the operator of a persisting alarm condition, such as low power in power supply 24 sensed by low power detector 26 , even after power supply 24 has been fully depleted.
When tourniquet cuff 4 is applied to a patient's limb and tourniquet instrument 8 is supplying pressurized gas to cuff 4 during a surgical procedure and hazard monitor 2 is configured as shown in FIG. 1, hazard monitor 2 senses both the voltage applied to the monitored electrical component within tourniquet instrument 8 and the pneumatic pressure in tourniquet cuff 4 . In the event that the sensed pneumatic pressure in tourniquet cuff 4 exceeds a predetermined pressure level when electrical power is not supplied to the monitored electrical component in tourniquet instrument 8 , hazard monitor 2 detects this hazardous condition and produces a alarm signal and an audio-visual alarm perceptible to the operator via visual indicator 30 and audible indicator 32 . The alarm signal continues to be produced, and both visual indicator 30 and audible indicator 32 continue to indicate the alarm condition, until the pressure in tourniquet cuff 4 drops below the predetermined pressure level, or until electrical power is supplied to the component in tourniquet instrument 8 .
When cuff 4 is not pressurized above the predetermined pressure level, the switch contacts of pressure transducer 20 are closed, and hazard monitor 2 does not produce any alarm unless low power detector 26 senses that power supply 24 is below a predetermined minimum voltage and requires replacement; in that event, hazard monitor 2 responds to low power detector 26 by producing a low-power alarm perceptible to the operator via visual indicator 30 and audible indicator 32 . Visual indicator 30 continues to produce the low-power alarm until power supply 24 is replaced with another power supply having a voltage level greater than the predetermined minimum voltage, while audible indicator continues to produce the low-power alarm until power supply 24 is completely depleted.
FIG. 2 is a simplified schematic diagram of the preferred embodiment that shows the interconnections of the major components of the preferred embodiment.
Power supply 24 is a 3 volt lithium-ion battery. In FIG. 2, the positive terminal of power supply 24 is shown labeled as Vbatt and the negative terminal is shown connected to the ground. Power supply 24 is connected to voltage regulator 34 , which produces a reference voltage of 1.5 volts, labeled as Vref, which is used by voltage detector 22 and low power detector 26 , as described below.
As is common practice when describing logic circuits the terms “high” and “low” are used to describe the states of signals in the following description of the circuit schematic shown in FIG. 2 . When a signal is described has “high” its voltage is near the level of the voltage produced by power supply 24 . When a signal is described as low it has a voltage level near zero.
The normally closed electrical contacts of pressure transducer 20 are shown in FIG. 2 by the symbol for a switch. One of the switch contacts is connected to ground and the other switch contact is connected to both high-impedance pull-up resistor 36 in series with Vbatt, and to one of the inputs of AND gate 38 . When the pressure sensed by pressure transducer 20 is less than the predetermined pressure the switch contacts of pressure transducer 20 are in the closed position and the level of the signal at the input of AND gate 38 is low. When the pressure sensed by pressure transducer 24 is greater than the predetermined pressure, the switch contacts of pressure transducer 20 open and the level of the signal at the input of AND gate 38 is high.
Voltage detector 22 is comprised of analog comparator 40 and high-impedance resistors 42 and 44 configured as a voltage divider network. The voltage signal from the monitored component within tourniquet instrument 8 is shown in FIG. 2 with the label Vtourn. Vtourn as conducted by electrical cable 18 is communicated to the voltage divider network formed by resistors 42 and 44 . Analog comparator 40 compares the level of the voltage-divided Vtourn signal at the junction of resistor 42 and 44 with the level of the reference voltage Vref. Analog comparator 40 is configured so that when the level of the voltage-divided signal from Vtourn is less than the level of Vref, the signal level at the output of analog comparator 40 will be low. When the level of the voltage-divided signal from Vtourn is greater than level of Vref, the signal level at the output of analog comparator 40 will be high. Analog comparator 40 has hysteresis to prevent oscillations in its output signal when the level of the voltage-divided signal from Vtourn is near the level of Vref.
Low power monitor 26 is comprised of analog comparator 46 and high-impedance resistors 48 and 50 configured as a voltage divider network. Vbatt is connected to the voltage divider network formed by resistors 48 and 50 . Analog comparator 46 compares the level of the voltage-divided Vbatt signal at the junction of resistor 48 and 50 with the level of the reference voltage Vref. Analog comparator 46 is configured so that when the level of the voltage-divided signal from Vbatt is less than the level of Vref, the signal level at the output of analog comparator 46 is low. When the level of the voltage-divided signal from Vbatt is greater than level of Vref, the signal level at the output of analog comparator 46 is high. Analog comparator 46 has hysteresis to prevent oscillations in its output signal when the level of the voltage-divided signal from Vbatt is near the level of Vref.
Alarm control 28 is implemented via low-power CMOS logic gates, AND gate 38 , OR gate 52 , and NOT gates 54 and 56 . As shown in FIG. 2 the logic gates comprising alarm control 28 are configured such that the output of alarm control 28 is a alarm signal which is at a high level when either: (a) the signal from voltage detector 22 is at a low level and the signal from pull-up resistor 36 connected to pressure transducer 20 is at a high level; or (b) the signal from low power detector 26 is at a low level.
As shown in FIG. 2, the output of alarm control 28 is communicated to the clock input of positive-edge triggered mono-stable multi-vibrator 58 , the clock input of negative-edge triggered mono-stable multi-vibrator 60 , and audible indicator 32 . Positive-edge triggered mono-stable multi-vibrator 58 has its output connected to the set input of visual indicator 30 , while negative-edge triggered mono-stable multi-vibrator 60 has its output connected to the reset input of visual indicator 30 . In this configuration, when the alarm signal makes a transition from low (alarm condition not present) to high (alarm condition present), positive-edge triggered mono-stable multi-vibrator 58 applies a pulse to the set input of visual indicator 30 , changing the display on visual indicator 30 from the inactive to active state which indicates to the operator that an alarm condition is present. When the alarm signal changes makes a transition from high to low, negative-edge triggered mono-stable multi-vibrator 60 applies a pulse to the reset input of visual indicator 30 , changing the display on visual indicator 30 from the active to inactive state. The pulse-width and amplitude of the pulses produced by positive-edge triggered mono-stable multi-vibrator 58 and negative-edge triggered mono-stable multi-vibrator 60 are configured so the current and voltage supplied to the set and reset inputs of visual indicator 30 is sufficient to cause visual indicator 8 to change state. As shown in FIG. 2, the alarm signal output from alarm control 28 is also communicated to audible indicator 32 , a piezoelectric pulse-tone generator which generates an audible alarm when the alarm signal is high.
It will be apparent to those skilled in the art that hazard monitor 2 may be adapted to integrate with differing designs of prior-art tourniquet systems. For example, if desired, transducer 20 of hazard monitor 2 may be adapted to connect directly in line with the pneumatic tubing between instrument 8 and cuff 4 , rather than via a T-piece adapter as in the preferred embodiment, such that tourniquet instrument 8 is pneumatically connected through hazard monitor 2 to tourniquet cuff 4 .
If desired, hazard monitor 2 may be physically integrated into a prior-art tourniquet instrument, sharing the same physical housing but having separate circuitry, power supply and alarms. The hazard monitor may be further adapted by being more fully integrated into certain types of prior-art tourniquet instruments, by sharing a common battery or some common audio-visual alarms or other components to simplify the overall design and reduce overall costs. For example, the prior-art tourniquet of McEwen '099 produces a cuff over-pressurization alarm when the difference between the actual pressure that is sensed in a tourniquet cuff and a reference pressure level selected via the tourniquet instrument exceeds a cuff over-pressurization limit; in such a prior-art tourniquet, some audible and visible alarm indicators could be used in an adaptation of hazard monitor 2 . Also, McEwen '099 employs a tourniquet cuff having two pneumatic ports; for overall simplicity and to reduce overall costs, hazard monitor 2 could be adapted to employ one of these two ports to communicate pneumatically with the cuff to determine cuff pressurization.
Some prior-art tourniquet instruments have a “soft” electrical power switch wherein the switch must be actuated by an operator for a period of time before power to the components of the instrument is interrupted, in order to reduce the likelihood of inadvertent power interruption by the operator; the hazard monitor may be adapted and integrated with such tourniquet instruments to produce an alarm and also to prevent the power from being interrupted if the switch is actuated in an attempt to turn the power off at a time when the cuff is pressurized.
It will also be apparent to those skilled in the art that hazard monitor 2 may be adapted to simultaneously monitor two cuffs and one tourniquet instrument controlling both cuffs, and it will also be apparent that hazard monitor 2 may be adapted to monitor dual-port cuffs and tourniquet instruments connected to those dual-port cuffs. Additionally, it will be appreciated by those skilled in the art that LEDs, LCDs and audio speakers may be used to implement other forms of visual and audible alarms perceptible to a human operator of a tourniquet instrument and others in the vicinity.
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A hazard monitor for surgical tourniquet systems comprises: pressure transducing means for detecting a pressure in a pneumatic tourniquet cuff; power monitoring means for monitoring the supply of electricity to an electrically powered component of a tourniquet instrument, wherein the tourniquet instrument is connectable pneumatically to the tourniquet cuff to supply pressurized gas to the cuff, thereby producing a pressure in the cuff; and hazard detection means responsive to the pressure transducing means and the power monitoring means for producing an alarm if a pressure is detected in the tourniquet cuff when electricity is not supplied to the component.
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BACKGROUND OF THE INVENTION
This invention relates generally to pipe couplers, more specifically to an adjustable coupler with an improved gasket.
Clamps and couplers used to connect sections of pipe, end-to-end, are known to the art. Such clamps often are employed to connect sections of pipe or hopper tees on tank cars. In certain applications, particularly in dry bulk hauling, the integrity of the seal at the pipe connections is critical in preventing cross contamination of the products sequentially hauled in the tank cars. Often pellets or powders are hauled in the tank cars. The pellets or powders are unloaded through gravity gates valves or hoppers located on the bottom of the tank cars. Hopper tees attached to the bottom of the hopper are connected to collection pipes. Sometimes a vacuum is employed through the pipe to facilitate the emptying of the dry bulk products. All of the dry bulk product must be removed to prevent contamination of subsequent loads. For example, if the hauler is carrying black plastic resin beads, all of the black plastic resin must be removed from the car, as well as the hopper and piping, to prevent contamination of a subsequent white or other colored plastic resin load. Another example is the transportation of edible white flour. If flour is trapped in the tank car or the piping system and develops mold, a subsequent flour load will be exposed to the mold. Obviously, there can be cross contamination of bulk liquids as well as bulk dry loads. Such contamination can destroy a load, force its disposal, and at heavy costs.
It is known in the art that contamination can occur at the point of coupling the pipes and the hopper tees. Prior art clamps employ gasket seals that can trap product. FIGS. 1-4 illustrate components of a typical prior art clamp. Prior art clamp 1 is a typical overcenter clamp having two semi-circular sides 3 and 5 connected by hinge 7. A conventional overcenter lever 9 and cam 10 clamping means is used to draw the two halves tightly together to surround the clamp joint. A deformable gasket 11 lines the interior groove 12 of clamp 1. A deformable gasket of the prior art type is shown in FIGS. 3 and 4. As can be seen, gasket 11 has outer walls 13 and 14 with a center member 16 designed to deform and press against the pipe joint. Gaps 18 and 20 between the respective sides and the middle member create areas in which material, for example, dry bulk material such as plastic resins or flour, can become entrapped. It is nearly impossible to remove such material once it is lodged deep in the gaps 18 and 20.
There are other problems other than cross contamination associated with prior art clamps such as clamp 1. Such prior art clamps have no means for adjustment. The clamp, even when new, can be difficult to open and close. Lever 9 and cam 10 wear during use until clamp 1 loosens and fails. This type of clamp must be changed and discarded, leading to waste and increased costs.
Furthermore, such clamps of the type shown in FIG. 1 are made of cast iron and mild steel parts. Clamp 1 can corrode from exposure to the environment. Once corroded, the clamp is nearly impossible to remove from the pipe P or hopper T. The user must pry lever 9 with a pry bar or length of small diameter pipe. Then the user must beat two halves 3 and 5 apart with a hammer to separate them.
Finally, such clamps are not versatile in that they are not easily adapted to connect different pipe sections together. For example, the clamp may be needed to connect two sections of smooth pipe, connect two section of grooved pipe or connect a smooth pipe to a grooved pipe. Prior art clamps may work to connecting similar pipes, but do not accommodate different styles of pipe.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a pipe coupler having an adjustable clamping bail that can be adjusted to accommodate changes in tolerances due to wear.
Yet another object of the invention is to provide a pipe coupler that can be adapted to connect sections of grooved pipe end-to-end, connect a grooved pipe to a smooth pipe end-to-end, or connect two sections of smooth pipe, end-to-end.
Another object of the present invention is to provide a pipe coupler employing a gasket seal that compresses flush to the pipe sections leaving no spaces or gaps to collect material.
Still another object of the present invention is to provide a gasket seal that provides greater sealing surface and the pipe joint.
Still another object of the present invention is to provide such a pipe coupler made from long lasting corrosion-resistant material.
Yet another object of the present invention is to provide a pipe coupler that requires no tools to couple or uncouple.
Still another object of the present invention is to provide a pipe coupler that is durable, long lasting, economical to manufacture.
In accordance with the invention, briefly stated, a pipe coupler is provided having an adjustable clamping bail and a gap sealing gasket. The coupler has a first and second, semi-circular clamping arms which, together, define an annular opening to encircle the respective ends of the pipes to be joined. The arms are connected with a hinge. The first arm has a cam with a lever. An adjustable clamping bail is connected to the lever. The second arm has a boss to engage the bail when clamped on pipe. The first and second clamping arms each have a generally U-shaped profile defined by a bottom wall and first and second opposed side walls. A sealing gasket seats in a groove between the walls and is compressed by the two halves when the coupler is closed. In one embodiment of the invention each of the clamping arm side walls has a raised rib thereon. The rib engages an annular groove formed in a end of a section of pipe to connect two grooved sections of pipe together. In another embodiment, the first side wall on each arm has a raised rib that engages a grooved pipe and the second side wall on each arm has a smooth flange to engage a smooth end of pipe. This embodiment is used to connect a smooth pipe to a grooved pipe. In a third embodiment, each arm side wall has a smooth flange formed thereon to engage a smooth pipe to connect two smooth ends of pipe together. The inner wall of the gasket has raised ridges with one ridge positioned to seal the pipe joint. As the coupler is installed, it compresses the gasket around the pipe at the joint and spreads the ridges to fill up the inside diameter of the clamp to provide a greater sealing surface at both the pipe joint. The gasket has no gaps or grooves to collect material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a prior art pipe clamp;
FIG. 2 is an isometric view of a prior art pipe clamp applied to two sections of pipe;
FIG. 3 is an isometric view of a prior art pipe clamp gasket;
FIG. 4 is a cross sectional view of the prior art gasket taken along lines 4--4 of FIG. 3;
FIG. 5A is an isometric view of one illustrative embodiment of the pipe coupler of the present invention;
FIG. 5B is a cross sectional view taken across lines 5B--5B of FIG. 5A;
FIG. 5C is a cross sectional view taken along lines 5C--5C of FIG. 5A;
FIG. 6 is an enlarged, front plan of the bail assembly of the pipe coupler of the present invention;
FIG. 7 is an isometric view of the pipe coupler of FIG. 5, partially applied to two sections of pipe;
FIG. 8 is an isometric view of the pipe coupler of FIG. 6 with an improved gasket of the present invention in place;
FIG. 9 is an isometric view of the pipe coupler of FIG. 7 applied to two sections of pipe;
FIG. 10 is an isometric view of the coupler gasket of the present invention;
FIG. 11 is a cross-sectional view taken along lines 11--11 of FIG. 10;
FIG. 12A is an isometric view of another illustrative embodiment of the pipe coupler of the present invention;
FIG. 12B is a cross-sectional view taken along lines 12B--12B of FIG. 12A;
FIG. 12C is a cross-sectional view taken along lines 12C--12C of FIG. 12A;
FIG. 13 is an isometric view of the pipe coupler of FIG. 12A partially applied to two sections of pipe;
FIG. 14A is an isometric view of another illustrative embodiment of the pipe coupler of the present invention;
FIG. 14B is a cross-sectional view taken along lines 14B--14B of FIG. 14A;
FIG. 14C is a cross-sectional view taken along lines 14C--14C of FIGS. 14A, and
FIG. 15 is an isometric view of the pipe coupler of FIG. 14A partially applied to two sections of pipe.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An illustrative embodiment of a pipe coupler of the present invention is indicated generally by reference numeral 30 in FIG. 5 and 6. Coupler 30 has a first clamping arm 32.and a second clamping arm 34. The respective clamping arms are generally semi-circular in profile. First clamping arm 32 has a first end 36 and a second end 38. A hinge portion 40 is integrally formed at the first end. A conventional hole and pin 44 function as the hinge portion. There is a mount 46 at the second end. Mount 46 has a first wall 48 and a second wall 50 defining a space 52. A hole 54 is formed centrally in cam wall 48 and there is a corresponding aligned hole (not shown) in wall 50. A pin (not shown) extends through the holes to form a lever hinge as will now be explained.
A bail lever 56 is pivotally attached to mount 46. Lever 56 is generally arcuate in profile and has a handle section 58 at a first end and a hole (not shown) at a second end. As stated above, the pin 54 is inserted in the mount holes and extends through the hole in the second end of lever 56 to form a hinge. A raised boss 60 is integrally formed on the interior curve of lever 56. As can be seen in FIG. 5B, first clamping arm 32 has a generally U-shaped cross-section. Arm 32 has a first side wall 62, an opposed second side wall 64 and a bottom or base wall 66. The respective walls define a groove 68 to seat a gasket, as will be explained below. First side wall 62 has a raised rib 70 integrally formed thereon. Rib 70 extends the length of wall 62. Second side wall 64 has a raised rib 72 formed thereon. Rib 72 extends the entire length of wall 64.
An adjustable bail assembly 80 is pivotally attached to bail lever 56. Bail assembly 80 is shown in greater detail in FIG. 6. Bail assembly 80 has a generally U-shaped bail 82 with a horizontal section 83 and opposed arms 84 and 86. Bail arm 84 terminates in a threaded portion 88. Arm 86 terminates the threaded portion 90. A pivot rod 92 extends through a hole (not shown) in bail lever 56. A first end 95 of rod 92 has a flat side 96. A second end 98 of rod 92 has a flat side 100. A pair of spacers 102 and 104 are positioned on rod 92 on each side of lever 56. Spacers 102 and 104 can be made out of teflon, plastic, harden rubber or any other appropriate wear-resistant material. A first tightening nut 106 is threadily engaged on threaded portion 88 above rod end 95. Second tightening nut 108 is threadily engaged on the threaded portion 88 below rod end 95. A third tightening nut 110 is threadily engaged on the threaded portion 90 of arm 86 above rod end 98 and a fourth tightening nut 112 is threadily engaged on threaded portion 90 below rod end 98. It should be noted, at this point, that bail 80 and rod 92 as well as the other components, other than the spacers, are made from a harden steel or other appropriate material. The construction of bail assembly 80 allows for the adjustment of bail 80 relative to lever 54. Bail assembly 80 can be tightened by the various tightening nuts to properly adjust the tension on the bail when the coupler is fastened in place even if there are changes in tolerances due to wear.
Second clamping arm 34 has a first end 120 and a second end 122. There is a conventional hinge portion 122 on the first end 120 and designed to cooperate with hinge portion 40 to form a secure hinge. The hinge allows the clamping arms to pivot relative to each other for opening and closing.
A boss 124 is integrally formed at the second end of clamping arm 34. Boss 124 has a groove 125 formed therein to seat horizontal portion 83 of bail 82 when the coupler is closed and locked. As can be best seen in FIG. 5C, arm 34 has a generally U-shaped profile nearly identical to that of arm 32. Arm 34 has a first side wall 126, a second side wall 128 and a bottom wall 130. The respective walls define a groove 132 to seat a gasket as will be explained below. First side wall 126 has a raised rib 134 integrally formed thereon. Rib 134 extends the length of wall 126. Second side wall 128 has a raised rib 136 formed thereon. Rib 136 extends the length of wall 128.
Coupler 30 is designed to join together two sections of pipe having annular grooves cut in the surface of the respective pipe sections near the joint as best illustrated in FIGS. 7-9 pipe sections P1 and P2 have annular grooves 140 and 142 formed therein near joint J. The respective raised ribs 70, 72, 134 and 136 seat in the corresponding grooves 140 and 142 when the clamping arms 32 and 34 are pivoted about the hinge toward each other. The respective clamping arms encircle joint J. A gasket 150, which will be described in greater detail hereinafter, is seated in grooves 68 and 132 and surrounds joint J. For clarity of illustration, FIG. 7 shows the arrangement of the coupler 30 relative to the pipe sections without gasket 150 in place. FIG. 8 illustrates the arrangement of the coupler and the pipe with gasket 150 in place. As shown in FIG. 9, horizontal section 83 of bail 82 engages groove 125 on boss 124. Lever 54 is pushed down until boss 60 abuts arm 32. Bail 82 is pulled into groove 125, and lever 56 locks down, securing couple 30 in place. Gasket 150 is compressed under the respective clamping arms, as to completely seal joint J. The configuration of the bail 82 and the groove 125 on boss 124 is such as to allow a lesser leverage pressure required to manipulate the lever 56 to lock and unlock the coupler during its usage and applications.
Gasket 150 is shown in greater detail in FIGS. 10 and 11. Gasket 150 is made from a deformable, impervious material such as rubber, or polymer. Gasket 150 has an annular body 153 with an outer surface 155 and an inner surface 157 with a material thickness 158 inbetween. Inner surface 157 defines internal bore 160. Inner surface 157 has three symetrical ridges 160, 161 and 162 integrally formed as a serration like surface thereon. The middle ridge 161 is positioned to align with pipe joint J. Since gasket 150 is made of a deformable material, the ridges 160-162 compress and flatten when the coupler is closed and locked. The compression flattens and spreads ridges 160-162 and seals joint J. There are no gaps.
Another illustrative embodiment of the coupler of the present invention, is shown in FIGS. 12A-13 and is indicated, generally, by reference numeral 200. Coupler 200, as will be appreciated by those skilled in the art, is designed to connect two sections of pipe, one section having a smooth end surface and the other having an annular groove cut in the surfaces. Coupler 200 has a first clamping arm 232 and a second clamping arm 234. The respective clamping arms are generally semi-circular in profile. First clamping arm 232 has a first end 236 and a second end 238. A hinge portion 240 is integrally formed at the first end. A conventional hole and pin 244 function as a hinge. There is a cam 246 at the second end. Cam 246 has a first wall 248 and an opposed second wall 250. A pin (not shown) extends through the holes to form a lever hinge, as will now be explained. A bail lever 256 is pivotally attached to cam 244. Lever 256 is generally arcuate and profile having a handle portion 258 at a first end and a hole (not shown) at a second end. As stated above, pin 244 extends through the holes in the hinge portion and through the hole (not shown) in the second end of the lever 256 to form a hinge for the pivotal movement of bail lever 256. A raised boss 260 is integrally formed on the interior curvature of lever 256.
As can be seen in FIG. 12B, first clamping arm 232 has a generally U-shaped cross-section. Arm 32 has a first side wall 262, a second side wall 264 and a bottom wall 266. The respective walls define a groove 268 to seat a gasket, as previously explained relative to coupler 30. First side wall 262 has an integral flange 270 which protrudes outwardly from side wall 262 and also extends the length of wall 262. Second side wall 264 has a raised rib 272 integrally formed thereon. Rib 272 extends the entire length of wall 264. An adjustable bail assembly 280 is pivotally attached to bail lever 256. Bail assembly 280 is identical in construction and function to bail 80, as previously described with reference to coupler 30 above.
Second clamping arm 234 has a first end 290 and a second end 292. There is a conventional hinge portion 294 on first end 290 that cooperates with hinge portion 240 to form a conventional hinge, as previously explained. A boss 295 is integrally formed at the second end of arm 234. Boss 295 has a groove 296 formed therein to seat the bail when the coupler is locked, as previously described. As can best seen in FIG. 12C, arm 234 has a generally U-shaped profile which is a mirror image of that of arm 232. Arm 234 has a first side wall 300, second side wall 302 and a bottom wall 304. The respective walls define a groove 306 to seat a gasket. Obviously, in usage, a gasket as previously described, will fit within the coupler. First side wall 300 has an integral flange 308 integrally formed thereon. Flange 308 protrudes out from wall 300 and extends the length of wall 300. Second side wall 302 has a raised rib 310 formed thereon. Rib 310 extends the length of wall 302.
Coupler 200 is designed to join together segments of pipe, one having an annular groove machined in the surface near the joint and the other having a smooth surface, as illustrated in FIG. 13. Pipe section P1 has an annular groove 315. The raised ribs 272 and 310 seat in the groove 315. Flange 270 and 308 protrudes outwardly from the respective arm walls and abut the smooth end of pipe P2. Coupler 200 is shown without a gasket in FIG. 13 for clarity of illustration. However, in use, a gasket, as illustrated in FIG. 10, is placed around pipe joint J and seats in the respective grooves between the respective clamping arm side walls.
FIGS. 14A through 15 shown another illustrative embodiment of the pipe coupler of the present invention, for use in coupling two ends of smooth and ungrooved pipe sections together. Indicated generally by reference numeral 400. Coupler 400 has a first clamping arm 402 and a second clamping arm 404. The respective arms are generally semi-circular in profile. First clamping arm 402 has a first end 406 and a second end 408. First end 406 has a conventional hinge arrangement as previously described with reference to the other illustrative embodiments. There is a cam 410 at the second end. Cam 410 has a first wall 412 and a second wall 414 defining space 416. A hole 418 is formed centrally in cam 48 and there is a corresponding hole (not shown) in cam wall 414 (not shown). A pin (not shown) extends through the hole to form a lever hinge as previously explained. A bail lever 420 is pivotally attached to cam 406. Lever 420 is generally arcuate and profile, as previously explained, and has a handle section 422. As stated above, a hole in the second end of the lever fits into cam 406 in a hinge-like arrangement. Raised boss 424 is integrally formed on the internal curve of the lever.
As can been seen in FIG. 14B, first clamp arm 402 has a generally U-shaped cross section. Arm 402 has a first side wall 430, a second side wall 432 and a bottom wall 434. The respective walls define a groove 440. Groove 440 is disposed to seat a gasket as previously explained. First side wall 430 has an integral flange 442 formed thereon and protruding outwardly from side wall 430. Flange 442 extends the length of wall 430. Second side wall 432 has an integral flange 444 formed thereon, protruding outwardly from wall 432 and extending the length of wall 432. The coupler 400 has an adjustable bail assembly, shown generally at 450, which is identical to bail assembly 80 previously described. Second clamping arm 34 has a first end 460 and a second end 462. There is a conventional hinge type apparatus connecting the respective first ends of the clamping arms as previously described with reference to the other embodiments. A boss 464 is integrally formed on the second end of arm 404. Boss 464 has a groove 466 to seat the bail when the coupler is locked as previously described. As can be best seen in FIG. 14C, arm 404 has a generally U-shaped profile nearly identical to that of arm 402. Arm 404 has a first side wall 470, a second side wall 472 and a bottom wall 474 the respective walls define a groove 476 for the seating of a gasket as previously explained. First side wall 670 has an integral flange 480 formed thereon and protruding out from side wall 470. Flange 480 extends the length of wall 470. Side wall 472 has a flange 482 integrally formed thereon and protruding outwardly from the wall. Coupler 400 is designed to join two sections of smooth pipe, as illustrated in FIG. 15. Coupler 400 is shown without a gasket for clarity of illustration. The respective flanges 442, 444, 480 and 480 abut the smooth surfaces of pipes P3 and P4 to secure them together.
It will be appreciated by those skilled in the art that various changes and modifications can be made in the coupler without departing from the scope of the appended claims. Furthermore, the various couplers are shown connecting sections of pipe. It will be understood that the coupler is intended to join sections of pipe to hopper tees. Both grooved and smooth, as well as connecting sections of conventional pipe.
Therefore, the foregoing description and accompanying drawings are intended to be illustrative only and should not be construed in a limiting sense.
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A pipe coupler for interconnecting pipes and components together, for transferring bulk and fluid materials, and useful for connecting sections of pipe-end-to-end. The coupler connects grooved pipe to ground pipe, smooth pipe to grooved pipe or smooth pipe to smooth pipe. Also tees, valves, and pipe sections can be secured together. The coupler has an adjustable bail that can be adjusted to assure a tight seal despite any wear. The coupler also eliminates any gaps that may trap material and lead to cross-contamination of subsequent loads.
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This application is a continuation of application Ser. No. 07/498,292, filed on Mar. 23, 1990 now abandoned.
TECHNICAL FIELD
This invention relates generally to semiconductor integrated circuits and to methods for fabricating them.
BACKGROUND OF THE INVENTION
As integrated circuits become increasingly smaller and more complex, it has become necessary to create multiple layers of conductive interconnections between transistors. These conductive interconnections are often, although not necessarily, made from metal and are termed "runners."
In a typical Field Effect Transistor (FET) integrated circuit fabrication process, the source, drain and gate are formed first. Then a layer of dielectric material is formed to cover the source, drain and gate. The dielectric is subsequently patterned to create openings, often termed "windows" or "vias" over transistor regions (such as the source, drain or gate) to which an electrical contact is desired. For convenience and simplicity, dielectric openings will be termed "vias" in the following paragraphs. In typical subsequent processing, a conductive material may be deposited both in the vias and as a blanket layer upon the dielectric.
In certain integrated circuit designs, the vias may be filled utilizing the same process which forms the blanket metallic layer. In other designs, a conductive plug may be formed within the via and then the overlying blanket metallic layer may be formed in a separate step. In certain designs, the plug may be made of a different material from the overlying blanket metallic layer. In other designs, the plug and the overlying metallic layer may be made of the same material. After the blanket metallic layer has been formed, the blanket layer is patterned to form runners which may connect individual transistors.
When the plug and the overlying blanket layer are formed from the same material, various problems may arise during subsequent processing. For example, there is a danger that a misalignment of the runner mask will permit the runner etching process to expose a portion of the upper surface of the plug and etch the plug (at least in the vicinity of the via wall), thereby damaging it.
One solution to the misalignment problem is to employ "nailheads." Nailheads are portions of increased width within a runner. Nailheads are dimensioned and positioned within the runner to completely cover a plug even if a mask misalignment should occur. Thus, if the protective nailhead is properly positioned, a slight misalignment of the runner mask will not pose any danger to the underlying plug because the plug will remain covered by the nailhead during the runner etching process. However, one disadvantage to the use of nailheads is that they consume extra space in the circuit layout. As integrated circuit geometrics shrink, designers have consistently sought ways to reduce space consumption.
In more complex integrated circuits, additional layers of conductive interconnection may be fabricated by a repetition of the process described above. For example, a second layer of dielectric material may be formed which covers both the previously formed runners and the first dielectric layer upon which those runners are formed. Then vias may be opened in the second dielectric layer. The vias may be filled with conductive material and an overlying blanket metallic layer may then be patterned to form a higher level runner. The higher level runners electrically connect the lower level runners through the vias.
The next few paragraphs discuss some of the more commonly used interconnection materials. Sputtered aluminum is a commonly used material for forming conductive interconnections. However, the use of aluminum presents certain problems to the integrated circuit designer. Sputtered aluminum generally exhibits poor step coverage in vias and does not fill them adequately. Special procedures or techniques must often be employed to create aluminum plugs which will adequately fill vias. Furthermore, aluminum does not tolerate high temperature processing very well. Consequently, after aluminum runners have been formed, subsequent thermal processing of the integrated circuit must be restricted to low temperatures.
Tungsten has become an increasingly popular material for integrated circuit fabrication. Tungsten plugs may be formed within high aspect ratio vias by techniques known to those skilled in the art. Often a tungsten plug is formed by etching back a blanket tungsten layer. A disadvantage is that the blanket tungsten, which fills the vias somewhat conformally, often exhibits a central seam in the via and/or a dimple on top of the via. The seam is particularly vulnerable to the etching process used to form the plugs. Thus, the process of forming the plugs from blanket tungsten may destroy or at least impair the tungsten material within the via. The tungsten plug is frequently contacted by an overlying aluminum blanket layer. The aluminum layer is subsequently patterned to form runners. However, as mentioned before, the presence of the aluminum runners means that subsequent thermal processing must be restricted to lower temperatures. Another disadvantage is that aluminum and tungsten may react to form an intermetallic compound.
Integrated circuits designers have given increasing attention to the use of tungsten as an interconnection material, i.e., as a runner. The conductive tungsten runners are comparatively impervious to subsequent routine high temperature processing. For example, after vias are defined, a blanket layer of tungsten is deposited, which both fills the vias and covers the dielectric. Then the tungsten is patterned to form runners. However, the use of blanket tungsten to both fill vias and form runners may have disadvantages. One disadvantage of the blanket tungsten approach is that adhesion between the tungsten and underlying dielectric is often poor. Also, the process for etching tungsten to form runners can result in an etch down the plugs if the photoresist is misaligned.
SUMMARY OF THE INVENTION
In an illustrative embodiment of the present invention, a patterned dielectric is formed having at least one opening. The opening is at least partially filled with a first material. Then a second material layer is formed in contact with the first material layer and with the dielectric layer. A third material layer is formed on top of the second material layer. Then the third material layer is patterned by a process which includes etching while the second material layer serves as an etch stop. Next the second material layer is patterned.
Illustratively, the first and third material layers may include such materials as aluminum, tungsten, nickel, copper and mixtures or alloys rich in these metals. The second material layer may include tungsten silicide, titanium nitride, or titanium-tungsten.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1-8 are partially perspective, partially cross-sectional views illustrating the method of fabricating an illustrative embodiment of the present invention.
DETAILED DESCRIPTION
The present invention may perhaps be most easily understood if the fabrication process employed in an illustrative embodiment is outlined. Turning to FIG. 1, reference numeral 11 denotes a material body which may include silicon, doped silicon, epitaxial silicon, silicon dioxide, various nitrides, etc.--the exact composition of body 11 is not critical. Regions 19 and 22 are conductive. For example, 19 may be the upper portion of an FET gate. Region 22 may denote a source or drain of an FET. Alternatively, regions 19 and 22 may be conductive lower-level runners (typically made from metal). Or, regions 19 and 22 may be local interconnections formed from polysilicon or silicide or salicide. Alternatively, regions 19 or 22 may be contacts to a bipolar transistor. Whatever regions 19 or 22 denote, it is desired to form an electrical connection to both regions and to have the subsequently formed electrical connection separated from regions 19 and 22 by dielectric material.
Accordingly, reference numeral 21 designates a dielectric layer covering conductive regions 19 and 22. For example, reference numeral 21 may denote silicon dioxide from a silane-based reaction or from other precursor material. Some examples of suitable precursors are tetraethoxysilane (Si(OC 2 H 5 ) 4 ) with the acronym "TEOS," tetramethoxysilane (Si(OCH) 4 ) with the acronym "TMOS," diacetoxyditertiarybutoxysilane (C 10 H 26 O 4 Si) with the acronym "DADBS," and tetramethylcyclotetrasiloxane (C 4 H 16 Si 4 O 4 ) with the acronym "TMCTS" sold under the trademark "TOMCATS" by J. C. Schumacher, a unit of Air Products and Chemicals, Inc. Dielectric 21 may be formed by plasma enhanced chemical vapor deposition if desired. It will be noted that upper surface 17 of dielectric 21 is depicted in FIG. 1 as being relatively flat (i.e., at least locally planarized). Such planarization is not necessary to the practice of the present invention--it merely makes the figure simpler. Openings 13 and 15 have been created in dielectric 21 by techniques known to those skilled in the art, e.g., by plasma etching. Opening 13 is above conductive region 19, while opening 15 is above conductive region 22. Openings 13 and 15 are illustrated with square or rectangular cross-sections (in the plane of surface 17). However, practical present-day lithography frequently produces openings with somewhat circular cross-sections, i.e., openings having somewhat circular cylindrical shapes. The precise shape of openings 13 and 15 is unimportant for the practice of the present invention. It will be noted that opening 15 is illustrated somewhat deeper than opening 13. The present invention may be employed whether or not all of the openings have the same depth.
Turning now to FIG. 2, openings 13 and 15 have been filled with conductive material 31 and 33, respectively. It will be noted that opening 13 is completely filled, whereas opening 15 is only partially filled. Some material formation processes may completely fill all of the openings within a dielectric, whereas other deposition processes may not completely fill all of the openings. The present invention is applicable to both situations. As mentioned before, the conductive material 31 and 33 within openings 13 and 15, respectively, is frequently termed a "plug." For example, as mentioned before, plugs 31 and 33 may be formed by the selective deposition of tungsten. ("Selective tungsten" is a term used to describe tungsten which deposits on silicon, metals or silicide and not on silicon dioxide.) A variety of processes for forming selective tungsten are known to those skilled in the art. Typically these processes involve reduction of tungsten hexafluoride by hydrogen or silane under process conditions that favor selectivity. Thus, the selective tungsten process produces a tungsten plug inside the via and does not (generally) produce any significant accumulation of tungsten on the upper surface of the dielectric. Furthermore, the selective tungsten process, which tends to fill the opening from the bottom upwards, does not generally exhibit a central seam. Other suitable plug materials are, for example, aluminum, copper, nickel, aluminum-rich mixtures, aluminum-rich alloys, copper-rich mixtures and copper-rich alloys.
FIG. 3 illustrates the formation of layer 41 after plugs 31 and 33 have been formed. Material layer 41 should be a material which serves as an effective etch stop against the etching procedures used to define the subsequently formed runners. For example, if the to-be-formed runners are tungsten, material layer 41 may be titanium nitride or titanium tungsten. However, if in situ processing is desired, layer 41 may be tungsten silicide (WSi 2 ). Should the to-be-formed runners be aluminum, layer 41 may be titanium nitride, titanium tungsten or tungsten silicide. If the to-be-formed runners are copper, material layer 41 may be titanium nitride or titanium tungsten. Layer 41 may exhibit a dimple or depression 43 over vias such as 15 which are not completely filled.
Turning to FIG. 4, conductive layer 51 is formed over layer 41. Layer 51 may be, for example, a layer of blanket tungsten. Blanket tungsten may be formed by reducing tungsten hexafluoride with hydrogen or silane. Other source gases such as tungsten hexachloride may also be used. Other refractory metals besides tungsten may be used; these metals may often be formed by hydrogen reduction from their respective chlorides. Alternatively, layer 51 may be aluminum or copper, or an aluminum-rich mixture, an aluminum-rich alloy, or a copper-rich mixture or a copper-rich alloy. A slight depression 53 may or may not be observed in layer 51 in the region where it completes the filling of opening 15. The presence or absence of a depression or seam 53 is not critical to the successful practice of the present invention.
In FIG. 5, layer 51 is patterned by techniques known to those skilled in the art. For example, if layer 51 is tungsten, it may be patterned by reactive ion etching using CF 4 or SF 6 . The etch procedure used to pattern layer 51 creates runners 55 and 57. Whatever etch procedure is employed, it should exhibit selectivity against layer 41, i.e., layer 41 should serve as an etch stop. It will be noted from an examination of FIG. 5, that runners 55 and 57 are slightly offset from plugs 31 and 33. Such offsets are a common result of misalignments during mass production techniques. Were layer 41 not present to serve as an etch stop, the etching procedure used to define runners 55 and 57 might etch downward into the otherwise exposed regions of plugs 31 and 33, denoted roughly by reference numerals 61 and 63, respectively. However, the presence of protective layer 41 preserves the integrity of plugs 31 and 33.
Turning to FIG. 6, it will be noted that layer 41 has been patterned using runners 55 and 57 essentially as masks. Layers 411 and 412 beneath runners 55 and 57 are created by the etching of layer 41. For example, if layer 41 is tungsten silicide, it may be patterned by CF 4 , SF 6 mixed with chlorine or chlorofluorohydrocarbons. The etching procedure employed to etch layer 41 should exhibit good selectivity against plug material 31 and 33. The lesser the selectivity, the greater the care needed to etch layer 41. Since, for example, upper surface 61 of plug 31 is exposed by the etching of layer 41, it is, of course, necessary that layer 41 be conductive so that electrical conduction may take place between plug 31 and runner 55 and between plug 33 and runner 57. Thus, it will be noted that layer 41 has prevented intrusion of the runner-defining etch process into plugs 31 and 33, while ultimately, facilitating electrical conduction between these plugs and their respective associated runners.
The presence of layer 41 can present additional advantages when material layer 51 and plugs 31 and 33 are of dissimilar materials. For example, if layer 51 were aluminum, (and hence, runners 55 and 57) and plugs 31 and 33 tungsten, the use of titanium nitride for layer 41 will inhibit the formation of intermetallic tungsten-aluminum compounds.
An additional advantage of the present invention is depicted in FIG. 7. Should runner 55 be broken, by perhaps electromigration or other failure, into two or more portions, designated in FIG. 7 by reference numerals 552 and 551, ordinarily electrical conduction would cease. However, the presence of underlying layer 411 may still serve to preserve conduction. An additional advantage of the present invention is that it tends to reduce the size of (or completely eliminate) depressions such as 53 because the openings such as 15 are filled from the bottom when selective tungsten processes are used first. (Such depressions may be more severe if a blanket tungsten process is used throughout.) Consequently, stacked vias are more easily designed with the present process.
An additional embodiment of the present invention is illustrated in FIG. 8. Reference numeral 111 represents a substrate which may be any suitable material. Dielectric 121 overlies substrate 111 and surrounds conductive portion 119 which may be, for example, a source, a gate, a drain, a runner, a local interconnection, etc. Opening 133 has been made in dielectric 121 and partially filled with conductive material (plug) 115. (Optionally, opening 133 may be completely filled just as opening 13 is completely filled by plug 31 in FIGS. 3-7). Conductive layer 413 covers plug 115. Runners 155 and 157 both contact layer 413 and, thus, also electrically contact portion 119 through plug 115. Thus, the design illustrated in FIG. 8 permits the effective connection of two runners 155 and 157 together through the same via 133 to an underlying portion 119. Patterned material layer 413 thus serves as a local interconnection.
Fabrication of the structure shown in FIG. 8 is accomplished by first forming a blanket layer of material 413 and an overlying conductive material (similar to FIG. 4). Then the overlying conductive material is patterned to create runners 155 and 157, with the underlying layer serving as an etch stop (similar to FIG. 5). Then the underlying layer is patterned using a separate mask which defines layer 413 so that it connects both runners 155 and 157 with plug 115. The resulting structure may be contrasted with the structure of FIGS. 5 and 6 in which runners 55 and 57 effectively serve as masks for the patterning of underlying layer 41.
The present invention is applicable to bipolar technology and to integrated circuits using substrates other than silicon, such as III-V compounds.
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An integrated circuit and method of fabrication are disclosed. The invention provides an etch-stop layer between a plug formed in a via and an overlying runner. The etch stop layer serves a variety of functions, including protecting the plug during the etching process which defines the runner.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a §371 of PCT International Application Serial No. PCT/EP02/06966, filed Jun. 24, 2002.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention is in the field of security elements, particularly for bank notes.
Security threads are used as a security feature in a great variety of products, in particular security papers. One of the best known applications, which must meet extremely high security requirements, is the embedding of the security thread in bank note paper, the optical code in most cases forming positive or negative writing to be checked with the naked eye in transmitted light. The optical code can instead or additionally be a code to be checked by optical devices, in particular a bar code (WO 99/28852).
To impede imitation of the security thread, the thread is usually equipped with further security features in addition to the optical code, in particular an electroconductive coating and/or a coating with magnetic properties, said coatings being disposed one above the other. Such security features are tested by machine and therefore also referred to as “machine features.” The optical code is usually formed by the machine features themselves by the associated coatings forming either positive writing or, through corresponding gaps in the coatings, negative writing. A customary way of producing the optical code is to partially demetalize a metalized thread, whereby the layer with magnetic properties thereabove is either removed at the same time (EP 0 748 896 A1), or disposed so as not to interfere with the demetalizing zones or applied so thin that the demetalized areas of the security thread are visually recognizable in transmitted light despite the magnetic layer present (EP 0 498 186 A1).
Instead of producing the electroconductive layer by vacuum metalization of the security thread, the electroconductive coating can also be applied as metal-pigmented printing ink, e.g. silver bronze (EP 0 516 790 B1, FIG. 8 ). Alternatively, the magnetic layer can additionally be made electroconductive by admixture of carbon black particles, so that all three security features—magnetic, electroconductive, negative writing—are produced simultaneously by printing a single layer.
In addition, it is known to apply the layer with magnetic properties in such a way that it forms a special code (EP 0 914 970 A2). Said magnetic code can consist of magnetic material or material that is detectable by magnetoresistors (EP 0 610 917 A1), the code being detectable not only due to the local distribution of material but also due to different magnetoresistive properties (EP 0 610 917 A1) or different magnetic layer thicknesses (EP 0 914 970 A2) or different magnetic properties such as remanence properties or coercivity (WO 99/28852).
From WO 99/28852 it is in addition known not only to apply the magnetic coating in the form of a special code but also to produce a special conductivity code by applying the electroconductive metal layer in certain portions.
If the optical code does not need to be visible in transmitted light, the magnetic coating can have, instead of gaps in the form of negative writing for example, a corresponding inscription printed on the magnetic layer with conventional ink (EP 0 610 917 A1, EP 0 748 896 A1).
A general concern with security threads is that potential forgers should not become aware of the presence of the machine features. This cannot be readily avoided, however, since a magnetic coating usually has a totally different appearance from an electroconductive metal coating with metallic luster.
WO 99/28852 therefore proposes disposing the magnetic layer and the electroconductive metal layer in exact register one above the other so that they completely conceal each other. This measure is only successful when the security thread is viewed only from one side or at least has an opaque base material. With security threads in bank notes whose optical code is tested in transmitted light, however, the security thread is usually transparent so that a different appearance would result depending on the viewing side. For this case of a security thread visible on both sides, EP 0 516 790 B1 and EP 0 748 896 A1 propose covering the magnetic coating with the electroconductive material completely on both sides so that a uniform appearance results in the paper in reflected and transmitted light.
A different manner of concealment is adopted by EP 0 914 970 A2, which proposes “masking” a magnetic bar code by providing masking bars of the same magnetic material in the areas between the magnetic bars, the masking bars differing from the bars forming the magnetic code only in the thickness of the material, and thus in the intensity of the magnetic feature. A potential forger is thus optically deceived since he will at first assume that the masking bars are part of the magnetic code. However, the production quality of the security thread and the measuring device quality for testing the security thread must meet very high requirements for the masking bars to be reliably recognized as such and not attributed to the magnetic code.
SUMMARY OF THE INVENTION
This invention relates to a security element, in particular for bank notes, having a carrier material and a magnetic code and/or a code independent thereof based on electroconductivity, hereinafter referred to as a conductivity code, and in addition an optical code. The invention further relates to a security document, in particular a bank note, having such a security element. The security element is in particular a security thread.
The problem of the present invention is to provide a security element, in particular for bank notes, that does not readily show all its security features and can be produced with little effort and reliably tested.
The inventive concealment of the security features of the security element is based on, among other things, applying different security features to a carrier material and forming said different security features of materials that are not distinguishable from each other optically, that is, with the naked eye. The carrier material can be an opaque or transparent material, preferably plastic, especially preferably transparent plastic.
Specifically, the inventive concealment is based on providing in addition to the technically testable security features (“machine features”), that is, in addition to the coating with the electroconductive material and/or the coating with the magnetic material, a further coating that does not have the characteristic physical properties of the machine features, i.e. is not electroconductive or does not have the special magnetic properties.
Said further coating of “neutral” material covers at least also areas of the security element that are not covered by the machine features. Since the viewer cannot distinguish between the individual materials he is faced with a visually recognizable pattern, for example a bar code or combination of characters (hereinafter “optical code”), that is formed by joint viewing of the areas covered by machine features and the areas covered by neutral material. The viewer cannot see whether or where in the optical code machine features might be located.
The machine feature areas and the areas of the security element covered with neutral material can be present separately from each other in the simplest case. However, more effective concealment results if the areas are adjacent or preferably overlap each other partly or optionally completely. An especially preferred embodiment provides that the security element is a security thread and that each longitudinal portion of the thread is provided with at least one of the coding materials so that the thread is coated over its total length with material looking the same. Said continuous coating preferably has gaps in the form of a negative writing as the optical code. In this case the viewer will at first think he is faced with a conventional, allover coated security thread having the typical gaps in the form of negative writing. Production of the inventive security element is especially simple if the different coating materials are based on printing inks that look the same and are admixed with particles having the machine-testable features. The uncoated areas of the security element associated with the optical code then do not need to be produced by an elaborate demetalizing method, but can simply remain unprinted. The invention is therefore especially suitable for a transparent security thread that is visible in transmitted light when embedded in the paper. For the purposes of increasing the contrast in transmitted light, the machine-testable coating materials and the neutral material are opaque, preferably dark, and preferably based on the same printing ink.
Additionally, further security features can be integrated into the security element, in particular a thermochromic and/or luminescent security feature.
According to a preferred embodiment, the security element is a security thread, i.e. the security element has the form of a thread or strip that is embedded at least partly into a document material, such as bank note paper, or can be disposed on the surface. The following examples will therefore be described with reference to this preferred form. However, it is likewise possible within the scope of the invention to give the security element any other desired outline form.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the invention will be described by way of example with reference to the accompanying figures. The proportions shown in the figures do not necessarily correspond to the relations existing in reality and serve primarily to improve clarity.
FIG. 1 shows a security element with a continuous electroconductive coating with a magnetic code printed thereover and an optical code in the electroconductive coating;
FIG. 2 shows a security element with a magnetic coating with a conductivity code printed thereover and an optical code in the conductivity code and the magnetic coating;
FIG. 3 shows a security element with spaced apart magnetic code, conductivity code and optical code;
FIG. 4 shows a security element with a conductivity code partly superimposed by a magnetic code and forming an optical code therewith and with a third coating;
FIG. 5 shows a security element with a magnetic code superimposed on an optical code of electroconductive and neutral coating portions; and
FIG. 6 shows a continuously coated security element with a conductivity code, thereover a magnetic code and a neutral coating between the two codes, and an optical code in the form of negative writing in the continuous coating.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 to 6 each show the security element in a top view and, thereunder, schematically in a side view. The plan view shows the appearance of the security element the way it presents itself to the viewer in a top view with use of a white or light security element or in transmitted light with use of a transparent security element. The side view shows the particular layer structure of the security element. If it is a security thread, the width is usually in the range of 1 to 2 millimeters. All figures show only a short portion of the security thread, which is usually produced as an endless thread.
In the figures the same layer materials are consistently designated with uniform reference numbers.
FIG. 1 shows continuously conductive, magnetically coded negative text element 1 . That is, optical code 20 is formed by gaps forming characters in continuous, electroconductive coating 30 of security element 1 . Security element 1 consists of transparent plastic 10 so that optical code 20 is visible in transmitted light if security element 1 is embedded for example in bank note paper or another security document.
Continuous coating 30 is printed with special magnetic code 40 that is not distinguishable in its optical appearance from coating 30 thereunder to the naked eye. Magnetic code 40 forms a bar code for example. In the simplest case the code can be a continuous coating, like continuous electroconductive coating 30 in the embodiment.
In this way the impartial viewer is not aware that the security element has not only optical codes 20 but also magnetic code 40 . “Magnetic code” refers according to the present invention to any “magnetic coating” provided due to its special magnetic material properties for testing the authenticity of the security element by said magnetic properties. Such coatings may also be for example coatings of a material that is identifiable by magnetoresistors and thus reliably distinguishable from other materials of the security element.
The security element according to FIG. 1 has altogether three security features, namely optical code 20 , magnetic code 40 and continuous electroconductivity 30 . It is thus “triple coded.” The inventive purpose is also attained, however, if coating 30 does not have any special physical properties and is for example a neutral printing ink. The most essential condition to be met by coating 30 is that it is optically indistinguishable from the material of magnetic ink 40 .
FIG. 2 shows similar security element 1 to FIG. 1 having a transparent plastic as carrier material 10 but being coated continuously with magnetic ink 40 which is coated with a special code of electroconductive ink 30 . Instead of a special magnetic code this security element thus has special conductivity code 30 , and instead of continuous electroconductivity this security element is continuously magnetic. In contrast to the security element shown in FIG. 1 , optical code 20 is present not only in continuous magnetic coating 40 of security element 1 but also in areas of electroconductive coating 30 . Since optical code 20 is negative writing, both magnetic layer 40 and electroconductive layer 30 have accordingly formed gaps in the areas of optical code 20 . Continuous magnetic coating 40 could be replaced by a neutral printing ink in this embodiment, too, but this would reduce the number of security features of the security element from three to two.
Due to the elevated security and the special deception of the viewer and potential forger, the preferred embodiments of the invention provide three security features, an optical, a magnetic and an electroconductive security feature, said security features being produced using coating materials that are optically indistinguishable and applied to security element 1 in the form of printing inks by a suitable method, preferably printing technology. The printing technologies are for example screen printing, gravure, offset and flexography, whereby screen printing and gravure are preferred. The security features can of course also be applied by any other suitable method, such as spraying or vapor deposition technologies. If vapor deposition technologies are used, vacuum coating methods are preferred.
FIG. 3 shows a further embodiment of inventive security element 1 . In this case, optical code 20 consists of characters 20 a and 20 d and trapezoidal bars 20 b , 20 c . Individual components 20 a to 20 d of optical code 20 are each formed of a certain coating material on security element 1 . Component 20 a “G&D” is formed by coating 50 of neutral material without any special physical properties. Component 20 b of the optical code and component 20 d “PL” are formed by magnetic coating 40 . Component 20 c of the optical code is in turn formed by electroconductive coating 30 . Character components 20 a and 20 d thus have different physical properties from each other, and trapezoidal bars 20 b , 20 c also have different physical properties from each other but different ones from character components 20 a , 20 d . The viewer at first suspects nothing of these different properties since the coating materials of optical code 20 are indistinguishable from each other to the naked eye. The coating is present on plastic carrier 10 , as in FIG. 1 .
FIG. 4 shows inventive security element 1 whose optical code 20 is a bar code formed by uniformly spaced bars of different length. The viewer will at first think he is faced with a usual bar code. As can be seen by the side view of security element 1 , however, the individual bars of bar code 20 are formed by different coating materials, namely by electroconductive coating portions 30 , magnetic coating portions 40 and neutral coating portions 50 that are neither magnetic nor electroconductive. The element thus has conductivity code 30 due to electroconductive coating portions 30 , magnetic code 40 due to magnetic coating portions 40 , and optical code 20 due to the totality of electroconductive, magnetic and neutral coating portions 30 , 40 , 50 .
Coating portions 50 thus serve to complete optical code 20 and it would be sufficient, deviating from the view according to FIG. 4 , if coating portions 50 were only adjacent to magnetic and/or electroconductive portions 40 , 30 . However, this presupposes very high production precision to avoid gaps between the individual coating portions. It is therefore preferred due to the simpler producibility in particular by printing technology to dispose the coating portions so that adjacent coating portions overlap. Production tolerances are uncritical in this case. The coating is present on plastic carrier 10 , as in FIG. 1 .
FIG. 5 shows a further embodiment of inventive security element 1 wherein optical code 20 again comprises characters 20 a and bars 20 b , 20 c . Bars 20 c with the negative writing “PL” consist of electroconductive coating 30 , and bar 20 b with the negative writing “G&D” consists of neutral, opaque printing ink 50 . Electroconductive coating 30 thus forms a conductivity code that is not recognizable to the viewer in its special code form, since the viewer will assume that neutral coating area 50 is also part of the code. Additionally, the security element has a third code, namely magnetic code 40 formed by printing magnetic ink 40 on bars 20 a , 20 b in certain portions. The partial areas of magnetic code 40 are located outside negative writing 20 a so that magnetic code 40 can be produced as a classic bar code by printing technology in very simple fashion. The coating is present on plastic carrier 10 , as in FIG. 1 .
FIG. 6 in turn shows inventive security element 1 that confronts the viewer as a continuously coated security element with negative writing 20 . The security element has conductivity code 30 and magnetic code 40 different therefrom, said codes being formed by corresponding coatings 30 , 40 . Areas of the security element not covered by coating areas 30 , 40 were previously printed with neutral, opaque ink 50 . However, the coating order is irrelevant for the purposes of the invention, since in any case the resulting security element 1 appears to be printed completely opaque and has the same appearance from both sides even in the case of a transparent element. The coating is present on plastic carrier 10 , as in FIG. 1 .
In the case of a transparent security element, the coatings can also be present on different sides of carrier material 10 .
Areas 40 forming the magnetic code on the security element can be divided into subclasses that differ in their magnetic remanence and/or coercive field strength. These different classes of magnetic areas can be distinguished from each other in identification machines by their different magnetic properties. The different magnetic and machine detectable properties of the subclasses can be adjusted by means of different magnetic materials or by means of a material varying in quantity and/or pigment distribution. Pigment distribution refers for example to the pigment size or the packing of the pigments (density).
The magnetic materials can be both hard- and soft-magnetic materials and mixtures thereof.
Magnetic inks that can be used are hard-magnetic pigments incorporated in binder, for example Fe3O4, and soft-magnetic powder inks, for example of Fe or NiFe.
Electroconductive areas 30 are produced just like magnetic areas 40 e.g. by means of printing inks by printing technology. This has the advantage that the optical appearance of the electroconductive ink can be readily adapted to the optical appearance of the magnetic ink. In addition it is possible without effort to provide gaps or special contours in the electroconductive coating for forming the optical code without any need for an elaborate demetalizing process for example. For printing the conductive areas it is possible to use for example inks like Electrodag from Acheson Industries or carbon black incorporated in binder, e.g. Printex XE2B from Degussa-Hüls AG.
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A security element is equipped with first code of magnetic material and/or second code of electroconductive material and has in addition third, optically read-able code, for example as negative writing and/or as a bar code, which is present in the magnetic and/or electroconductive code or is produced preferably together with third, neutral material, the neutral material not being either electroconductive or magnetic. According to the invention it is provided that all three aforementioned materials are indistinguishable to the viewer optically, that is, with the naked eye, and therefore appear as a uniform coating made of a single material.
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FIELD OF THE INVENTION
[0001] The invention generally relates to tools and techniques for developing computer programs. Particularly, the invention relates to tools and techniques for developing workflow applications that provide decision support for the end-user.
BACKGROUND OF THE INVENTION
[0002] A “workflow” is a familiar concept to many people. Generally, a “workflow” is any series of steps or activities necessary for completing a particular task. A “workflow process” is any set of related activities that the workflow application treats as a single unit of activity. For example, the process of obtaining permanent resident status (a “green card”) for an alien employee could be described as a workflow. To obtain a green card, someone must file a labor certification with the Department of Labor. The Department of Labor then must process the certification, first at the state level and then at the national level. If the Department of Labor approves the certification, someone must file a second application with the Immigration and Naturalization Service (INS), which then investigates and approves or rejects the application. Of course, each of the filing and processing activities are themselves comprised of smaller tasks and activities, but in this example, each of the filing and processing activities probably would be treated as a workflow process.
[0003] A “workflow application” is any computer program designed to coordinate or manage a workflow, particularly in an enterprise setting. Thus, in the above example, a workflow application could coordinate the workflow processes (the filing and processing activities) among the filer, the Department of Labor, and the INS.
[0004] Workflow applications are common. Many workflow applications are highly specialized for a specific industry, such as the medical application disclosed in U.S. Pat. No. 6,697,783 (issued Feb. 24, 2004). Other such systems, though, have been designed to accommodate more generalized needs, including the system disclosed in U.S. Pat. No. 6,567,783 (issued May 20, 2003).
[0005] Decision support systems also are common in the enterprise world. In general, a decision support system is any means for gathering information from one or more sources, analyzing the information, and predicting the impact of a decision before it is made. A decision support system frequently is implemented as a computer program, and just as frequently is integrated with other types of programs to create a more comprehensive application. U.S. Pat. No. 6,697,783, U.S. Pat. No. 6,567,783, U.S. Patent App. No. 2003/0195762 (published Oct. 16, 2003), and WO 2002/29682 (published Apr. 11, 2004), for example, all disclose a workflow application with some form of integrated decision support system.
[0006] Tools for developing workflow applications and decision support systems probably are as common as the applications themselves. Again, though, many of these tools are specialized for a specific industry or type of application. WO 2002/29682, for example, discloses a tool for developing an automated loan processing system to meet the needs of an individual enterprise. Other tools, though, have attempted to generalize the development process, such as the tools described in U.S. Pat. No. 6,567,783 and U.S. Patent App. No. 2003/0195762.
[0007] Thus, neither the concept of a “workflow” nor a “decision support system” is new. Nor is the use of a computer to implement a workflow process or a decision support system new. The structure and organization of such implementations, however, have seen rapid change in recent years. In particular, advances in network architectures have changed application development significantly.
[0008] Like all computer programs, workflow applications and decision support systems may be stand-alone programs or part of a tiered-architecture. In general, a tiered-architecture includes multiple tiers (or “layers”) of software that provide a different layer of service at varying levels of detail to the tiers above and beneath them. For years, many applications were designed to run in a two-tier architecture, referred to commonly as a “client-server architecture.” The functionality of such an application generally was divided between a “client” program and a “server” program. The client program generally provided a user interface and implemented most of the application's logic (commonly referred to in an enterprise context as “business logic”). The server program, on the other hand, provided centralized access to data, so that multiple clients could access the data through a single server. In recent years, though, this traditional two-tier client/server system has been displaced slowly by more sophisticated multi-tier systems. In general, a multi-tier system places at least one intermediate component between the client and the server. These components are referred to commonly as “middleware.” Today, programmers often implement an application's logic in middleware programs, rather than in a traditional client program.
[0009] Tools for developing workflow applications and decision support systems generally have been designed for traditional, two-tier client-server architectures, or even for monolithic (single-tier) architectures. Tools for developing multi-tier workflow applications are far less common, and existing tools do not provide an effective means for integrating a decision support system into a workflow application. The invention described in detail below addresses the need in the art for such a means.
[0010] This and other objects of the invention will be apparent to those skilled in the art from the following detailed description of a preferred embodiment of the invention.
SUMMARY OF THE INVENTION
[0011] The invention described below is a new and useful process, and appurtenant apparatus, for developing and using workflow applications with decision support. Specifically, the invention comprises a decision support engine and a programmatic interface thereto. The decision support engine is a middleware computer program that receives queries from a workflow application, connects to external data sources, executes queries, and returns query results to the workflow application. The programmatic interface allows a developer to integrate business logic and queries into a workflow application that supports decision-making.
BRIEF DESCRIPTION OF DRAWINGS
[0012] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0013] FIG. 1 represents an exemplary network of computers and other hardware devices, through which a Decision Support Engine may communicate with workflow applications and data sources;
[0014] FIG. 2 is a schematic diagram of a Decision Support Engine, its components, and other resources;
[0015] FIG. 3 depicts the interaction of a workflow application with a Decision Support Engine to provide decision support to a user of the workflow application; and
[0016] FIG. 4 provides a detailed illustration of the interaction between a workflow process and a Decision Support Engine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The principles of the present invention are applicable to a variety of computer hardware and software configurations. The term “computer hardware” or “hardware,” as used herein, refers to any machine or apparatus that is capable of accepting, performing logic operations on, storing, or displaying data, and includes without limitation processors and memory; the term “computer software” or “software,” refers to any set of instructions operable to cause computer hardware to perform an operation. A “computer,” as that term is used herein, includes without limitation any useful combination of hardware and software, and a “computer program” or “program” includes without limitation any software operable to cause computer hardware to accept, perform logic operations on, store, or display data. A computer program may, and often is, comprised of a plurality of smaller programming units, including without limitation subroutines, modules, functions, methods, procedures. Thus, the functions of the present invention may be distributed among a plurality of computers and computer programs. The invention is described best, though, as a single computer program that configures and enables one or more general-purpose computers to implement the novel aspects of the invention. For illustrative purposes, the inventive computer program will be referred to as the “Decision Support Engine (DSE),” which comprises smaller programming units that will be referred to as the “connection manager,” “query manager,” and “application program interface (API).”
[0018] Additionally, the DSE and its components will be described with reference to an exemplary network of hardware devices, as depicted in FIG. 1 . A “network” comprises any number of hardware devices coupled to and in communication with each other through a communications medium, such as the Internet. A “communications medium” includes without limitation any physical, optical, electromagnetic, or other medium through which hardware or software can transmit data. For descriptive purposes, exemplary network 100 has only a limited number of nodes, including workstation computer 105 , workstation computer 110 , server computer 115 , and persistent storage 120 . Network connection 125 comprises all hardware, software, and communications media necessary to enable communication between network nodes 105 - 120 . Unless otherwise indicated in context below, all network nodes use publicly available protocols or messaging services to communicate with each other through network connection 125 .
[0019] DSE 200 , including connection manager 205 , query manager 210 , and API 215 , typically are stored in a memory, represented schematically as memory 220 in FIG. 2 . The term “memory,” as used herein, includes without limitation any volatile or persistent medium, such as an electrical circuit, magnetic disk, or optical disk, in which a computer can store data or software for any duration. A single memory may encompass and be distributed across a plurality of media. Thus, FIG. 2 is included merely as a descriptive expedient and does not necessarily reflect any particular physical embodiment of memory 220 . As depicted in FIG. 2 , though, memory 220 may include additional data and programs. Of particular import to DSE 200 , memory 220 may include workflow application 230 , with which DSE 200 interacts. An “application,” as used herein, includes without limitation any computer program, or any combination or aggregation of computer programs, designed to interact with an end-user, especially to implement business operations or rules. API 215 comprises a set of utility programs, methods, or objects that a developer can use to integrate DSE 200 functionality into workflow application 230 . DSE 200 and workflow application 230 also may share common resource data 240 .
[0020] FIG. 3 depicts the interaction of workflow application 230 with DSE 200 to provide decision support to a user of workflow application 230 . Referring to FIG. 3 for illustration, DSE 200 services queries from workflow application 230 . More specifically, DSE 200 services queries from workflow processes 305 - 315 within workflow application 230 . Each workflow process 305 - 315 interfaces with DSE 200 through API 215 . An application developer can use API 215 to specify one or more external data sources and submit a query to DSE 200 . The term “data source” includes without limitation any medium used to store structured data or any computer program operable to retrieve data from such a structured data storage medium, such as a file, database, memory, data mining application, database server, or application server. In FIG. 3 , database 320 , data mining application 325 , internet web services 330 , and application service provider 335 all are exemplary data sources.
[0021] FIG. 4 provides a detailed illustration of the interaction between a workflow process and DSE 200 . Workflow process 410 , which may be any of the workflow processes 305 - 315 depicted in FIG. 3 and described above, submits a query, which also identifies one or more external data sources, to DSE 200 through API 215 ( 415 ). Query manager 210 receives the query and extracts the identity of each data source 420 , which may include any of the data sources 320 - 335 depicted in FIG. 3 and described above ( 425 ). Connection manager 205 then opens a connection to each data source 420 ( 430 ). Query manager 210 next relays the query to each data source 420 ( 435 ), which processes the query and returns the results to query manager 210 . Finally, query manager 210 relays the results to workflow process 410 through API 215 ( 440 ).
[0022] A preferred form of the invention has been shown in the drawings and described above, but variations in the preferred form will be apparent to those skilled in the art. The preceding description is for illustration purposes only, and the invention should not be construed as limited to the specific form show and described. The scope of the invention should be limited only by the language of the following claims.
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The invention comprises a new and useful process, and appurtenant apparatus, for developing and using workflow applications with decision support. Specifically, the invention includes a decision support engine and a programmatic interface thereto. The decision support engine is a middleware computer program that receives queries from a workflow application, connects to external data sources, executes queries, and returns query results to the workflow application. The programmatic interface allows a developer to integrate business logic and queries into a workflow application that supports decision-making.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an actuator element comprising a housing, a drive arranged in the housing, a movably mounted rod operatively connected to the drive to execute a force transmitting movement, and at least one means for detecting position, and to a modular system for producing an actuator element according to the invention.
[0002] Actuator elements for operating actuator devices such as flap valves, rotary slide valves or other valves are known in the prior art. For many applications, it is necessary to detect and monitor at least the end positions of a piston rod, which is connected to the drive of the actuator element. It is known from EP 0 345 459 B1 that an electric switch, which can be operated as a function of the position of the piston rod in relation to the housing, may be provided inside a pressure chamber of a pneumatic actuator element. When the piston rod reaches a predetermined position, the switch is actuated and thus delivers an electric signal. The switch is intentionally located in the pressure chamber of the pneumatic actuator element to thus be protected from soiling and corrosion due to corrosive media. Likewise, those skilled in the art are familiar with actuator elements with which the position detection is performed based on the reduction in the signal of a loop potentiometer.
[0003] One disadvantage of these solutions is the susceptibility of this contact-controlled end position detection to wear as well as the resulting susceptibility from the standpoint of a reliable signal output. Likewise there is the risk of corrosion of the contacts or the loop contacts of the potentiometer, especially in contact with chemicals or corrosive material. Another disadvantage of the loop potentiometer is the temperature drift that occurs with large changes in temperature and the consequent unreliability of the signal output.
SUMMARY OF THE INVENTION
[0004] Accordingly, it is the object of the invention to provide an improved actuator element with integrated position detection.
[0005] Another object of the invention is to provide an actuator element with integrated position detection, which will have a simple design.
[0006] A further object of the invention is to provide an actuator element with integrated position detection which avoids abrasion or frictional wear.
[0007] Yet another object is to provide an actuator element with integrated position detection which can be adapted for use in a wide spectrum of applications by simply replacing a few parts.
[0008] A still further object of the invention is to provide an actuator with integrated position detection which not only detects actuator element end positions, but also is capable of detecting positions along the path between the end positions.
[0009] These and other objects are achieved in accordance with the present invention by providing an actuator element comprising a housing, a drive situated in the housing, a rod movably mounted in the housing and operatively connected to the drive for executing a force transmitting movement, and a position detector; the position detector comprising at least one stationary Hall sensor and at least one magnet that is movable relative to the Hall sensor in response to motion of the rod and that produces a magnetic field for generating a magnetic flux in the Hall sensor.
[0010] In accordance with a further aspect of the invention, the objects are achieved by providing a modular system for producing actuator elements for driving actuator devices wherein individual parts can be combined freely with one another and actuator elements with or without position detection and with or without conversion of translational force to rotational force are produced by different combinations of parts, the modular system comprising: a housing with a drive; at least two rods with means for selective connection to the drive and that are movably guidable in the housing, the at least two rods comprising a first rod bearing at least one magnet and a second rod without a magnet; at least two rotatable disks with means for selective connection to one of the rods such that translational movement of the rod is converted to rotational movement of the disk, the at least two rotatable disks comprising a first disk bearing at least one magnet and a second disk without a magnet, and at least one Hall sensor for selective arrangement in a stationary mount in the housing for detecting translational movement of the rod which bears a magnet or for detecting rotational movement of the rotatable disk which bears a magnet.
[0011] The inventive actuator element has a housing with a drive situated in it and at least one means for position detection, in which a rod, e.g. a piston rod, mounted movably in the housing is appropriately connected to the drive to exert an acting force. The means for position detection in this case comprises at least one Hall sensor in a stationary configuration and at least one magnet movable relative to the Hall sensor. The magnetic field created by the magnet generates a magnetic flux through the Hall sensor as a function of the position of the magnet in relation to the Hall sensor. The drive is preferably constructed as a vacuum housing with a diaphragm, i.e., a pneumatic design, but it may also be based on an electric, mechanical or hydraulic design. The structure of the actuator element in this case may be made entirely of plastic, or of a mix of plastic and metal materials, or it may be made entirely of metal.
[0012] The rod which is movably mounted in the housing preferably has a square cross section, but it may also have a circular, oval or polygonal cross section without any restriction. Likewise it may also be straight or curved. It is correspondingly connected to the drive, and the connection may also be of a detachable or non-detachable type. It is also possible to construct the connection via an intermediate gear or switching gear or some other type of force transfer.
[0013] In the inventive actuator element, the position detection may be realized as a non-contact detection by a Hall sensor stationarily mounted in or on the housing with at least one corresponding movable magnet. The magnetic field generated by the magnet creates a magnetic flux through the Hall sensor as a function of the position of the magnet in relation to the Hall sensor and therefore creates a modified signal at the output of the Hall sensor. Since the output Hall voltage is proportional to the magnetic induction, Hall sensors are used to measure magnetic fields.
[0014] Known Hall sensors have either an analog or a digital signal output and some of them are fully programmable, so that any temperature drift or other interfering quantities can be eliminated through the programming and in terms of their functioning they can be regarded as non-contact potentiometers. Due to their type of mounting, Hall sensors can accommodate translational movement sequences including the endpoints thereof as well as rotational movement sequences including the endpoints and angular position. This is accomplished by the changing magnetic field and magnetic flux as the magnet approaches or retreats from the sensor.
[0015] The advantages of this invention can be seen very clearly in the non-contact detection of the change in position and the increased field of potential use which can even include aggressive media and large temperature fluctuations. Due to the non-contact position detection, mechanical wear is completely avoided so that the reproducibility and longterm durability and the resistance to interference are greatly increased. In addition, the technical complexity of this inventive solution is lower than in the prior art because the position detection takes place within the actuator element independently of the drive and thus can be adapted to a wide variety of possible drives. Examples include pneumatic actuators for rotary valves or switching valves. Likewise, a pneumatic drive for a central lock system in automotive engineering would also be conceivable as well as many other embodiments in which an actuator element is needed for adjustment of an actuating device with the need for position detection.
[0016] In one advantageous embodiment of this invention, the piston rod is correspondingly connected to a shaft by at least one rotatable disk and thus converts a translational movement of the piston rod into a rotational movement of the shaft. This is comparable, for example, to the crank drive of a bicycle in which a substantially translational movement of the leg with respect to the pedal is converted into a rotational movement on the chain drive. Due to the fact that the piston rod is movably connected in the housing and correspondingly connected to the drive of the actuator element, it is possible for the piston rod to permit a certain angular offset to thereby follow an approximately circular path of the connecting point between the piston rod and the rotatable disk in the outer area of the rotatable disk. However, it is also conceivable for this conversion to take place by way of a type of translation gear, which converts the translational movement into a rotational movement.
[0017] The shaft driven in this way may turn, for example, a switch valve, a switch valve connection or a rotatable disk within a certain angular range. However, other possibilities are also conceivable, where a transmission of force through a rotational movement is necessary. The rotatable disk may be in the form of an essentially circular disk based on volume, but here again, the design possibilities are almost unlimited. Thus the rotatable disk may also have an angular or oval shape and in the extreme case it may even consist of only one articulated shaft. The kinematic conversions required for this are well known to persons skilled in the art and thus do not require any further examples here.
[0018] According to one advantageous embodiment of this invention, the Hall sensor of the position detection device is detachably situated in the housing of the actuator element. This includes the fact that means by which the Hall sensor is detachably connected via a detachable connection such as a screw connection, a clip connection or a strict plug connection as well as any other types of connections known in the state of the art are provided in the housing and correspond to the Hall sensor. This has the advantage in particular of making the use of the Hall sensor optional. In addition there is the possibility of attaching the Hall sensor to several mounting points provided in the housing depending on the intended use and the conditions of use at various points in the housing for position detection.
[0019] In an alternative embodiment, the Hall sensor is non-detachably situated in the housing of the actuator element. Therefore, the Hall sensor is attached to the housing at the mounting point in the housing provided for that purpose by an adhesive joining method or a welding method or some other means known in the state of the art for non-detachable connection of two elements. Due to this non-detachable connection, possible errors due to a change in position of the Hall sensor, e.g., due to vibration and the consequent corrupted signal output can be minimized or avoided.
[0020] According to one specific embodiment of this invention, at least one flux guide plate is situated on the Hall sensor to amplify the magnetic flux of the magnet, which is movably mounted, and this flux guide plate essentially overlaps the poles of the magnet in predetermined positions. With the help of this flux guide plate, the magnetic flux can be amplified by a factor in the hundreds, which results in a higher precision of the position detection and a greater insensitivity to external influences such as contamination due to soiling or oil. This flux guide plate is correspondingly connected to the Hall sensor and covers at least a partial area of the path of the magnet that is movably guided in the housing in the change in position due to the piston rod. The shape of the flux guide plate is preferably that of a U shape, with the two legs of the U overlapping the north and south poles, respectively, of the magnet at at least one point along the magnet's path of movement.
[0021] In another embodiment of this invention, at least one magnet is situated on the rod and the Hall sensor detects the transitional change in position of the rod. In this case the at least one magnet is preferably integrated into the piston rod so as to yield the least possible hindrance on the magnetic flux. The magnet here can be integrated into recesses in the piston rod and attached to it by detachable or non-detachable connecting means. The magnet here preferably has a cylindrical shape or a rod shape, but other shapes are also conceivable and technically feasible. The magnet executes a relative movement in relation to the stationary Hall sensor when the drive is actuated and the piston rod moves accordingly, so a different signal for identifying the change in position and/or for detection of the end position is output by the Hall sensor due to the change in magnetic flux as a function of the position of the magnet.
[0022] According to yet another embodiment of this invention, at least one magnet is situated on the rotatable disk, and the Hall sensor detects the change in rotational position of the shaft. The Hall sensor here is in a stationary mount in the housing so that it can pick up a change in position of the rotatable disk and the shaft connected to it accordingly due to the resulting change in magnetic flux corresponding to a change in position of the magnet due to rotation of the rotatable disk. It is thus simple to detect angles of rotation starting from a zero position of the driven shaft. The preferred application here is for rotary slide valves, which are connected to the shaft, or switch valves or switch valve walls, but other applications are also possible and conceivable in which the position of the shaft and the angle of rotation of the shaft are of relevance for an analysis.
[0023] When using a programmable Hall sensor, there is also the possibility of a two-point calibration with the function test including the component to be switched. This is possible, for example, directly at the end of the production line in manufacturing and thus greatly increases the time and cost efficiencies. The actuator element including the component to be switched can thus be calibrated easily and advantageously, which results in a high relevance of the results. The data output by the Hall sensor may thus be forwarded to the engine controller in the motor vehicle, for example, thereby meeting the requirements of on-board diagnosis (OBD) which is required in modern vehicles to comply with emission regulations and to achieve redundancy. The at least one magnet provided on the rotatable disk can be detachably or non-detachably connected to the rotatable disk. Movement of the magnet relative to the stationary Hall sensor due to the rotational motion of the rotatable disk causes a change in magnetic flux. The shape of the magnet has no effect on the function of position detection.
[0024] According to another embodiment of this invention, the Hall sensor for detection of predetermined positions has an output for a digital signal. This makes it possible to easily detect, for example, the end positions of the motion and output a signal indicating they have been reached. In this case the Hall sensor functions like a simple end position detection device and thus replaces the closing contact known in the prior art. Thus almost any end position and position detection can be implemented as a function of the signal strength and possible programming of the Hall sensor.
[0025] In accordance with still another embodiment of this invention, it is likewise possible for the Hall sensor to have an output for an analog signal for detection of changes in position. In this case, the signal output changes as a function of the change in the magnetic flux. This change occurs as soon as the at least one movable magnet moves relative to the stationary Hall sensor. Thus, with the help of an analyzer logic unit, either constructed in the Hall sensor or provided externally, any point of movement of the piston rod or the rotary slide valve can be detected and output. This possibility thus also permits conclusions regarding the instantaneous position between the two end positions.
[0026] Another possibility of realizing the inventive actuator element is to construct the individual variants in a modular system. Using such a modular system, it is possible to manufacture actuator elements for driving actuator devices, in which the individual parts of the modular system can be combined freely with one another and in which the different combinations yield actuator elements with or without position detection and with or without force transfer or conversion of translational force to rotational force. In such modular systems, the design options vary from a simple actuator element with a piston rod which exerts a translational force to an actuator element with a piston rod appropriately connected to a rotatable disk to convert the acting force from a translational movement to a rotational movement, with position detection in which the position detection detects the entire movement sequence. The modular system includes a housing with a drive, at least two movable piston rods that can be optionally used and are guided in the housing, at least two rotary slide valves for corresponding optional connection to the piston rods, and at least one Hall sensor.
[0027] The at least two piston rods include at least one piston rod which does not have any magnet and at least one piston rod which is equipped with at least one magnet. The piston rods may be identical with regard to their actual design shape and they may differ only in the subsequent introduction of at least one magnet. Thus it is also possible for the modular system to have at least two identical piston rods and in addition at least one magnet to be included for subsequent mounting on one of the piston rods.
[0028] The at least two rotatable disks differ from one another, as is the case with the piston rods, in the arrangement of at least one magnet on one of the rotatable disks. Here again the two rotatable disks may be identical in configuration and the at least one magnet may be situated subsequently on one of the two rotatable disks. Thus, it is possible for the user to appropriately connect the rotatable disks to the piston rods with or without a magnet depending on the choice in order to thereby realize the conversion of translational force to rotational force with position detection. In addition, it is possible for the rotatable disks to be connected to a shaft, e.g., for a rotary slide valve or a switching valve assembly.
[0029] Through the use of different fastening points preselected in the housing, it is possible optionally to mount the at least one Hall sensor stationarily in the area of the path of movement of the piston rod or in the area of the path of movement of the rotatable disk. Use of the Hall sensor here is adaptive and preferably occurs, of course, in combination with either the piston rod equipped with the at least one magnet or with the rotatable disk equipped with at least one magnet.
[0030] These and other features of preferred embodiments of the invention, in addition to being set forth in the claims, are also disclosed in the specification and/or the drawings, and the individual features each may be implemented in embodiments of the invention either alone or in the form of subcombinations of two or more features and can be applied to other fields of use and may constitute advantageous, separately protectable constructions for which protection is also claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention will be described in further detail hereinafter with reference to illustrative preferred embodiments shown in the accompanying drawing figures in which:
[0032] [0032]FIG. 1 is a schematic view of an actuator element with position detection and force transfer,
[0033] [0033]FIG. 2 shows a sectional view of the force transfer according to A-A in FIG. 1,
[0034] [0034]FIG. 3 shows a schematic view of an actuator element with position detection without force transfer,
[0035] [0035]FIG. 4 shows a schematic view of an enlargement of the position detection device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] [0036]FIG. 1 shows a schematic view of an actuator element 10 , constructed in this case as a vacuum actuator element, with a vacuum connection 11 which is connected to a vacuum chamber 12 with a spring 13 disposed therein. The vacuum chamber is formed by a housing top part 14 , which is connected to a housing bottom part 15 with a seal. The spring 13 is supported at one end against the housing top part 14 and on the other side against a spring support 16 which is connected to a piston rod 17 .
[0037] The piston rod 17 is movably guided out of the housing bottom part 15 in the lower area thereof, and the vacuum chamber 12 is separated from the environment by a diaphragm 18 with a seal. The diaphragm 18 and the spring support 16 are joined together so that when a vacuum is applied, the piston rod 17 is pulled toward the housing top part 14 against the force of the spring 13 .
[0038] At its lower end, the piston rod 17 has a transverse bore 19 through which a pin 20 passes. Pin 20 is rotatably mounted eccentrically in a rotatable disk 22 . To secure the pin 20 in the through-bore 19 , a locking ring 21 is installed on the end of the pin 20 . The rotatable disk 22 is fixedly joined concentrically to a shaft 23 , and the shaft is mounted by a ball bearing 24 . Due to the tight connection between the rotatable disk 22 and the shaft 23 , a rotational force can be transmitted from the rotatable disk to the shaft. Along the remaining course of the shaft 23 a rotary slide valve or a switching valve assembly which is rotatably actuated, for example, can be connected. Since the piston rod 17 is movably mounted in the housing bottom part 15 , in the lower area it can follow the circular path of the pin 20 attached to the rotatable disk 22 , so that the rotatable disk 22 and the shaft 23 connected to it can be made to execute a rotational movement as a result of an upwardly directed translational movement of the rod 17 .
[0039] In the upper area of the piston rod 17 , two magnets 25 a and 25 b are situated. They are embedded in the piston rod 17 and are fixedly connected to it. A Hall sensor 26 is arranged at a fixed location in the housing at the level assumed by the magnet 25 a when the piston rod 17 is in its lowermost position. The Hall sensor is connected by a closed conduit for a conductor cable 27 to an output plug 28 . The system comprised of the Hall sensor 26 , the conduit 27 for a conductor cable and the output plug 28 is inserted in direction X into and clipped in a clip opening 29 provided in an upper area of the bottom part 15 of the housing. With this design of the actuator element 10 , it is possible either to detect the two end positions of the piston rod 17 via Hall sensor 26 with a digital output or to record the entire path of the piston rod 17 via a Hall sensor 26 with an analog output signal.
[0040] The lower end position of the piston rod 17 is characterized in that the magnet 25 a here is at the level of the stationary Hall sensor 26 . The upper end position of the piston rod 17 is reached as soon as the magnet 25 b is at the level of the Hall sensor 26 . Since the Hall sensor 26 responds to a change in the magnetic field strength and/or the magnetic flux, it emits an end position signal on reaching the highest magnetic field strength. The highest magnetic field strength is reached as soon as the magnet is exactly at the height of the Hall sensor.
[0041] The simple design of the inventive actuator element is clearly discernible here. Due to the arrangement of the Hall sensor 26 and the magnets 25 a and 25 b outside of the pressure chamber 12 , a pneumatic drive having a very small structural height can be achieved. The noncontact sensing has proven to be especially advantageous in this situation because this area is necessarily not entirely free of contamination and/or corrosive media.
[0042] If a Hall sensor with an analog output is used in this arrangement, then the precise path of the piston rod 17 can be followed based on the reduction in, the magnetic field strength between the two magnets 25 a and 25 b . These values can then be analyzed, for example, by an engine control unit and then incorporated into the calculation, for example, of an engine characteristic curve.
[0043] [0043]FIG. 2 shows section A-A as a lateral plan view of the rotatable disk 22 . Parts corresponding to FIG. 1 are identified by the same reference numbers. In this view it can be seen that the rotatable disk 22 is situated concentrically on the shaft 23 and is connected to it in a rotationally fixed manner. The connecting pin 20 between the piston rod 17 and the rotatable disk 22 is eccentrically positioned and thus causes the rotatable disk 22 and the shaft 23 which is connected to it, to rotate when the piston rod 17 executes a translational movement.
[0044] [0044]FIG. 3 shows a schematic view of a variant of the inventive actuator element 10 . Once again, parts corresponding to in FIG. 1 are identified by the same reference numbers. This pneumatic actuator element 10 differs from the actuator element 10 in FIG. 1 in that in this case there is no conversion of the translational movement of the piston rod 17 into a rotational movement of a shaft 23 . Another important difference is that in this case only one magnet 25 is provided on the piston rod 17 . When the Hall sensor has a digital design, only the end position of the piston rod 17 is detected via the Hall sensor when the actuator element 10 is acted upon by a vacuum. As soon as the magnet 25 is brought into overlapping position with the Hall sensor 26 due to displacement of the piston rod 17 toward the housing top part 14 , the Hall sensor outputs a signal that the actuator has reached the end position. The actuator element 10 in FIG. 3 is shown in the second end position of the piston rod 17 , which is limited mechanically by the walls of the housing bottom part 15 . This is a simple variant of the inventive actuator element. Alternatively, by using a Hall sensor 26 which has an analog output in this arrangement, the position of rod 17 can be detected along its entire course. In this case, the strength of the magnetic field increases continuously up to the end stop in the form in which it is acted upon by a vacuum. If the Hall sensor 26 is suitably programmed and calibrated, even this simple form can achieve a controlled recording of the path of the rod. If it is not possible to mount an enclosed conduit 27 for a cable on the housing due to space reasons, then it is likewise possible with all variants to work with an exposed cable and to arrange the output plug 28 on another component near the actuator element.
[0045] [0045]FIG. 4 shows a schematic view of an enlargement of the Hall sensor with flux guide plates mounted on it. Parts that correspond to those in FIG. 1 are identified by the same reference numbers. In FIG. 4 the piston rod 17 moves into the plane of the paper and the system for position detection is shown in a sectional view taken through the Hall sensor 26 . It can be seen here that a sensor housing 31 having an output plug 28 has been clipped into a corresponding receptacle on the housing bottom part 15 . The Hall sensor 26 and two flux guide plates 30 are embedded in the sensor housing 31 . It can be seen here that in this position, the flux guide plates 30 completely overlap the magnet 25 integrated in the piston rod 17 . The magnetic flux emitted by the magnet 25 is amplified by the flux guide plates 30 by a factor in the hundreds, thus increasing the sensitivity of the Hall sensors 26 to a change in the magnetic flux to the same extent. Upon movement of the piston rod 17 into or out of the plane of the paper, the resulting change in the magnetic field strength produces a different magnetic induction in the Hall sensor 26 and thus an altered output signal at the output plug 28 . The presence of the flux guide plates 30 is optional, however, and is not absolutely necessary for detecting an altered magnetic field strength due to a movement of the piston rod 17 . The flux guide plates 30 are used to increase the magnetic field and thus entail the possibility of using a less sensitive Hall sensor 26 with the cost advantages associated with that.
[0046] The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations within the scope of the appended claims and equivalents thereof.
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An actuator element suitable, for example, for actuating a rotatable disk or a flap valve shaft. The actuator includes a housing, a drive situated in the housing, and at least one position detector, in which a movably mounted piston rod in the housing is operatively connected to the drive for exerting a force effect, and in which the position detector includes at least one stationary Hall sensor and at least one magnet movable relative to the Hall sensor such that the magnet produces a magnetic field for generating a magnetic flux.
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FIELD OF THE INVENTION
The invention relates to the general field of MEMS structures with particular reference to cantilever beams.
BACKGROUND OF THE INVENTION
MEMS (micro electromechanical systems) sensors and actuators, such as accelerometers, pressure sensors, and gyroscopes are manufactured using either a bulk micromachining process or a surface micromachining process. “Bulk” micromachining refers to structures formed by deep anisotropic etching. “Surface” micromachining refers to structures formed from thin film layers deposited or grown on the surface of a substrate. Surface micromachining has advantages over the previous bulk micromachining process of fabricating IC sensors and actuators because it permits smaller devices and may be integrated with other circuits on an IC (integrated circuit). One form of bulk micro-machining typically involves etching in a silicon substrate deep trenches between 10 microns to 100 microns deep. The resulting silicon structures (called “beams”) are partially released (i.e., detached) from the silicon substrate by known processes such as wet or dry etching. This deep trench technology is described, for example, in Klaassen, et al. “Fusion Bonding and Deep Reactive Ion Etching: A New Technology for Microstructures”, Transducers '95, Stockholm, Sweden, 1995. The contents of this article are incorporated herein by reference.
A variety of methods that have been discussed in the literature have been devised for fabricating micromachined structures such as accelerometers. However, most such processes require multiple masking steps, wafer-to-wafer bonding, or the use of wet chemistry. It has been found, however, that the use of such multiple masks and bonding techniques can introduce alignment errors, which reduce yield and increase device cost, making such processes unsuitable for submicron structures.
A routine search of the prior art was performed with the following references of interest being found:
U.S. Pat. No. 5,930,595 (Isolation process for surface micromachined sensors and actuators) discusses a method of fabricating MEMS sensors/actuators using a process wherein deep trenches are etched and released beams formed by using oxide spacer to protect beam sidewall. The key feature of this patent is that it provides a novel method of forming trenches which are filled with isolation oxide so as to form silicon islands on three sides while the fourth side is connected to the sensor/actuator beams. Recently, another patent application has been filed in IME, namely, “A High Aspect Ratio Trench Isolation Process for Surface Micromachined Sensor and Actuators (PAT00-005/MEMS001)” which uses a novel process to form an isolation island that can be used in fabrication of MEMS sensors/actuators.
U.S. Pat. No. 5,563,343 describes a method of fabricating accelerometers utilizing a modified version of the Single Crystal Reactive Etching. And Metallization (SCREAM) process which is also described in U.S. application Ser. No. 08/013,319, filed Feb. 5, 1993. As stated in that application, the SCREAM-I process is a single mask, single wafer, dry etch process which uses optical lithography for fabricating submicron micro-electromechanical devices. In that process, a silicon dioxide layer is deposited on a single crystal silicon wafer, this oxide layer serving as the single etch mask throughout the process. Photolithography is used to pattern a resist, and then dry etching, such as magnetron ion etching, is used to transfer the pattern of the accelerometer structure into the oxide. Once the resist material is removed, the patterned oxide masks the silicon substrate to allow a deep vertical silicon RIE (reactive ion etching) on exposed surfaces to produce trenches having predominately vertical side walls and which define the desired structure.
Next, a conformal coating of PECVD oxide is deposited for protecting the side walls of the trenches during the following release etch. The trench bottom oxide is removed within an isotropic RIE, and a second deep silicon trench etch deepens the trenches to expose the sidewall silicon underneath the deposited side wall oxide. The exposed silicon underneath the defined structure is etched away, using an isotropic dry etch such as an SF6 etch to release the structure and leave cantilevered beams and fingers over the remaining substrate. In the SCREAM-I process, aluminium is deposited by sputtering to coat the sidewall of the released beams and fingers to thereby form the capacitor plates for the accelerometer.
In U.S. Pat. No. 6,035,714, a high sensitivity, Z-axis capacitive micro-accelerometer having stiff sense/feedback electrodes and a method of its manufacture are provided. The micro-accelerometer is manufactured out of a single silicon wafer and has a sili-con-wafer-thick proofmass, small and controllable damping, large capacitance variation and can be operated in a force-rebalanced control loop. The multiple stiffened electrodes have embedded therein-amping holes to facilitate both force-rebalanced operation of the device and controlling of the damping factor. Using the whole silicon wafer to form the thick large proofmass and using the thin sacrificial layer to form a narrow uniform capacitor air gap over a large area provide large capacitance sensitivity. The structure of the micro-accelerometer is symmetric and thus results in low cross-axis sensitivity.
In U.S. Pat. No. 5,660,680, a method of forming polysilicon structures using silicon trenches with partially trench-filled oxide as molds has been described. The oxide layer acts as the sacrificial layer to release the polysilicon structures.
BOSCH Polysilicon (Epi-poly) process: This process makes use of thick epitaxial polysilicon (20-30 microns) grown on a silicon substrate. This poly layer is then used in forming beams of various depths for forming MEMS structures. This process uses an epi reactor and hence is quite expensive. For thick poly, residual stress is still a potential issue.
Additional references of interest were:
U.S. Pat. No. 6,133,670 (Rodgers) shows a poly beam (finger) in a MEMS device. In U.S. Pat. No. 6,175,170 B1, Kota et al. show another poly finger MEMS device and process while, in U.S. Pat. No. 6,171,881 B1, Fujii shows another MEMS device.
SUMMARY OF THE INVENTION
It has been an object of the present invention to provide a cost-effective process for manufacturing IC sensors and/or actuators that completely electrically isolates the sensor beams from the substrate that supports them.
Another object of the present invention has been to provide a process for manufacturing IC sensors and/or actuators that have low parasitic capacitance.
Yet another object of the present invention has been to provide a process for manufacturing IC sensors and/or actuators that is compatible with CMOS processes.
These objects have been achieved by providing a process which makes use of polysilicon beam as the structural material instead of single crystal silicon for the fabrication of MEMS sensors/actuators. The invention describes the process for fabricating suspended polysilicon beams by using deep trenches etched into silicon substrate as molds to form polysilicon beams. The polysilicon beams are subsequently released by isotropically etching away the silicon surrounding the polysilicon beams. This results in free standing polysilicon members, which form the MEMS structures. In addition to the general process, three approaches to making electrical contact to the beams are presented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 illustrate how trenches may be etched, lined with insulation and then filled with polysilicon.
FIGS. 5 and 6 illustrate how a mask is used to etch a cavity around the filled trenches.
FIGS. 7 and 8 are cross-sectional views of the cantilever beams that are formed after the pedestals are released from the cavity floor.
FIG. 9 is a plan view of which FIG. 8 is a cross-section.
FIG. 10 illustrates the first of three embodiments that teach how electrical contact may be made to the cantilever beams.
FIGS. 11 and 12 show two steps in implementing the second of three embodiments that teach how electrical contact may be made to the cantilever beams.
FIG. 13 illustrates the last of the three embodiments that teach how electrical contact may be made to the cantilever beams.
FIGS. 14-15 illustrate the formation of the busbar island area.
FIG. 16 is a plan view of three silicon beams connected through a busbar mask.
FIGS. 17-19 illustrate steps in the formation of the busbar island mask.
FIG. 20 illustrates beam release within the busbar island area.
FIG. 21 shows how space between the beams of FIG. 20 gets filled with oxide.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Most of the prior art described above make use of a deep trench etch process to define the beams and subsequently release the silicon beams while using oxide spacers to protect the sidewalls. This press has the following limitations:
It is difficult to get a conformal spacer layer for high aspect ratio trenches (>20). This makes it difficult to protect beam sidewalls during pre-release and final release etch. This makes the beam sidewall very irregular due to ‘mouse bites’ at these sites. In order to solve this problem, thicker spacer oxide is deposited. This in turn compels designers to widen the trench openings thus reducing the sensitivity of the actuator/sensor.
The release etch process after releasing the beams, further erodes the beam thus reducing the beam depth. This results in Joss of beam depth across the wafer. The sidewall spacer also hangs like a tail where the beams have been encroached. This oxide tails act as a potential sources of contamination due to their flimsy nature. During operation they may even break off and be redeposited between the sensing fingers, causing devices to behave unpredictably.
In the case of the SCREAM process, a metal layer is deposited over the beams to make the sensor/actuator beams conductive. However, it is not possible to get conformal aluminum deposition inside deep trenches.
We now provide a detailed description of the process of the present invention, presented as four embodiments thereof:
1 st Embodiment (general process)
Referring to FIG. 1 we show there a schematic cross-section of solid body 11 (preferably, but not necessarily, of silicon, with other possibilities including other semiconductors and metals such as aluminum, copper, gold, etc. in which deep trenches such as 12 have been etched to a depth between about 60 and 70 microns. As shown in FIG. 2, the floors and sidewalls of these trenches are then coated with a layer of an insulating material 21 which could be any of several possible materials such as silicon oxide, silicon nitride, etc., with silicon oxide being preferred.
The trenches are then just filled (by overfilling and then planarizing) with one or more layers of conductive material. Although only a single conductive filling material such as polysilicon, aluminum, copper, gold, etc. could be used, our preferred process has been to first under-fill with low resistivity (achieved by doping with phosphorus oxychloride) polysilicon layer 31 followed by overfilling with polysilicon layer 32 , as shown in FIG. 3 . Layer 31 of polysilicon is deposited to a stress level that is below about −1×10 8 dynes per sq. cm while the second layer of polysilicon is deposited to a stress level that is below this. The first deposited layer of polysilicon had a resistivity between about 10 and 12 ohm-cm while the second layer of polysilicon had a resistivity between about 11 and 13 ohm-cm, after an annealing cycle to distribute the phosphorus uniformly across the thickness of the polysilicon.
It is also possible, in principle to fill the trenches with a magnetic material for use in, for example, detecting and measuring magnetic fields. In general, filling of the trenches with conductive material may be implemented using any of the known methods for doing so, including chemical vapor deposition, physical vapor deposition, and electroplating.
The next step, as illustrated in FIG. 4, is the deposition of insulating layer 41 over the entire surface. A mask 51 is then formed on the surface of layer 41 . This mask serves to protect the filled trenches 31 / 32 as well as to define an opening, said opening being disposed so that the filled trenches lie partly inside and partly outside it. Then, through mask 51 , conductive body 11 is etched to form a cavity 61 (see FIG. 6) that extends downwards to a depth between about 75 and 80 microns so that it is greater than the depth of the filled trenches, resulting in the formation of pedestals.
With mask still in place, all exposed conductive material is removed, using a release etch, which results in the formation of cantilever beams 71 , as shown in FIG. 7 (seen following the removal of mask 51 ). This is followed by the selective removal of all exposed insulating material as shown in FIG. 8 . FIG. 9 is a plan view, with FIG. 8 being a cross-section made through 8 — 8 . As can be seen in this example, four cantilever beams 31 / 32 extend away from conductive body 11 and are suspended within cavity 61 . They are physically embedded in conductive body 11 but are electrically insulated from it by insulating layer 21 .
Three different ways of then making electrical contact to the beam are the basis for the next three embodiments:
2 nd Embodiment (busbar island formation)
This embodiment uses the general process of the first embodiment with the following additional steps:
We refer now to FIG. 14 which is a plan view of the cross-section shown in FIG. 18 . Prior to starting the general process, layer of silicon oxide 97 (see FIG. 18) is deposited on the upper surface to a thickness between about 2 and 3 microns and then patterned to form a busbar island mask. Silicon substrate 11 is then etched to form trenches 98 to a depth between about 60 and 70 microns.
Layer of silicon oxide 96 (5-7,000 Å thick) is deposited and then etched-back using RIE as shown in FIGS. 18 and. Using an isotropic release etch silicon beam 99 is released to form the suspended silicon beams 100 as shown in FIGS. 20 and 21.
Later, silicon oxide is deposited to fill the trenches as shown in FIGS. 15 and 16. Using contact mask 102 and metal mask 103 , an electrical connection is made between the interconnect metal and busbar silicon 100 on polysilicon beam 31 / 32 as seen in FIGS. 10 and 16.
Finally, mask 51 is opened to etch silicon that is surrounding the polysilicon beams to form cavity 61 as shown in FIGS. 5 to 7 .
3 rd Embodiment (liner oxide isolation)
This embodiment uses the general process of the first embodiment with the following additional steps:
Referring now to plan view FIG. 11, at the time of forming the trenches that are to act as molds for the cantilever beams, an additional trench 111 is formed. This trench touches the other trenches (three in this example) and is at right angles to them. When cavity 61 is formed it is positioned so that trench 111 lies outside the opening 61 while trenches 31 / 32 lie entirely inside the opening (see FIG. 12 ). The liner oxide of the first embodiment is used as electrical insulation between the polysilicon inside trench 111 and silicon substrate 11 . Liner oxide 21 is shown in FIGS. 11 and 12. After depositing oxide layer 41 , as shown in FIG. 4, a contact window is opened on the polysilicon 111 . Later, metall is deposited and patterned ( 103 ) as shown in FIG. 10 . Finally, mask 51 is etched and silicon surrounding polysilicon beams 31 / 32 is etched to form 61 , as shown in FIGS. 7 and 8.
4 th Embodiment (oxide bar lateral isolation)
This embodiment uses the general process of the first embodiment but begins with the formation of a single trench to a depth between about 60 and 70 microns that is then just filled with silicon oxide. This is shown in FIG. 13 as trench 131 . In a similar manner to the third embodiment, one or more trenches 31 / 32 that run at right angles to the oxide filled trench are then formed, as shown in FIG. 13 . These touch the oxide filled trench and are used for the formation of the polysilicon beams as in all the previous embodiments. Before the lafter are formed, a metallic contact pad 132 that lies on trench 131 is formed. Said pad has ‘fingers’ that extend outwards part way along each beam's top surface in order to make electrical contact.
The four embodiments described above have been found to exhibit the following characteristics:
Compressive stress for low stress polysilicon after deposition was about −1.28×10 8 dynes/cm 2 . After POCl 3 doping, the second polysilicon deposition, and a final anneal, it dropped to about −2.69×10 7 dynes/cm 2 . The sheet resistance of the polysilicon after anneal was about 12.97 ohms/square.
In summary, the invention that we have described above offers the following advantages over the prior art:
(i) It is possible to achieve deep polysilicon beams with low residual stress as the polysilicon beams are formed by folding the film vertically.
(ii) Very large thicknesses of polysilicon beams can be achieved by depositing only between 1 to 3 micron thick polysilicon films. This results in low cost of production. In contrast, thick polysilicon beams have been traditionally achieved by thick depositions and etching the polysilicon away from the required structures (see, for example, the Bosch process).
(iii) Beam depth is uniform across the wafer as the beams are formed from a silicon mold.
(iv) No spacer oxide-tail issue arises in this process, as compared to the SCREAM or LISA processes. The present invention is CMOS compatible and hence can be integrated with a CMOS processes.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.
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A process has been described which makes use of polysilicon beam as the structural material instead of single crystal silicon for the fabrication of MEMS sensors/actuators. The invention describes the process for fabricating suspended polysilicon beams by using deep trenches etched into silicon substrate as a kind of a mould to form polysilicon beams. The polysilicon beams are subsequently released by isotropically etching away the silicon surrounding the polysilicon beams. This results in free standing polysilicon members, which form the MEMS structures. In addition to the general process, three approaches to making electrical contact to the beams are presented.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to machines which lay out spaced assemblies of textile yarns or similar fiber structures. The general field would include conventional looms and knitting machines along with more specialized equipment such as that described in U.S. Pat. No. 4,249,981 to Pelletier. However, unlike the vast majority of such machines, this invention relates to laying out yarn arrays which are eventually incorporated into a continuous web in which the yarns are neither parallel nor perpendicular to the edges of the web but inclined at an angle thereto between ten and eighty degrees. This invention is particularly adapted to laying out yarns which are kept substantially straight and are not woven, knitted, sewn, or otherwise regularly distorted from a straight path, except to the extent necessary at the edges of the web to form a selvage or similar structure.
This invention is most particularly adapted for laying out straight laid narrowly multidirectional yarn arrays such as are disclosed in an application for United States Patent entitled "Improved Joining Tape and Process Therefor" by applicants Dhiraj H. Darjee and Daniel E. Devine, filed on the same date as this application and assigned to the same assignee as this application under Ser. No. 672,988.
As outlined in more detail in said application by Darjee and Devine, hereinafter cited simply as Darjee, a common requirement of industry and commerce is to convert a material manufactured in continuous web form into an endless belt. One of the most common methods for accomplishing this purpose is called a butt joint. A reinforcing material, variously called a tape, patch material, etc. is usually added to one side of the butt joint to strengthen it.
The particular type of tape described by Darjee is used primarily for joining coated abrasive products into endless belts. Such joints are normally made at an angle other than perpendicular to the edge of the belt. The Darjee tape is reinforced with yarns for increased tensile strength, and it is naturally advantageous for these reinforcing yarns to be oriented in or near to the running direction of the belts made with it. For reasons detailed by Darjee, the most practical method of achieving this goal is to lay out the yarn array during the manufacture of the tape with the yarns at an angle to the edge of the layout. In order to avoid a tendency of the patch material to split under certain types of stress, the yarns are not laid out strictly parallel to one another, but instead in two groups. Yarns within each group are parallel, but the two groups cross each other at a small angle up to 5°.
2. Description of the Prior Art
Triaxial weaving machines, which lay out two groups of yarns corresponding to the fill of a conventional fabric at both sixty degree angles to the warp yarns, are known but are believed to be little used. Knitting and stitch-bonding machines which can lay out yarns in angled patterns are also known. However, all these machines are designed primarily for making fabrics and thus normally require that at least some of the yarns used be interlaced, knitted, or otherwise repeatedly diverted from a straight path. The Pelletier machine already noted lays out what are called "weft webs" in which the yarns are straight, but it is adapted only to laying out such webs with the yarns perpendicular to the edges of the webs. We are not aware of any prior art machine efficiently adapted to laying out biased webs of straight laid yarns at variable angles to the edge of the webs.
SUMMARY OF THE INVENTION
We have found that an effective machine for laying out biased arrays of straight laid yarns can be constructed by combining on a single machine frame two mechanically driven continuous yarn carrier strips, each provided on its edge facing the other carrier with a plurality of spaced yarn restrainers, and a reciprocating conveyor capable of conveying a small array of spaced parallel yarns, oriented at the desired angle or angles, back and forth between the two carrier strips in such a manner that the yarns will be retained on the restrainers during each complete cycle of the reciprocating conveyor. Continuous yarns are supplied by conventional means under constant low tension to the input of the conveyor. The relative motions of the carrier strips and the reciprocating conveyor are controlled so that the web of yarns produced is regularly patterned. If the motion of the carrier strips is discontinuous in a properly coordinated manner, all the yarns laid out will be parallel to each other. If the motion of the carrier strips is continuous at the proper speed, two sets of mutually parallel yarns intersecting the yarns of the other set at small angles will result.
The basic machine for laying out biased webs may advantageously be combined with conventional laminating and/or liquid adhesive coating and processing equipment to encapsulate the yarn array and make it into joining tape. A means for compressing the combined array of yarns and adhesive is also a useful adjunct. Conventional unwind stands, windup rolls, web guiding equipment, and slitters may also be advantageously combined for continuous commercial operations.
The conveyor means for laying out yarns at an angle may conveniently consist of two parts: (1) a yarn guiding section capable of maintaining a small array of several yarns in properly spaced parallel and planar array as it moves and (2) means for generating reciprocal angled motion of the guiding section across the width of the space between the two carrier strips.
The guiding section can consist of (1) upper and lower vertically fixed yarn guideboards containing a pattern of eyelets through which individual yarns are threaded and (2) two yarn depressors, one on each side of the lower guideboard, which are capable of moving up and down at appropriate times during the travel of the guiding section to control the vertical position of the yarn.
The means for generating reciprocal angled motion can consist of (1) a first sliding carriage which slides back and forth in a first direction, preferably perpendicular to the direction of motion of the yarn carrier strips, under the urging of a rotating drive bar moving in a slot of the first sliding carriage and (2) a second sliding carriage suspended from the first sliding carriage by tracks which allow it to move with respect to the first sliding carriage in a direction substantially divergent from, preferably perpendicular to, the direction of sliding of the first sliding carriage. A projection from the second sliding carriage fits into an angled slot cam in a guide plate attached to the main machine frame, so that the extent of motion of the second sliding carriage in the direction in which the yarn carrier strips travel is controlled for any position between these yarn carrier strips which the second sliding carriage can assume. The yarn guiding section may be attached to one end of the second sliding carriage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a preferred machine incorporating several conventional elements along with the essentials of our invention.
FIG. 2 is an isometric view of the parts of the machine, other than the yarn carrier chains, which control the positioning of the yarns. The line to the right of the isometric axis point which lies slightly right of the center of the lower part of FIG. 2, i. e., the line of this figure crossed by the lead lines from numbers 81, 86, and 87, corresponds to the front side of FIG. 1.
FIG. 3 is a view, partially broken away, of the mechanism 52 of FIG. 2 from the direction of the left side of FIG. 1.
FIG. 4 is a top view of component 112 of FIGS. 2 and 3 on a substantially larger scale, showing the preferred pattern (but not the proper relative size) of the eyelets for yarn.
FIG. 5 is a side view of the upper and lower carriages of FIG. 2 from the direction of the arrow marked S in FIG. 2.
FIG. 6 is a top view of guide plate 86 of FIG. 2.
FIG. 7 is a view from the left side of FIG. 1 of a yarn restrainer of the preferred type, a small hook with its opening on the top; these are attached to the rear edge of front carrier strip 50 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The yarn carrier strips may be made of any material suitable for an endless belt capable of precise mechanical motion. Thus cloth or rubber belts, perforated metal strips, commercial tenter chains, etc. could all be used. However, our preferred carrier strips are composed of conventional triple width steel drive chain capable of being joined into endless carrier strips of any desired length which is an integral multiple of the length of the chain links, about 12 mm. The triple width gives the chain suitable stiffness to maintain precise alignment in the parts of its path from the point where it receives newly laid down yarns to the point of yarn encapsulation. The chain is designed to be driven by a toothed wheel which can be powered by an electric motor for precise speed control.
A wide variety of mechanical devices could also serve as the actual yarn restrainers which are attached to the carrier strips. It will be apparent to those skilled in the art that the design of the yarn restrainers must be correlated with that of the reciprocating yarn conveyor which moves the yarns between the two carrier strips, so that the restrainer can smoothly accept the spaced yarn array from the guiding section and maintain the yarn array in proper spacing as the carrier strips move toward the adhesive encapsulation zone. Thus a conventional pin tenter chain might be employed with a guiding section which passes the small yarn array over the pins and any suitable conventional device, such as a wire brush wheel, for forcing the looped sections of the yarns formed at the edges of machine over the pins so that the yarns will be retained thereon. With sufficiently stiff yarns conveyed between the carrier strips by a device which remained inward of the small yarn array during its travel toward the carrier strip, a clip tenter could be used. Yarn restrainers of the type described by the already cited Pelletier patent might also be used, although for our purposes it would be necessary to modify the Pelletier mechanism so that the line connecting the opening points of the compressible blocks which restrain the yarns in that design would make a biased angle with the direction of forward motion of the carrier strips. This design would not be expected to be convenient for our purposes, because it would likely be awkward to adjust the points of block opening to correspond to a variety of angles for laying out the yarns.
Our preferred yarn restrainers, for use in conjunction with the yarn conveying mechanism to be described below and with yarns from about 150 to 600 denier, are small hooks capable of being spaced within 1 mm of each other in an even spacing along the entire length of the chain carrier strips. Convenient units of sixteen such hooks 60 cast with a single shank may be obtained from Unitechna Aussenhandelgesellschaft, DDR-108 Berlin, Mohrenstrasse 53/54. The shape of these hooks is shown in FIG. 7. Such sets of hooks are attached to the inner part of the carrier chain links in such a way that any straight section of the path of the carrier chain has uniformly spaced hooks, with their openings facing upward as shown in FIG. 7, along the entire inner edge of the carrier chain. The hooks of preferred size for use with 220 or 440 denier polyester yarns are spaced about 0.8 mm apart and have ends beyond the angle about 5 mm long. The hook size should be adjusted as necessary for changes in yarn size and desired yarn spacing.
The preferred drive means for the carrier strips is a variable speed electric motor with conventional controls. A single motor preferably drives the yarn carrier strips, the yarn conveying assembly, and the compression rolls (if present) in order to achieve precisely coordinated motion of these components.
A wide variety of conventional yarn conveying equipment could be adapted to use in our machine. Conveyors of the Pelletier type, carrying only one or perhaps two yarns at a time should be workable, although inefficient. It is obviously preferable from the viewpoint of speed of assembly of the desired array to carry many rather than few yarns with each pass. Our preferred reciprocating yarn conveyor is an original design illustrated in FIGS. 2 and 3.
The yarn conveyor 52 is shown in FIG. 2, which also shows the attachment of the conveyor to the machinery, excluding the motor, which causes it to move reciprocally between the yarn carrier strips. This machinery is described further below. Yarns, which are not shown in any of the figures, pass from conventional storage and tensioning devices such as creels with spools, bobbins, beams, etc. under appropriate tension control to one of the eyelets shown in the upper yarn guideboard 110. These eyelets are provided with low friction plastic liners to minimize fiber abrasion. Normally each yarn is fed through an individual eyelet. If low density yarn layouts are desired, it is not necessary for every eyelet to be used. The yarns pass from the upper yarn guide board 110 to the lower yarn guide board 112, which urges the yarns into a linear configuration called a small yarn array as already noted above. Details of the array are considered further below. Yarn depressors 111 are provided on each side of the lower yarn guide board. These depressors are sufficiently long for the entire array of yarn in the position defined by the lower yarn guideboard to pass under the depressors, and the small yarn array in fact passes under the one of the depressors which is situated rearward of the direction of motion of the lower yarn guideboard during most of a cycle of the laying assembly.
The yarn depressors 111 are capable of vertical motion from a position above the tops of the yarn restrainers 60 carried on the inner part of the yarn carrier chains 50 to a position well below the point of most stable yarn positioning on these yarn restrainers. As the reciprocating yarn conveyor passes approximately the central axis of the machine on its way toward one of the carrier chains, the depressor on the rearward side of the motion of the conveyor moves to its lowest position, and the other depressor, which had been in its lowest position, rises to its highest one. The lowest position of the yarn depressors is sufficiently far below the constant vertical position of the lower yarn guideboard 112 so that the portion of the yarns between these two parts of the conveyor makes an angle of about 60° with the horizontal. With continued motion of the conveyor, the lower yarn guideboard 112, which is vertically positioned so that it barely clears the tops of the yarn restrainer hooks, pulls the small yarn array across the tops of the hooks and sufficiently far outside the line of hooks that the point of each yarn between adjacent hooks is just below the top of the hooks. Because the chains in the preferred mode of operation are moving forward continuously, this motion results in the retention of the yarns on the hooks as the conveyor begins to move backward toward the center of the machine. A looping motion of the yarn layout mechanism considered in more detail below assists in retaining the yarns. As the carrier moves past the central axis of the machine toward the other carrier chain, the two depressors again reverse vertical positions. This downward motion of what is now the rearward depressor further urges the yarn edge loops most recently formed toward the position of maximum stability on the restrainers and helps hold them in that position until the next set of yarn loops is made on the yarn restrainers borne on the opposite carrier chain.
The pattern of eyelets in the lower yarn guideboard 112 is correlated with certain other choices in the operation of the machine. The preferred pattern of the centers of these eyelets is shown in FIG. 4, but the relative size of the eyelets is greatly exaggerated in the figure. Each eyelet 114 in this guideboard has an actual diameter of only about one millimeter and carries a single yarn. The eyelets are arranged in two groups of equal number. The spacing between eyelets is uniform within each group, but the space between the two groups is about one and one half times as large as the spacing within one group. The reason for this spacing is that in the preferred mode of operation of the machine, the yarn carrier chains are moved forward continuously during each complete cycle of the reciprocating yarn conveyor by a distance which is just one half the width of the small yarn array emerging from the lower yarn guideboard. Thus, half of the small yarn array deposited by each cycle of the laying mechanism overlaps the previously laid down small array. If the eyelets were evenly spaced throughout the entire lower yarn guideboard, an undesirable extra thickening of the overall composite yarn array held between the carrier chains would result at intervals along the line of restrainer hooks, the intervals being spaced by half the width of the small array of yarns. When the eyelets are divided into two groups and the spacing between the two groups is substantially larger than that between adjacent yarns of each group but substantially smaller than twice that spacing, the most uniform pattern of the total composite yarn array results.
A machine according to our invention can also be operated so that the carrier chain moves forward the full width of the small yarn array with each cycle. When this is done, a lower yarn guideboard with only a single group of uniformly spaced eyelets is used. In general, if n is any small positive integer, the chain can be operated at a speed to advance 1/n times the width of the yarn array, and the lower yarn guideboard should contain n groups of eyelets, all in a single straight line, with the spacing between adjacent eyelets uniform within each group but the nearest two eyelets of adjacent distinct groups spaced apart about one and one half times the spacing within a single group.
It will be appreciated by those skilled in the art that many variations in operation are possible. For example, if a lower density layout of yarn is desired, only every alternate eyelet could be filled with a yarn.
The positioning of the yarn depressors is controlled in part by air cylinders 113. These are single acting spring return air cylinders with 25 mm stroke length. Further details of the mechanism 52 are shown in FIG. 3. The depressors 111 are mounted on thrust rods 123 provided with matching inner toothed tracks 121. The hatched surfaces in FIG. 3 are the cross sections of solid metal structures which define guideways for the motion of the thrust rods 123, so that the latter are constrained to move up and down only, without significant sidewise motion. The tracks 121 engage with a rotatable spur gear 122 in such a fashion that the downward motion of one of the depressor thrust rods produces upward motion of the other depressor thrust rod by the same distance. Conventional electric relays and sensors not shown determine which of the air cylinders 113 is supplied with appropriate air pressure to lower or raise its attached thrust rod and depressor, depending on the position of the yarn carrier assembly with respect to the two yarn carrier chains.
A variety of means for generating reciprocal angled motion could be envisioned, but our preferred means is an original design illustrated in FIGS. 2 and 5. The slideway S of FIG. 2 is rigidly attached to the machine frame F and need not move during operation of the machine. Guide plate 86 also need not move during operation but is interchangeable with alternatives for different angles of motion or other variations of operation. The moving parts of primary interest are the upper sliding carriage 81, the lower sliding carriage 82, and the upper carriage drive bar 83.
The upper sliding carriage 81 is supported by four grooved rollers 87, of which only three are visible in FIG. 2. These rollers fit into slideway tracks 88 on each side of the carriage in such a fashion that the carriage is free to move along the direction indicated by the double headed arrow shown near the end of the lead line from identifying number 81 on FIG. 2, parallel to the direction of tracks 88. This direction is preferably perpendicular to the line of motion of the yarn carrier chains. The carriage 81 bears on its upper surface a guide track 89 with a slot 90 extending across its entire width. A cylindrical guide rod 91, of which only the top is visible in FIG. 2, extends from the bottom of the guide bar 83 into the slot 90. The opposite end of guide bar 83 has a counterweight, not shown, to balance the weight of the guide rod. The guide rod has a diameter only slightly less than the width of the slot 90, so that as guide bar 83 is rotated during operation of the machine, the attached guide rod 91 urges the entire upper sliding carriage 81 back and forth along the path permitted by its sliding track. The maximum amplitude of motion of the upper sliding carriage 81 is sufficient to extend across a width slightly larger than the distance between the sets of yarn restrainers borne on the two yarn carrier chains 50, which determine the width of the web of patch material to be made. Guide bar 83 is driven by shaft 84 which in turn is driven by belt 85, which is driven by an output from the same electric motor as the carrier chains.
On the bottom of the upper sliding carriage are fixed four additional rollers 101 essentially identical to those on the top. These bottom rollers can not be seen in FIG. 2, but two of them are shown in FIG. 5. (Parts of mechanism 52, which although at the rear might otherwise be visible in FIG. 5, have been omitted.) The lower sliding carriage 82, with attached tracks 92, fits between and is suspended by the rollers 101 and can move along the direction defined by the tracks 92 between the rollers 101; this direction of motion is shown by the double headed arrow near the end of the lead line from designating number 82 on FIG. 2. Thus the lower sliding carriage 82 can move with respect to the upper sliding carriage 81 along the direction perpendicular to that along which the upper sliding carriage can move with respect to the main machine frame. (Some other angle than perpendicular between the two sliding directions of the the two sliding carriages could be used, but the machine would have to be made larger to cover the same width between the carrier strips and the range of layout angles needed.)
Because the lower sliding carriage is carried by and thus partakes of the motion of the upper sliding carriage, a given point on the lower sliding carriage can, within the constraints of these two motions, assume any position within a rectangle broad enough to span the distance between the lines of yarn restrainers on the yarn carrier chains and long enough to reach from one set of yarn restrainers to the opposite one when moving at an angle with respect to the yarn carrier chains which is desired for the straight laid yarns.
The actual positions which the lower sliding carriage will assume in operation are determined by the interaction of a cam follower 102, attached to the lower sliding carriage 82, with a guiding cam 104 cut in guide plate 86. An edge portion of the guide plate is shown in FIG. 2. A top view of the guide plate, showing the preferred exact shape of the guiding cam, is given in FIG. 6. The central portion of the guiding track or cam 104 consists of a parallel edged slot with width just slightly wider than the diameter of cam follower 102. The central axis of this slot is inclined an an angle X to the transverse edges of the guide plate. The angle X corresponds to the complement of the central angle with respect to the edges of the yarn carrier chains around which the yarn array will be laid out by operation of the machine, and the length of the track formed by cam 104 is sufficient so that at each end of its travel, the reciprocating yarn conveyor will convey the yarns being laid down slightly outside the line of yarn restrainers on that edge.
One side of the cam slot 104 at each end is widened by a curved portion as shown in FIG. 6. The purpose of this widening is to cause the yarn carrier to move from one extreme end of its travel back toward the center line of the machine in a path approximately perpendicular to the carrier chain edges rather than at its usual angle to these carrier chain edges. This motion, together with the forward motion of the yarn restrainer hooks, causes the yarns to loop around the outside of the yarn restrainers on its return path. The shape of this widened section of cam 104 does not appear to be critical, but the shape shown in FIG. 6 has the advantage of generating a relatively smooth motion of the yarn carrier which reduces mechanical wear.
As the position of the yarn conveyor returns to control by the main part of the guide cam 104, the yarns being conveyed are pulled by the tension of the conveyor back into the desired angle with respect to the carrier chain edges, leaving only a small loop around the restrainer hook to hold the yarn in place until it is encapsulated with adhesive. The edge part of the web which includes the looped ends of yarn is discarded after encapsulating and slitting.
The guide plate 86 is affixed to the machine frame by bolts, so that it can be easily changed for different angles of operation.
In the preferred mode of operation for the manufacture of narrowly multidirectional belt joint tape or patch material, the motion of the carrier strips is continuous when the reciprocating yarn conveyor is operating. If for any reason, a web in which essentially all yarns are parallel is desired, this can be accomplished by a conventional mechanism which will alternately stop and start the carrier strips in proper correlation with the motion of the yarn layout means. In such a situation, additional means might be needed for urging the yarns onto the hooks or other restrainers when the lower yarn guideboard is outside the line of hooks, if the forward motion of the chain was not sufficient for this purpose.
The essential and original components of the machine of our invention as described above can advantageously be combined with previously known components for some uses. A preferred embodiment of such a machine suitable for making coated abrasive belt joint tape or patch material on a large scale is shown in FIG. 1. The main framework F is constructed of welded, heavy duty tubular steel, has machined pads on mounting surfaces, and is self-supporting. The entire machine can be moved as a unit while maintaining its dimensional integrity.
Unwind stands 42 and 42' are rigidly mounted directly to the machine frame. Webs A and A' of dry film adhesive, with or without auxiliary webs, can be supplied from these unwind stands to the laminating station 46. Windup roll 45 is used to store any release paper or similar material supplied on adhesive web A' but not desired in the final patch material. After lamination, the web continues to move forward in a horizontal plane under the tension generated by windup rolls 44, 44', and 45, while after only a part of this distance, the carrier strips bend downward as shown in FIG. 1. This divergence of directions detaches the web of tape or patch material from the carrier chains 50. Another divergence between the web paths separately defined by windup roll 45 and the pair of such rolls 44 and 44' then separates the tape or patch material from any web supplied with the adhesive but not desired in the patch. The patch material or tape is then slit to the desired width in score slitting station 47. The slit patch material is accumulated on the two controlled tension windup rolls 44 and 44' which jointly comprise a split winding station.
The lamination is accomplished between an upper cored rubber covered roller 48, which is adjustable in position vertically under the control of two air cylinders, and an electrically heated permanently positioned driven steel roller 49. In the direction perpendicular to the plane of FIG. 1, both these rollers fit between the two yarn carrier chains 50, of which only one is visible. These yarn carrier chains run along a path as shown in FIG. 1. Web assembly occurs in the part of the upper path of the chains between mechanism 53 and laminating rollers 48 and 49. The two chains 50 run toward the laminating rollers in this part of their path. The details of the mechanism marked 53 on FIG. 1, which lays out the yarn array, have already been described above.
All webs other than the unencapsulated yarn array are guided through the machine under proper tension and positional control by numerous ball bearing mounted steel idler rolls 51.
A typical example of the use of the machine of our invention is as follows:
EXAMPLE
The yarns for the patch material of this example were each 440 denier 100 filament number high tenacity polyester (with tenacity approximately 8 gm/denier). One such yarn was supplied to each eyelet of a lower guideboard with the pattern shown in FIG. 4. The machine described above as the preferred embodiment was used.
To start the production of patch material, the ends of the yarns of the small array were drawn through the lower yarn guideboard and tied to one or more of the yarn restrainers on one carrier chain. Power was then applied to the machine so that the carrier chains were moved continuously at such a rate that each small array of yarn overlapped half the previously laid down small array on the restrainer hooks, and the reciprocating conveyor laid down yarns between the two sets of yarn restrainers, as already described above. The yarns thus were initially straight laid in two distinct arrays which intersected each other at an angle of about 2.7°. The two arrays were arranged symmetrically around an angle of 67° to the carrier chains 50 or the edge of the web; this corresponds to 23° for the angle marked X in FIG. 6. Each of the two arrays consisted of 12 substantially evenly spaced yarns per centimeter of width (cm). The yarns of each array were parallel within 0.7° as laid out before compression. A 0.06 mm thick film of dry but readily softenable adhesive prepared according to the directions of Example 2 of U.S. Pat. No. 3,770,555 was applied to each side of the combined yarn arrays and bonded thereto under a pressure of about 40 daN/cm at a temperature of about 85° C. for a period of about 5 seconds. The patch material thus prepared was found to have a thickness of about 0.15 mm and a tensile strength of about 50 daN/cm along the direction halfway between the orientation directions of the two original yarn arrays in the patch. The volume of yarn in the patch material was about 56% of the total volume of both yarn and adhesive in the patch material.
The patch material thus formed can be used to form belts from conventionally backrubbed coated abrasive web material by a two stage pressing. The first stage is a pressing at about 10 daN/cm of width for three seconds between metal bars heated to about 149° C. The second stage is a final pressing for about thirty seconds between metal bars at a pressure of about 715 daN/cm of width. During this final pressing, the bar touching the coated side of the coated abrasive is maintained at a temperature of about 115° C., and the bar touching the patch material is maintained at about 127° C.
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This invention provides a machine for efficiently laying out biased arrays of yarns. The machine combines on a single supporting machine frame (1) two mechanically driven continuous yarn carrier strips, each provided on its edge facing the other carrier strip with a plurality of spaced yarn restrainers, and (2) a reciprocating conveyor capable of conveying a small array of spaced parallel yarns, oriented at an angle to the motion of the carrier strips between 10°-80°, back and forth between the two carrier strips in such a manner that the yarns will be held on the restrainers at each pass of the conveyor. Continuous yarns are supplied by conventional means under constant low tension to the input of the conveyor. The relative motions of the carrier strips and the reciprocating conveyor are controlled so that the web of yarns produced is regularly patterned.
The best means for generating reciprocal angled motion combines (1) a first sliding carriage free to move back and forth in a direction perpendicular to the direction of motion of the yarn carrier strips, under the urging of a rotating drive bar moving in a slot of this carriage, (2) a second sliding carriage suspended from the first sliding carriage by tracks which allow it to move back and forth in a direction parallel to the direction of motion of the carrier steps, and (3) a guide plate attached to the main machine frame. A projection from the second sliding carriage fits into an angled slot in the guide plate to constrain the motion of the second sliding carriage to the desired path. A device for holding several yarns parallel to each other as they are drawn out is attached to one end of the second sliding carriage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to apparatus for pumping liquids, and more particularly to apparatus for positively pumping liquid and viscous liquid food products.
2. Description of the Prior Art
Positive displacement pumps for pumping liquid food products of various viscosities are well known. For example, catalog number PR73 published by the Ladish Co., Tri-Clover Division, Kenosha, Wis., describes positive displacement rotary pumps capable of pumping both high and low viscosity consumable liquids.
A primary requirement of the food processing industry is that all apparatus must meet rigid sanitation standards. U.S. Pat. No. 3,095,203 illustrates one design for sealing a liquid food product from possible sources of contamination within a pump. Sanitation requirements dictate, to a large extent, the design of food handling pumping equipment. Unlike pumps for handling non-edible liquids, as for example, hydraulic oil, sanitation pumps do not have bearings outboard of the pump impeller. Such bearings are not feasible because of inherent problems with lubrication, seal requirements and bearing materials. In addition, sanitary pump users demand pumps that are designed to be disassembled, cleaned and reassembled with a minimum of effort and down time. U.S. Pat. No. 3,227,088 discloses means for retaining the components of a pump as a unit during operation, but which allows quick and easy disassembly for cleaning.
The lack of outboard bearings on the impeller shaft makes shaft deflection a critical factor in the design and operation of sanitary pumps. As discharge pressures increase, the shaft deflection also increases. Discharge pressures in a typical well-known pump are limited to about 50 psig to 70 psig. Higher pressures result in reduced internal clearances to the point of interference between the rotors or impellers (hereinafter called impellers) and the pump housing. The consequence is that the tips of the impellers wear, which increases clearance with the housing, reduces pump efficiency and increases noise and vibration. Also, the abraded particles may be a source of contamination to the food product.
A related wear problem is involved in the mounting of the pump impeller to the impeller shaft. For ease of assembly and disasssembly, the impeller typically is driven by and is located on splines machined into the shaft. Due to normal manufacturing tolerances, a splined impeller inherently possesses a certain amount of looseness with respect to the shaft. The looseness is detrimental in that the impeller may cock slightly on the shaft splines, causing the impeller lobe tips to contact the housing, resulting in wear.
In sanitation pumps, problems arise in axially securing the impeller to the impeller shaft because of two conflicting requirements. On the one hand, it is necessary to firmly secure the impeller to the shaft. On the other hand, the impeller must be quickly and easily removable from the shaft for cleaning. One common design is to thread a single lock nut onto the shaft and against the impeller. This design has not proven completely satisfactory. Pumps are reversible, and the nut has a tendency to loosen and even fall off the end of the shaft. To prevent the loosened nut from damaging the shaft and pump, a clearance space large enough to hold the nut must be provided around the end of the shaft. A jam nut in conjunction with a lock nut, although somewhat superior to the single nut concept, has also proven unsatisfactory, primarily because of the reversible nature of the pump. In fact, the two nut design requires a clearance space twice as large as with a single nut. If this space is not present to afford spinoff, the loosened nuts can wedge in the cover and cause considerable damage to the pump. Another problem is that workmen cleaning the pump tend to place the nuts on their faces on any convenient surface. The result is that the faces, which must be flat and smooth to mate properly, become nicked. Consequently, the holding force between two abutting nuts diminishes to the point of eventual ineffectiveness. Polishing the nicked faces is not feasible because of the difficulty of maintaining perpendicularity between the nut axis and the nut faces.
Accordingly, a need exists for a food processing pump that can be operated at high pressures without wear caused by pump deflection and that includes components that consistently lock securely together but that can be quickly and easily disassembled.
SUMMARY OF THE INVENTION
In accordance with the present invention, a positive displacement pump is provided which is capable of operating at high pressures without detrimental wear caused by impeller deflection. This is accomplished by apparatus which includes a pair of meshing lobed impellers which are eccentrically located within the cavity of an impeller housing with respect to the pumping cavity walls. The pumping cavity is defined in part by a center section comprising spaced-apart generally parallel side walls. The center section is bounded on each end by an end section defined by a semi-circular wall which merges into the side walls. The difference in radius of each end section wall with respect to the radius of the impeller is larger than this difference in prior art pumps. However, the center of rotation of each impeller is displaced or offset with respect to the center of the semi-circular end wall toward the respective end wall by an amount equal to the increase in the end wall radius. As a result, the radial clearance between the impeller and the wall varies along the wall but is the same as prior art pumps in the critical leakage area which effects pump efficiency. Preferably, the clearance is greatest in the region where the side walls merge into the semi-circular end walls adjacent the pump inlet and outlet, and the clearance is least at the mid-point of the semi-circular end wall where a longitudinal center line intersects the end walls.
In operation, fluid discharge pressure deflects the impeller shaft toward a merger region between the side wall and a curved end wall. Because of the increased clearance in the merger region, higher operating pressures are possible before contact occurs between the impeller and the walls. At the same time, the radial clearance between the impeller and the mid point of the semi-circular end wall is equal to the radial clearance of prior pumps, thus maintaining high volumetric efficiency.
The present invention is also concerned with rigid and accurate positioning of the impeller in the pumping cavity to prevent interference with the pumping cavity semi-circular end walls. For that purpose, a rotor ring is interposed between an outer surface of the shaft and an associated inner surface of the impeller. The mating or interfitting surfaces of the rotor ring, shaft and impeller are machined so as to accurately locate the impeller relative to the shaft but still allow quick assembly and disassembly.
Further in accordance with the present invention, there is provided an improved means for retaining the impeller on the impeller shaft. In the preferred construction, the retaining means comprises a pair of cooperating rotor nuts threaded onto the impeller shaft. The nuts are formed with mating frusto-conical surfaces. The rotor nuts are threaded onto the impeller shaft and are tightened against the rotor ring and against each other. The conical surfaces cooperate to securely lock the impeller onto the shaft. A retainer is provided to retain the rotor nuts on the impeller shaft and prevent spinoff. Preferably, the retainer comprises an annular ring of readily deformable material which is seated in a shaft groove and encircles the threaded end outboard of the rotor nuts. To prevent the nuts from completely unthreading from the shaft, except by manual manipulation, the outer diameter of the safety ring protrudes beyond the minor diameter of the shaft threads. These features reduce the clearance needed for nut spin-off and hence reduce the size of the pump.
Other objects and advantages of the invention will become apparent from the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, partially in section, of a sanitary positive displacement pump incorporating the present invention.
FIG. 2 is a sectional view taken along lines 2--2 of FIG. 1.
FIG. 3 is an exploded perspective view of the threaded end of the drive shaft showing the rotor nuts and retainer of this invention.
FIG. 4 is a partially schematic drawing of the impeller housing of the present invention showing the relationship between the impeller shafts and the internal walls of the impeller cavity.
FIG. 5 is a partial schematic drawing similar to FIG. 4 but showing the relationship between an impeller shaft and the impeller cavity internal walls of prior art pumps.
DETAILED DESCRIPTION OF THE INVENTION
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto.
Referring to FIG. 1, a rotary positive displacement pump 1 is illustrated which includes the present invention. The pump finds particular usefulness in handling liquid and viscous liquid food products. However, it will be understood that the invention is not limited to sanitary applications. The pump includes a main housing 3 to which is detachably fastened an inner plate 5 by fastening means, not shown. The main housing supports a drive shaft 7, which is typically connected to a drive motor with a coupling and a key 9. The drive shaft is suitably mounted for rotation in the main housing by means of conventional bearings, not illustrated herein. A driven shaft 11 is mounted for rotation in suitable bearings, not shown, in the main housing parallel to the drive shaft. The bearings constrain both shafts against axial movement. A pair of meshing gears of standard construction, not shown, is employed to drive the driven shaft in the opposite direction as the drive shaft.
Detachably mounted by means not shown to the inner plate 5 is an impeller housing 13 and an outer plate or cover 15. The inner plate 5 and impeller housing 13 may be accurately located with respect to the main housing by locating pins 14. The inner plate, impeller housing and outer plate define a cavity 17 (FIG. 2) which is the liquid handling portion of the pump. The cavity is shaped as a generally rectangular center 19 bounded on each end by semi-circular end sections 21. The internal walls 22 of the center section are generally parallel and merge into the curved walls 24 of the end sections in regions 26. The impeller housing is formed on its opposite sides with fluid ports 18 and 20. To seal the cavity from the interior components of the pump, such as the bearings and gears, conventional sealing members 23 are employed around the drive shaft 7 and driven shaft 11. Only the seals on the drive shaft are shown in FIG. 1.
The portion of the drive shaft 7 (FIG. 1) which extends into the cavity 17, and thus is in contact with the liquid being pumped, includes a hub 25, a splined portion 27 and a threaded end 29. The driven shaft 11 is similar to the drive shaft in that it includes a hub, not shown, a splined portion 30 (FIG. 2) and a threaded end 32. Preferably, the threads on ends 29, 32 are acme threads.
To propel the fluid through the impeller cavity of the pump, a pair of meshing impellers 31, 33 are mounted on the splined portions of the drive shaft 7 and driven shaft 11, respectively. Although the pump may be bi-directional, it will be assumed for the present purposes that the direction of rotation of the impellers is shown by arrows 35, 37. In that case, fluid port 18 is the inlet port and fluid port 20 is the outlet port.
To accurately and rigidly and positively position the inboard end of impeller 31 on the drive shaft 7, the impeller is formed with a counter-bore having an internal circular surface 34. The surface 34 is machined to closely mate with the outer diameter of hub 25. To accurately and rigidly position the outboard end of impeller 31 on the drive shaft 7, a rotor ring 39 is interposed between and interfits with the outer diameter of the spline 27 and internal circular surface 41 of an associated counterbore in the impeller. The spline outer surface, rotor ring and counter-bore are machined so that the impeller is more rigidly and accurately positioned on the spline than is possible with a conventional splined connection which typically has considerable radial play. Nevertheless, the impeller may be easily disassembled from the spline. In a similar fashion, impeller 33 is mounted to the driven shaft by a hub, not shown, similar to hub 25 and by a rotor ring 43 (FIG. 2).
The invention also provides improved locking rotor nuts 45 to secure each impeller 31, 33 to the shafts 7, 11 (FIGS. 1 and 3). Each pair of rotor nuts 45 comprises a male nut 47 and a cooperating female nut 49. In the preferred construction, the male nut 47 is interposed between an impeller and the female nut 49. However, it will be recognized that the nut 47 could be the female nut 49 and not the male nut. Each male nut 47 preferably includes a flange 51 of a sufficient diameter to provide adequate bearing contact with the rotor rings 39, 43. To facilitate tightening and loosening the nuts, both the male and female nuts may be fabricated with hexagonal outer surfaces 52, 53, respectively (Fig. 3). Following the preferred design, the male nut is formed with an external frusto-conical surface 55 and the female nut is formed with a corresponding internal tapered or conical surface 57. Both the male and female nuts are threaded to fit the acme threaded ends 29, 32. The conical surfaces of both nuts are highly polished. To secure an impeller to a shaft, the male nut 47 is first tightly turned against the impeller. The female nut 49 is then tightly turned against the male nut so that the conical surfaces mate. As a result, the impeller is more securely locked to the shaft than was previously possible, but ease of disassembly is maintained. Further, the conical surfaces are less likely to become damaged through careless handling than in previous designs wherein the locking surfaces were flat faces on which the nuts were commonly placed during cleaning. It has been found that the angle between the nut axis and the conical surfaces is quite critical. For example, an angle of 10 degrees does not satisfactorily lock the impeller to the shaft, whereas an angle of 15 degrees provides excellent locking force. The 10 degree angle is a self-locking taper, and one taper locks against the other before it can jam on the thread. The locked tapers also create a single unit that has to be removed from the shaft for separation.
To ensure that the rotor nuts 45 do not unscrew from the threaded ends 29, 32 should they ever loosen, the present invention includes safety stops or retainers 59, 61 on each threaded end outboard of the rotor nuts. In the preferred embodiment, each safety stop consists of a circular O-ring of readily deformable material such as rubber or neoprene. The O-ring is positioned in the threaded end by means of a groove, such as at 63 in FIG. 3. The groove, O-ring and acme threads are proportioned such that the outer diameter of the O-ring projects above the minor diameter of the acme threads. Thus the rotor nuts may be manually threaded over the O-ring but the O-ring will prevent the nuts, should they ever loosen, from spinning off the ends of the shafts. As a result, the clearance spaces 65, 67 between the ends of the shafts 7, 11, respectively, and the outer plate or cover 15 is kept to a minimum. This is in contrast to prior constructions wherein spaces large enough to afford complete spin-off of one or more loosened nuts was necessary to prevent wedging of the nuts with the cover 15.
In accordance with the present invention, the impellers 31, 33 are eccentrically located within the impeller housing 13 so as to allow high pressure operation with minimum wear. This is accomplished in the present instance by increasing, with respect to the radius in prior pumps, the radius of each curved end wall 24 relative to the radius of the impellers and by locating the axes of rotation of the shafts 7, 11 eccentric to the centers of the walls 24. It is believed that the invention will be most readily understood by comparing the present pump with a prior art pump. Referring to FIG. 5, reference numeral 13' represents the impeller housing of prior pumps. Reference numberal 19' represents the center section of cavity 17'. The center section is defined by side walls 22'. Reference numeral 21' represents an end section of cavity 17'. End section 21' is defined by semi-circular internal wall 24'. Wall 24' merges with walls 22' at merger region 26'. Reference numeral 69' represents the center of the wall 24', and reference numberal 71' represents the radius of the wall 24'. Reference numeral 75 represents the radius of the impeller. The impeller center of rotation in previous pumps coincided with the center 69' of the wall 24'. A constant clearance 77' existed between the impeller and the wall 24'. The clearance is shown greatly exaggerated for clarity. The clearance 77' was chosen for minimum internal leakage and thus high volumetric efficiency consistent with practical machining capabilities. It will be noted that the clearance 79' between the impeller end wall at the merger region 26' is the same as clearance 77' at mid point 83' of the wall 24'. Reference numeral 81' represents the approximate direction of impeller shaft deflection due to the fluid pressure at discharge port 20'.
Referring to FIG. 4, the construction of the preferred embodiment of the present invention will now be explained. Reference numeral 69 represents the center of the end section curved inner wall 24. Reference numeral 71 represents the radius of the wall 24, and that radius is larger than the radius 71' of prior art pumps. Reference numeral 75 represents the radius of the impeller, and that radius is the same as in previous pumps. Reference numeral 73 represents the center of rotation of the impeller. It will be noticed that the center 73 is displaced with respect to the center 69 in the direction toward the wall 24 and on the longitudinal center line 85. In the preferred construction, the amount of eccentricity between impeller axis 73 and the wall center 69 is equal to the increase in wall radius 71 over the prior art radius 71'. In that case, the clearance 77 in the pump of the invention at midpoint 83 and the centerline 85 intersects the wall 24 and is equal to the constant clearance 77', 79' of prior pumps. However, it will be noticed that the clearance 79 at the merger regions 26 is increased with respect to clearance 79' at the merger regions 26' of the prior pumps.
The advantage of this invention will now be explained. Referring to FIG. 4, angle A represents the critical leakage area that effects pump efficiency. This angle extends through approximately 34 degrees on either side of the end section midpoint 83. For optimum pump performance, the clearance 77 should be a minimum without contact between the impeller and cavity wall, and it should not change during pump operation. If the clearance 77 increases due to rotor wear or other reasons, the pump volumetric efficiency will decrease. Angle B represents the critical clearance area that is effected by impeller wear, which in turn affects pump life. This angle extends about 23 degrees along wall 24 and about 10 degrees along side wall 22 from merger region 26. Reference numerals 81 and 81' indicate the approximate direction of the deflection of the impeller shaft during operation (FIGS. 4 and 5). The deflections are produced by the high pressure of the liquid as it is discharged toward and out of outlet port 20. As the discharge pressure increases, the deflections along lines 81, 81' increase. In previous pumps, the deflection of the shaft, and thus the discharge liquid pressure, was limited by the clearance at 79' in the merger region 26'. If the deflection was too great, the impeller contacted the wall 24' and wear, noise and vibration could result.
By fabricating the walls 24 with increased radii 71 and by locating the impeller's axes of rotation eccentric to the centers of the walls 24, as taught by the present invention, the clearance 79 in the critical wear area is increased relative to prior designs. As a result, the useful operating pressure may be increased to approximately 120-150 psi for a pump which with the prior art design had working pressures of 50 to 70 psi, while providing longer life, lower maintenance and quieter operation than had previously been possible. At the same time, the minimum clearance 77 in the critical leakage area remains virtually unchanged and thus preserves the characteristics necessary for an efficient pump. In the preferred construction, the eccentricity between centers 69 and 73 may be on the order of about 0.005 inches. The clearance 77 may be about 0.004 inches. The clearance 79, with the shaft in the un-deflected condition, may be about 0.009 inches.
Thus it is apparent that there has been provided, in accordance with the invention, a positive displacement pump that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the appended claims.
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A sanitary positive displacement pump having increased internal clearances to allow increased operating pressures without detrimental wear while maintaining high volumetric efficiency. The invention includes rigid and accurate positioning of the liquid impellers to the shafts while maintaining ease of disassembly and assembly. The impellers are secured on the shafts by cooperating frusto-conical surfaces on each of a pair of nuts. A rubber retainer ring enables manual release of the nuts but prevents inadvertent spinoff.
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FIELD OF THE INVENTION
The present invention relates to secure, distributed web server authentication of users using a shared, single key in both a single enterprise and across separate enterprise multiple-server configurations.
BACKGROUND OF THE INVENTION
Currently, user authentication is accomplished in at least two ways: 1) user identification (“ID”) and password or 2) ITU-T X.509 certificates, ITU-T Recommendation X.509, published August 1997. In addition, large web sites often provide the same content on multiple web servers and use Domain Name Service (“DNS”), Internet Standards Track Standard 0013, STD0013-Domain Name System, published November 1987; round robin; or other technology to redirect user requests to one of the many servers. The use of multiple web servers is done to balance the load on the web site and provide the ability to take a server offline for maintenance or add servers during high load periods. In existing systems a user is prompted for authentication information, for example, user ID and password, each time the user hits a server the user has not yet visited.
FIG. 1 illustrates a simplified network flow diagram of existing user ID and password authentication systems. In FIG. 1 , user workstation 10 is connected to web site A 40 via the Internet 30 and Internet Service Provider (“ISP”) 20 . Web site A 40 is comprised of multiple web servers a, b, c and d 41 , 42 , 43 and 44 , respectively. Web server a 41 is shown coupled to web server b 42 via a first communication line segment 45 , web server b 42 is in turn coupled to web server c 43 by a second communication line segment 46 , web server c 43 is in turn coupled to web server d 44 by a third communication line segment 47 , and web server d 44 is in turn coupled to web server a 41 by a fourth communication line segment 48 to complete the network.
To access secure web site A 40 or a secure page on a web site A 40 , in FIG. 1 , the user first establishes an Internet connection using an Internet browser program (for example, Netscape Communicator® or Microsoft Internet Explorer®) which is running on user workstation 10 . Netscape Communicator® is licensed by Netscape Communications Corporation of Mountain View, Calif. Microsoft Internet Explorer® is licensed by Microsoft Corporation of Redmond, Wash. Once connected to the Internet, the user requests access to web site A 40 by entering the Universal Resource Locator (“URL”) for the home page of web site A 40 in the address block of the Internet browser program. After web site A 40 receives the user's connection request, the request is routed to an available web server, for example, web server a 41 , which sends a prompt for the user to enter a user ID and password. After the user enters and sends the user's user ID and password to web server a 41 , web server a 41 validates the user ID and password and establishes a connection between the user's browser at workstation 10 and the requested home page of web site A 40 . As the user moves through web site A 40 it frequently becomes necessary for the user to connect to a new web server. When this happens, the new web server, for example, web server b 42 , receives a request to connect to the user. The user is required to re-enter and send the user's user ID and password to web server b 42 for validation prior to establishing a connection between the user's browser at workstation 10 and the requested page at web server b 42 . In the system in FIG. 1 , the user may need to enter the user's user ID and password up to four separate times at web site A 40 to logon to each of the four web servers.
A prior art alternative to constantly requiring the user to re-enter the user's ID and password is to use X.509 certificates. These “certificates” are encrypted electronic signatures provided by a Certificate Authority (“CA”) that certify the identity of the user. Certificates are used by some web sites to provide user authentication and, while certificates do not require the re-entry of the user ID and password each time the user contacts a new server, certificates do require a trusted third party to “certify” the identity of the user. This trusted third party is the CA, such as, VeriSign, Inc. of Mountain View, Calif. The challenge with a certificate system is finding a common third party that both the user and the server trust. Another alternative is for the web site owner or Internet Service Provider (ISP) to issue the certificates themselves. Unfortunately, setting up and running a CA is neither a trivial nor a problem free task. In addition, once a company sets up the CA, it may find that other entities are using the company's certificates for authentication, as a result of the company's status and reputation. Additionally, revocation technology and the infrastructure for certificates is still being developed.
FIG. 2 illustrates a network diagram of an exemplary user certificate authority authentication system. FIG. 2 is identical to FIG. 1 except, in FIG. 2 , a CA 50 is connected to the Internet 30 and can communicate with both the user workstation 10 and web site A 40 .
In CA systems the initial user logon and traversal of the web site are essentially identical to the description provided for FIG. 1 . As in the process outlined above for FIG. 1 , when web server a 41 receives the user ID and password, web server a 41 sends the user ID and password to the CA 50 and requests a certificate validating the identity of the user. Once the CA 50 validates the user ID and password, the CA 50 creates a certificate and sends the certificate back to web server a 41 . Web server a 41 , in turn, sends the certificate to the user and then connects to the user. Another difference occurs when a new web server, for example, web server b 42 , needs to be accessed. Once web server b 42 receives the access request, web server b 42 reads and validates the user's certificate and establishes a connection between the user's browser at workstation 10 and the requested page of web site A 40 without requiring the user to re-enter the user's user ID and password again. However, if the certificate is not valid, then, web server b 42 must obtain a new certificate before connecting to the user. While this certificate system is an improvement over the basic ID and password system of FIG. 1 , the certificate system now requires that a third party or an additional and expensive local certificate system generate and certify the user certificates.
While current systems may use cookies to identify users, there are none that use the cookie to pass user credentials between servers nor are any of the current systems capable of working across multiple, separate enterprises.
Therefore, what is needed is a system that is simpler to implement and administer than ID and password or certificate systems, can only be used by the company or group that created the system, enables the passing of user credentials between multiple, separate enterprise servers, permits the immediate revocation of user authentication and access and is useable from any computer capable of Internet access without the user having to hand carry a special key or token to each computer.
SUMMARY OF THE INVENTION
Embodiments of the present invention provide a method and system for providing distributed web server authentication of users. The method and system include receiving a request to connect a user to a web server, determining if the user is a valid user and denying access to the user, if the user is not valid. If the user is valid, the method and system update the user password cookie using a shared secret key, when a valid user password cookie exists, or generate the user password cookie using the shared secret key, when no valid user password cookie exists. The method and system further include transmitting the user password cookie to the user and connecting the web server to the user.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a prior art network diagram of an exemplary user ID and password authentication system.
FIG. 2 illustrates a prior art network diagram of an exemplary user certificate authority authentication system.
FIG. 3 illustrates a network diagram of an embodiment of the present invention.
FIG. 4 illustrates a flow diagram of an embodiment of the present invention.
FIG. 5 illustrates a message flow diagram of an embodiment of the present invention.
FIG. 6 illustrates a message flow diagram of another embodiment of the present invention.
DETAILED DESCRIPTION
In accordance with embodiments of the present invention, when a user attempts to access a web server in an authentication ring, the web server requests a user ID cookie and a credential cookie from the user. An “Authentication Ring” is an arbitrary collection of web servers, commonly spread across multiple and separate enterprise web sites, that share a common authentication mechanism, user base and secret key. A “cookie” is a header which carries state information between participating web servers and users. The current HTTP/1.0 cookie specification is Internet Standards Track protocol RFC1945, Internet Official Protocol Standards, RFC1945-Hypertext Transfer Protocol—HTTP/1.0, published May 1996. A separate cookie is usually created by each separate web site and saved on the user's computer. The “User ID Cookie” contains the user ID for the user. The “Credential Cookie” contains the information needed to certify that the user is who the user claims to be. The web servers in the authentication ring can be grouped on a single web site or multiple web sites. If the user doesn't have a valid credential cookie for the site, for example, the time stamp is too old or the password is invalid, then, the user is redirected to a LOGON page where the user's user ID and password must be re-entered. If the User ID Cookie exists, it is filled in on the LOGON Page. The web server authenticates the entered user ID and password pair against a local authentication mechanism, for example, an operating system. If the user ID and password are authenticated, the web server creates an encrypted password cookie containing user information selected from, for example, the user's user ID and password, IP address and a time stamp, and where the encryption is performed using a secret key known only to those web servers participating in the authentication ring. A “time stamp” specifies the date and time that the password cookie was created or last updated. Each time the user hits a new web server, the new web server updates the time stamp in the password cookie. For example, if the time stamp is older than a system configurable interval, the user is redirected to the LOGON page to re-authenticate by re-entering the user's user ID and password.
Once the user is authenticated, the web server can apply access control to data to protect the data from disclosure, associate an identity with the user ID and track access and usage. Similarly, the user can navigate the site or authentication ring without being asked to re-enter the user's user ID and password again. Since the credentials (user ID and password), of the current user can be automatically retrieved from the user by the server at any time, it is unnecessary to request that the user re-enter the user ID and password credentials each time the user attempts to connect to a different server.
Embodiments of the present invention can be used by both individual and related local and remote web sites to implement user authentication without waiting for a fully functional certificate technology to emerge. Additionally, embodiments of the present invention will enhance and simplify the user's experience with the web site. In another embodiment, the present invention is used in virtual private web rings to give the user the appearance of a single log-in across multiple sites. “Virtual Private Web Rings” are a federated group of sites which support the same cookie key.
FIG. 3 illustrates a network diagram of an embodiment of the present invention. In FIG. 3 , all elements associated with the user workstation 10 , ISP 20 , Internet 30 and web site A 40 are as described in FIGS. 1 and 2 . Additionally, in FIG. 3 , a web site B 60 and a web site C are connected to the Internet 30 and both web site B 60 and web site C 70 are configured similar to web site A 40 . This similar configuration of web sites A, B and C is merely for ease of explanation and in no way limits the scope of the present invention. In fact, the exact configuration of the web sites is immaterial to all embodiments of the present invention. Web site A 40 and web site B 60 are shown associated in an authentication ring 80 . Note that while web site C 70 is not a part of authentication ring 80 in the embodiment shown in FIG. 3 , alternative embodiments are contemplated where web site C 70 is part of the authentication ring 80 .
FIG. 4 illustrates a flow diagram of an embodiment of the present invention. In FIG. 4 , in block 410 , a request to connect a user to a web server is received at the web server. In block 420 , the web server determines if the user request has come from a valid user. If, in block 420 , the web server determines that the user is not a valid user, then, in block 425 , the user is denied access to the web server and the process loops back to block 410 to wait for another user request to connect to the web server. If, in block 420 , the web server determines that the user is a valid user, then, in block 430 , the web server determines if there is a valid user password cookie. If, in block 430 , the web server determines that there is not a valid user password cookie, then, in block 435 , the user password cookie is generated using a shared secret key and the process continues with block 450 . If, in block 430 , the web server determines that there is a valid user password cookie, then, in block 440 , the user password cookie is updated using the shared secret key. In block 450 , the web server transmits the user password cookie in response to the request to connect the user. In block 460 the web server connects the user to whichever page was requested in the original connection request.
In accordance with embodiments of the present invention, determining if the user is a valid user involves reading a user credential cookie, requesting a user identification (ID) and password, receiving the user ID and password and validating the user's identity. Where, validating the user's identity involves authenticating the user ID and password with the credential cookie using a local authenticating mechanism, for example, an operating system, and if the user ID and password are authenticated, generating a password cookie for the user using a shared secret key, otherwise, the user ID and password are re-requested from the user.
In accordance with embodiments of the present invention, determining if the user is a valid user, involves obtaining the user password cookie and verifying that the user password cookie is valid. If the user password cookie is determined to be valid, then, the user is valid, if the user password cookie is determined to be not valid, then, the user is not valid.
In accordance with embodiments of the present invention, the web server is part of a common authentication ring having the shared secret key.
In accordance with embodiments of the present invention, generating the user password cookie using a shared secret key involves combining at least the user ID and password with a time stamp and encrypting the combined user ID, password and time stamp using the shared secret key.
In accordance with embodiments of the present invention, establishing a connection between the web server and a second user using a second user password cookie and the shared secret key involves receiving a request to connect the second user to the web server and determining if the second user is a valid user. If the second user is determined to be not valid, then, the second user is denied access to the web server. If the second user is determined to be valid, and if a valid second user password cookie exists, the second user password cookie is updated using the shared secret key. However, if the second user is valid but no valid second user password cookie exists, then, the second user password cookie is generated using the shared secret key. Regardless, whether the second user password cookie is updated or generated, the second user password cookie is transmitted in response to the request to connect the second user and the web server is connected to the second user.
In accordance with embodiments of the present invention, establishing a connection between the user and a second web server using the user password cookie and the shared secret key involves receiving a request to connect the user to the second web server and determining if the user is a valid user. If the user is determined to be not valid, then, the user is denied access to the web server. If the user is determined to be valid, and if a valid user password cookie exists, the user password cookie is updated using the shared secret key. However, if the second user is valid but no valid user password cookie exists, then, the user password cookie is generated using the shared secret key. Regardless, whether the second user password cookie is updated or generated, the user password cookie is transmitted in response to the request to connect the user to the second web server and the second web server is connected to the user. The second web server is part of the same common authentication ring as the web server.
FIG. 5 illustrates a message flow diagram in accordance with an embodiment of the present invention. In this embodiment, a user is accessing web pages from the Internet that are located at separate web sites.
In step 1 , in FIG. 5 user requests to connect to web site entering the URL for a protected page of web site A in the address block of an Internet browser program (for example, Netscape Communicator or Microsoft Explorer) which is running on user workstation 10 and the user had used to connect to the Internet. After web site A receives the user's connection request, the request is assigned to an available web server, which contains the desired information. In step 2 , the assigned web server reads the user's credential cookie. Then, in step 3 , the web server sends a prompt for the user to enter a user ID and password. In step 4 , the user enters and sends the user's user ID and password to the web server. In step 5 , the web server receives and validates the user's ID and password and, if the password is valid, generates an encrypted password cookie using a shared secret key by encrypting the combination of, at least, the user's ID, password and a time stamp. The shared secret key is known by all web servers at web site A and web site B and web site A and web site B are associated in an authentication ring. In step 6 , the web server at web site A sends the password cookie in response to the user's connection request. In step 7 , the web server at web site A establishes an authenticated connection to the user, through the user's browser at workstation 10 , to the requested page, which is resident on the web server at web site A. As the user moves through the web servers at web site A or as time passes it becomes necessary for the user to connect to a new web server at a new web site. As previously explained, this can be due either to the user explicitly requesting access to pages not accessible on the current web server/web site or as a result of web site A automatically transferring the user to the new server at the new web site. Several reasons can cause the web site to need to transfer users, for example, to balance the load on the web servers and related web sites or to maintain service if one of the web servers or web sites crashes. In step 8 , a request is sent to web site B to connect web site B to the user. This request can be sent from either the user or the web server at web site A. In step 9 , web site B receives the request and an available web server at web site B reads the user's password cookie. In step 10 , the web server at web site B decrypts and validates the user's password cookie, updates the time stamp and re-encrypts the password cookie using the shared secret key. In step 11 , the web server at web site B sends the re-encrypted password cookie in response to the request to connect web site B to the user. Finally, in step 12 , the web server at web site B establishes an authenticated connection between the user's browser at workstation 10 and the requested page on the web server at web site B. While not shown in FIG. 5 , if the password cookie is not valid in step 10 , then, the web server at web site B will repeat steps 2 through 7 to obtain a valid password cookie and then connect to the user's browser at workstation 10 . This procedure is used by all web servers in the same authentication ring as web sites A and B. While the embodiment of authentication ring 80 shown in FIG. 3 only comprises web sites A and B 40 and 60 , respectively, the use of the present invention is not limited to this embodiment. In fact, any number and combination of users, associated web sites (that is, authentication rings or virtual private web rings) and web servers is possible. As before, no special code is required at the user's browser to implement the present invention.
FIG. 6 illustrates a flow diagram of another embodiment of the present invention. In this embodiment, a user is accessing pages from an internal company Intranet Sheltered Employment Retirement Plan (“SERP”) web site and then requests access to a page or pages at a related Extranet Stock Option Plan (“SOP”) web site that is part of the same authentication ring as the Intranet web site.
In step 1 , in FIG. 6 , the user requests to connect to the Intranet web site by entering the URL for a protected page of the web site in the address block of an Internet browser program (for example, Netscape Communicator or Microsoft Explorer) which is running on user workstation 10 . After the Intranet SERP web site receives the user's connection request, the request is assigned to an available SERP web server, which contains the desired information. In step 2 , the SERP web server reads the user's credential cookie. Then, in step 3 , the SERP web server sends a prompt for the user to enter a user ID and password. In step 4 , the user enters and sends the user's user ID and password to the SERP web server. In step 5 , the SERP web server receives and validates the user's ID and password and, if the password is valid, generates an encrypted password cookie using a shared secret key by encrypting the combination of, at least, the user's ID, password and a time stamp. The shared secret key is known by all SERP web servers in the Intranet web site and the Extranet SOP web site and the Intranet SERP web site and Extranet SOP web site are associated in an authentication ring. In step 6 , the SERP web server sends the password cookie in response to the user's connection request. In step 7 , the SERP web server establishes an authenticated connection between the user's browser at workstation 10 and the requested page which is resident on the SERP web server at the Intranet SERP web site. As the user moves through the SERP web site or as time passes it becomes necessary for the user to connect to the external SOP web site. In step 8 , a request is sent to connect to the Extranet SOP web site. This request can be sent from either the user or the SERP web server. In step 9 , the Extranet SOP web site receives the request to connect to the user and an available web server at the Extranet SOP site and reads the user's password cookie. In step 10 , the Extranet SOP web server decrypts and validates the user's password cookie, updates the time stamp and re-encrypts the password cookie using the shared secret key. In step 11 , the Extranet SOP web server sends the re-encrypted password cookie in response to the request to connect the user to the Extranet SOP web site. In step 12 , the Extranet SOP web server establishes an authenticated connection with the user's browser at workstation 10 to the requested page on the Extranet SOP web server. While not shown in FIG. 6 , if the password cookie is not valid in step 10 , then, the Extranet SOP web server repeats steps 2 through 7 to obtain a valid password cookie and then connects to the user's browser at workstation 10 . While this embodiment of an authentication ring only comprises an Intranet web site and an Extranet web site, the use of the present invention is not limited to this embodiment. In fact, any number and combination of users, associated web sites (that is, authentication rings or virtual private web rings) and web servers is possible. In addition, no special code is required at the user's browser to implement the present invention.
A general embodiment of a web server for use in accordance with the present invention includes a processor unit coupled to a communications unit and a memory unit which is also coupled to the processor unit. The memory unit has a computer program stored in the memory unit and the computer program, which, when executed by the processor unit, configures the web server to receive a request to connect a valid user to the computer system through the communications unit, creates a user password cookie using a shared secret key and transmits the user password cookie to the valid user. In a simplified embodiment in accordance with the present invention, the web server includes an Intel® Pentium® processor coupled to a modem for communicating with the users and other web servers. The processor is also coupled to a main system random access memory (“RAM”), such as a dynamic RAM (“DRAM”), and to a mass memory storage system, such as a hard disk. The above described web server embodiments are merely illustrative of the possible embodiments and in no way limit the possible embodiments of the web servers that can be used with the present invention.
It should, of course, be understood that while the present invention has been described mainly in terms of Internet-based web site embodiments, those skilled in the art will recognize that the principles of the invention may be used advantageously with alternative embodiments involving local area networks and Internet portal sites as well as other communication networks. Accordingly, all such implementations which fall within the spirit and the broad scope of the appended claims will be embraced by the principles of the present invention.
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A method and system for providing distributed web server authentication of a user in web servers using a shared secret key. The method and system include receiving a request to connect a user to a web server, creating a user password cookie using a shared secret key and transmitting the user password cookie in response to the request to connect. An implementation of the method and system includes establishing a connection between the web server and a second user using a second user password cookie and the shared secret key. Another implementation of the method and system includes establishing a connection between the user and a second web server using the user password cookie and the shared secret key.
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This is a division of application Ser. No. 849,334 filed Apr. 8, 1986.
BACKGROUND OF THE INVENTION
The present invention relates to a prestressing steel material for use in the fabrication of prestressed concrete by post-tensioning, and particularly to a prestressing steel material having a coating layer of microcapsules.
Concrete is preloaded with compressive stresses by applying tension to prestressing steel materials. There are two general methods of prestressing, namely pretensioning which is conducted before the concrete sets and hardens, and post-tensioning performed after the setting and hardening of the concrete.
Post-tensioning may be performed in two different manners. In one method, concrete is bonded to the prestressing steel material by means of mortar; in the other method generally referred to as the unbonding process, the prestressing steel material is positioned close to the concrete but separated therefrom by an intervening flowable material such as grease or asphalt.
The first bonding method is typically implemented as illustrated in FIG. 1: prior to pouring concrete, a sheath made of a thin iron plate is buried in the area where the prestressing steel material is to be positioned, and the prestressing steel material is inserted into the space of the sheath before or after the concrete sets, and the concrete then is prestressed by applying tension to the prestressing steel material. Thereafter, any space left in the sheath is filled with a grout such as mortar which will solidify to provide an integral and strong combination of the concrete and the prestressing steel material.
Grout such as mortar may be effective in protecting the prestressing steel material from corrosion but its primary function is to increase the durability of the member so that it may have sufficient rigidity and strength against bending and shear stresses.
Structural designs used to prevent direct contact between the prestressing steel material and the surrounding prestressed concrete are illustred in FIGS. 2 and 3. The design shown in FIG. 2 can be used for the prestressing steel material having a steel member of any form of a wire, bar or strand. A steel member 1 having a grease coating 7 is sheathed with a PE (polyethylene) tube 8. When the steel member 1 with the PE tube 8 is placed within a concrete section 6, the lubricating effect of the intermediate grease coating 7 reduces the coefficient of friction between the steel member and concrete to as low as between 0.002 and 0.005 m -1 . Because of this low coefficient of friction, the design in FIG. 2 provides great ease in post-tensioning a long steel cable in concrete. However, if the prestressing steel material is of short length, the need for preventing grease leakage from either end of the PE tube presents great difficulty in fabricating and handling the prestressing steel material. Furthermore, steel members having screws or heads at ends are difficult to produce in a continuous fashion.
The steel member 1 shown in FIG. 3, which is encapsulated in asphalt 9, has a lightly greater coefficient of friction than that of the structure shown in FIG. 2. However, this design is extensively used with relatively short prestressing steel materials since it is simple in construction, is lead-free, and provides ease in unbonding the prestressing steel material from the concrete, even if the steel member has screws or heads at end portions.
One problem with the design in FIG. 3 is that the presence of the asphalt (or its equivalent such as a paint) may adversely affect the working environment due to the inclusion therein of a volatile organic solvent. Moreover, the floor may be fouled by the splashing of the asphalt or paint. As another problem, great difficulty is involved in handling the coated prestressing steel material during drying after the coating or positioning within a framework, and separation of the asphalt coating can easily occur unless utmost care is taken in ensuring the desired coating thickness.
Further, according to the construction as shown in FIG. 2, although the sufficient corrosion resistance can be obtained by simply tensioning the prestressing steel material after the setting and hardening of the concrete without additional operations such as grouting, the member is unable to exhibit as high a durability as can be attained by grouting, since the prestressing steel material is fixed merely to the ends of the concrete section.
It is therefore more common to adopt the bonding process, rather than unbonding, if design considerations require sufficient rigidity and strength against bonding and shear stresses. The problem however is that the bonding process including the grouting step involves cumbersome procedures as compared with the unbonding process. For example, the bonding process inevitably involves not only the procurement of the sheath, grout, and fittings to be installed at the ends of the concrete section in preparation for grout injection, but also inventory management and installation of these materials, as well as operations and management of grout injection, and an extension of the working time.
Compared with the bonding method, the unbonding process involving no grouting step is very simple to peform and this simplicity in operation makes the unbonding process most attractive from a practical viewpoint. An advantage resulting from this feature is the small number of factors that might contribute to degraded reliability for the resultant construction.
SUMMARY OF THE INVENTION
The primary object, therefore, of the present invention is to provide a prestressing steel material for use in the fabrication of prestressed concrete by eliminating the aforementioned problems of the prior art.
Another object of the present invention is to provide a prestressing steel material for use in the fabrication of prestressed concrete which has a coat that is dry and nonflowable so that the coat will not stick to associated devices or operator's clothes during transportation and handling of the coated prestressing steel material while retaining its soundness as a coat.
Still another object of the present invention is to provide a prestressing steel material for use in the fabrication of prestressed concrete by post-tensioning while keeping the most of the operational simplicity of the unbonding process without sacrificing the advantages offered by the bonding process, i.e., the capability to impart sufficient improvements in flexural rigidity, shear strength and the like.
The above objects are accomplished by first preparing microcapsules containing a flowable material and then applying such microcapsules to or installing them on the outer surface of a steel member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a conventional structure of a prestressing steel material for use in the fabrication of prestressed concrete by post-tensioning in accordance with the bonding process,
FIGS. 2 and 3 are views showing two conventional prestressing steel materials for use in the fabrication of prestressed concrete by post-tensioning in accordance with the bonding process,
FIG. 4 is a longitudinal sectional view showing the structure of a coated prestressing steel material in accordance with the present invention, where a steel member is a single wire,
FIG. 5 is a cross sectional view showing the structure of a coated prestressing steel material in accordance with the present invention, where the steel member is composed of stranded wires,
FIG. 6 is a view showing the structure of a coated prestressing steel material in accordance with the another embodiment of the present invention, and
FIG. 7 is a view for explaining the measurement of a frictional coefficient of a prestressing steel material.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described with reference to the accompanying drawings.
In accordance with the present invention, as shown in FIGS. 4 or 5, microcapsules 13 are employed as a coating material that exhibits the desired "unbonding" property when stress is applied to the coated prestressing steel material placed in concrete. The microcapsules are made by confining in a resin or gelatin wall any flowable material or compound such as water, an aqueous solution, oil, grease or asphalt.
The microcapsules used in the present invention are described, for example, in Japanese Patent Application Laid-Open Nos. 161833/81, 4527/86 or 11138/86. The diameter of a microcapsule is preferably 100-300 μm. If the diameter is less than 100 μm, it is difficult to form the microcapsule. If the diameter is more than 300 μm, the strength of the microcapsule is low. The so prepared microcapsules may be applied to the outer surface of the steel member with the aid of a water-soluble adhesive agent such as PVA (Polyvinyl alcohol), carboxymethylcellulose, or hydroxyethycellulose. After the solution of the adhesive agent is coated on the outer surface of the steel member, the microcapsules are applied to the surface. Alternatively, a coat of the microcapsules may be formed by mixing microcapsules with powders of polyolefin system hydrocarbon such as paraffin or low molecular weight polyethylene, melting the low-melting material of the mixture by heat, and then cooling and solidifying the mixture.
When the water-soluble adhesive agent is used, the coating process of the microcapsules may be repeated by more than two times so as to ensure a desired thickness.
The coating of microcapsules is generally required to have a thickness of at least 200 μm. If a particularly small frictional force is desired, a coat's thickness of about 500 μm is preferable.
When the prestressing steel material coated with a layer of these microcapsules is post-tensioned for prestressing purposes, the microcapsules will be ruptured under a small amount of elongation, thereby enabling efficient transmission of the tension to the concrete while ensuring the desired "unbonding" property between the coated prestressing material and the concrete.
The flowable material to be confined in the microcapsules may be selected from oil, grease or synthetic material such as phosphate esters and ethylene glycol. When the microcapsules are ruptured by post-tensioning, these materials will come out and provide a rust-preventing film around the prestressing steel material. If a better rust-inhibiting effect is needed, as shown in FIG. 6, a synthetic resin coat 12 may be applied to the steel member as a corrosion-protective layer prior to coating with the microcapsules.
Samples of coated prestressing steel material were prepared in accordance with the present invention and tested for their unbonding properties. The results are shown in Table 1 below.
TABLE 1__________________________________________________________________________Unbonding (Frictional) PropertiesLoad (Kgf) Friction- FrictionalSample Tensioned Fixed al Loss CoefficientNo. Side (Pi) Side (Po) (Kgf) λ (m.sup.-1) Remarks__________________________________________________________________________1 11,441 11,249 192 0.0070 Steel rod, 13φ Length of concrete2 11,418 11,170 248 0.0091 section: l = 2,435ppm3 11,423 11,237 186 0.00684 11,405 11,180 225 0.0083 Sample temperature: T = 25° C.5 11,438 11,230 208 0.00766 11,397 11,161 236 0.00877 11,410 11,198 212 0.0078 Frictional coefficient:8 11,384 11,124 260 0.0096 ##STR1##9 11,428 11,185 243 0.008910 11,409 11,237 172 0.0063__________________________________________________________________________
The method of measuring the frictional coefficient will be described with reference to FIG. 7.
First, the sample 24 as obtained from the above procedure was placed in concrete 23 and thereafter the concrete was solidified. Load cells 21 were provided at both end portions of the sample member or wire 24 which were exposed from both sides of the concrete 23 and then tension was applied to the sample member 24 by a jack 22 provided at one end of the sample member 24 as shown in FIG. 7. At this time, a load applied to one end of the sample member by using the jack 22 and a load transmitted through the sample member applied to the other end of the sample member, i.e., the fixed side of the sample member, were simultaneously detected through both of the load cells 21 by a load measuring detector 25. Here, if Pi is defined as the load at the application side of the tension using the jack and Po is defined as the load applied to the fixed side of the sample member 24, the friction between the sample member and the concrete is obtained by subtracting Po from Pi and the frictional coefficient λ at unit length of the sample member is obtained from the following equation:
λ=(Pi-Po)/Po.l=(Pi/Po-1)/l
A prestressing steel material having advantages of both the unbonding process and the bonding process is obtained by using microcapsules containing an age-hardening resin or an age-hardening material such as a two-part hardening resin wherein two resins will mix and coalesce together to experience age-hardening, as the flowable material. As one of the two resins, a resin having no volume contraction at the hardening, such as epoxy resin, may be used. As a hardening agent, diethylenetriamine or higher hydrocarbon diamine may be used to harden the epoxy resin at the room temperature.
When the prestressing steel material provided with a surface coating of microcapsules confining the flowable material is post-tensioned, the microcapsules will be disrupted under a fairly small amount of elongation, whereupon the flowable material will come out of each microcapsule to provide the necessary slip properties which allow the steel slide easily within the concrete section. On the other hand, by using an age-hardening material as the flowable material, after the concrete is stressed by post-tensioning, the prestressing steel material is fixed to the concrete to provide a strong integral steel-to-concrete body.
A two-part hardening resin may be used as follows. That is, firstly, microcapsules containing one resin are prepared separately from those containing the other resin. Then, the two types of microcapsules are uniformly mixed in predetermined proportions, and the mixture is applied to or installed on the outer surface of a steel member. When the prestressing steel material is post-tensioned in concrete, the two types of microcapsules are disrupted and the contents thereof react with each other to exhibit hardening and bonding properties, thereby imparting a strong bond between the concrete and the prestressing steel material.
A three-part hardening resin may also be used. The hardening mechanism is not limited to the mixing of two or more contact-hardenable resins. Other hardening mechanism such as hardening by reaction with water, basic hardening or hardening by calcium absorption may also be used. If desired, microcapsules each consisting of two or more compartments incoporating different resins may be used.
As described above, according to the present invention, microcapsules are applied to the surface of a prestressing steel material to provide bonding and/or unbonding property against concrete. The surface of the prestressing steel material applied with the microcapsules may be further coated with a sheath or film of resin material or may be processed to protect it with paper, cloth and the like.
As will be understood from the above description, the prestressing steel material of the present invention is well adapted to use in the fabrication of prestressed concrete in that it ensures high efficiency in unbonding operations and easy handling during service. In addition, this prestressing steel material exhibits highly reliable unbonding properties. Therefore, the prestressing steel material of the present invention will present great benefits to industry.
Further, the prestressing steel material of the present invention has the hitherto inherently conflicting features of the two conventional post-tensioning methods and will therefore prove very useful in the design and fabrication of a prestressed concrete structure.
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An elongated prestressing steel material for use in the fabrication of prestressed concrete comprises a steel member and an outer coat of many microcapsules each containing a flowable material in its interior.
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BACKGROUND OF THE INVENTION
The present invention relates to a device by which substantially parallelepiped products or stacks of products can be transferred from one conveyor to another.
The object of the present invention is to embody a conveyor device free from the drawbacks described above.
SUMMARY OF THE INVENTION
The stated object is realized in a device according to the present invention in which products or stacks of products are transferred from one conveyor to another.
Such a device comprises at least one compartment having a size defined in part by opposing vertical wall members capable of relative movement therebetween for adjusting the size of the compartment. A drive system first moves the wall members relative to one another to adjust the size of the compartment(s) and then moves the wall members at a substantially equal velocity in a direction substantially perpendicular to that in which the products are fed to the device. A central control unit receives a product size value and controls the drive system to move the wall members relative to one another to adjust the size of the compartment to the product size value and then move the wall members at substantially equal velocity to move the compartment in the direction substantially perpendicular to that in which the products are fed to the device.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail, by way of example, with the aid of the accompanying drawings, in which:
FIG. 1 is a schematic plan view of the device according to the present invention;
FIG. 2 shows a detail of FIG. 1, enlarged and with certain parts cut away better to reveal others;
FIG. 3 is the view from III FIG. 2, in which certain parts are omitted better to reveal others;
FIG. 4 is the section through IV--IV in FIG. 2, in which certain parts are omitted better to reveal others;
FIG. 5 is the section through V--V in FIG. 1 in which certain parts are omitted better to reveal others;
FIG. 6 shows a block diagram illustrative of one possible operative relationship of the device according to the invention;
FIG. 7 is a graph showing the operating steps of the device disclosed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The conveyor device according to the present invention is shown in its entirety in FIG. 1 and indicated generally at 1. Conveyor device 1 is positioned at the runout end of an infeed conveyor 21 and comprises at least one compartment 2 capable of movement in a direction perpendicular to that in which the products 10 run out ultimately from the infeed conveyor 21.
The device 1 may be equipped with a plurality of compartments 2 as in the embodiment of FIG. 1, to which reference is made throughout the following specification strictly by way of example and with no limitation implied in regards to the scope of the invention. Each such compartment 2 is encompassed by two vertical walls 3 and 4 parallel with one another, and by two horizontal ledges 5 and 6 that occupy a common plane and are associated respectively with the two walls in such a way as to form two mutually opposed wall members or L-shaped elements 7 and 8 (see FIG. 3). The walls 3 and 4 are splayed at the end of the compartment directed toward the infeed conveyor 21 in such a way as to favor the entry of the products 10. The L-shaped elements 7 and 8 are mechanically associated with respective drive means 11 and 12, which set the L-shaped elements in motion independently but also with a measure of interdependence, as will be made clear in due course. As discernible in FIGS. 1 and 2, one set of L-shaped elements 7 is associated mechanically with one drive means 11, and the other set of L-shaped elements 8 with the remaining drive means 12.
Each horizontal ledge 5 and 6 is anchored to the top of a respective trolley 23 and 24 (see FIGS. 5 and 4 respectively) supported by a rail 22 mounted in its turn to a frame 25 (see FIG. 5) and appearing as a closed loop with two rectilinear horizontal branches (FIGS. 3 and 5). The rail 22 affords three longitudinal channels of which two, denoted 22m and 22s, are laterally orientated (see FIG. 4). The third, denoted 22g, occupies the outwardly directed frontal face of the closed loop (see also FIG. 4). Each trolley 23 and 24 exhibits two pairs of freely revolving wheels 230, 240 and 23v, 24v rotatable about respective horizontal and vertical axes. Wheels 23v and 24v are arranged to rotate about vertical axes and to run in the frontal channel 22g of the rail 22, while wheels 230 and 240 rotate about horizontal axes running in the respective lateral channels 22m and 22s of the rail 22. In effect, the function of the wheels denoted 230 and 240 is to support the relative trolleys 23 and 24, whilst the wheels denoted 23v and 24v serve to maintain the position of the trolleys 23 and 24, as discernible from FIGS. 4 and 5.
The trolleys 23 and 24 are anchored mechanically to respective looped transmission components 19 and 20 occupying relative vertical planes on either side of the rail 22. Such transmission components are shown in FIG. 3 as a pair of timing belts 19 and 20 looped around respective pulleys 27 and 28 visible in FIG. 1. Pulleys 27 and 28 are driven by relative motors 29 and 30, which, together with the belts 19 and 20, constitute the drive means 11 and 12 mentioned above. More exactly, one trolley 23 is anchored to the relative belt 19 by means of a connecting pin denoted 23c, while the other trolley 24 is anchored to the remaining belt 20 by a connecting pin denoted 24c (FIG. 2). As discernible from FIGS. 1, 2 and 5, the horizontal ledge 5 of each of the L-shaped elements denoted 7 is associated with freely revolving rollers 13 and power driven rollers 14, each rotatable about an axis parallel to the direction established by the rectilinear branches of the rail 22. The freely revolving rollers 13 are supported directly by the corresponding ledges 5, whereas the power driven rollers 14 are carried by a separate structure 15 and set in rotation by respective drive means 16. In the particular embodiment illustrated in FIG. 5, the power driven rollers 14 are keyed to a shaft 31 carried by support means that includes in arms 32 forming part of the aforementioned structure 15 and articulated with the frame 25 by way of a pivot denoted 33. The arms 32 are capable of movement, brought about by actuator means 34 anchored to the frame 25, in such a way as to raise and lower the shaft 31 between two limit positions so that the uppermost portion of the peripheral surface of each power driven roller 14 lies respectively above and below the bearing surface of the corresponding horizontal ledge 5 when the shaft is raised and lowered. Accordingly, each ledge 5 affords a gap 35 through which the power driven rollers 14 can project. The drive means 16 includes a motor 36, carried by the arms 32 as illustrated in FIG. 5 and connected mechanically to the shaft 31.
FIGS. 1, 2, 4 and 5 further illustrate a vertical reference wall 37 disposed parallel to the rail 22, located on the side remote from the conveyor 21, which is supported adjustably by the frame 25 and capable of movement inwardly towards compartments 2 and outwardly away from compartments 2. The device 1 also comprises a number of sensors or encoders 38, 39 and 41 capable of monitoring the angular velocity and position of the motors 29, 30 and 36 (see FIG. 6). The encoders 38, 39 and 41, the motors 29, 30 and 36 and the actuator means 34 are all connected to a central control unit for 9 monitoring and controlling the operation of the entire device 1. The operation of the device 1 is governed entirely by the central control unit 9, into which an input device 40 such as a keyboard will be connected. The operating cycle commences with the belts 19 and 20 at standstill and the actuator 34 deactivated to leave the power driven rollers 14 in the at-rest position below the bearing surfaces of the relative ledges 5 (position 0 in FIG. 7). In this situation, the walls 3 and 4 are set apart from one another at a distance greater than the width value entered for the single product or stack of products 10, so that the product can be introduced more easily into the compartment 2.
The infeed conveyor 21 is activated to direct one or more products 10 toward the device 1. At the same time, the power driven rollers 14 are raised by the actuator 34 such that their rolling surfaces project above the bearing surfaces of the ledges 5, and set in rotation by the motor 36. Thereafter, the products 10 are released progressively from the conveyor 21 onto the ledges 5 and 6, and their passage into the respective compartments 2 is assisted by the action of the rollers 14. At a certain point, the products 10 are taken up onto the freely revolving rollers 13 and propelled further by the action of the power driven rollers 14 alone, until contact is made with the reference wall 37 (see FIG. 5). The actuator 34 is then deactivated, the motor 36 either being deactivated or continuing to operate, whereupon the motor denoted 29 is activated to set the corresponding belt 19 in motion, and with it the relative L-shaped elements 7 (step 1, FIG. 7). This has the effect of drawing the one vertical wall 3 toward the other wall 4 through a distance entered in the central control unit 9 and sensed by the relative encoder 38.
Once the central control unit 9 acknowledges, on the basis of the information received from the encoder 38, that the belt 19 and the walls 3 have moved through a distance equal to the difference between the distance separating the walls 3 and 4 corresponding to the dimension of the product 10), the motor 30 is activated by the central control unit 9, so as to set the remaining belt 20 and the relative walls 4 in motion (step 2, FIG. 7). The position of L-shaped elements 7 and 8, which determines the size of the compartments 2 in one dimension, will now be advanced synchronously by the two respective drive means 11 and 12. The control unit 9 continues, meanwhile, to receive information from the encoders 38 and 39 as to the angular position of the output shafts of the motors 29 and 30, which, in turn, determines the position of the vertical walls 3 and 4. On the basis of this information the control unit 9 will pilot the two motors 29 and 30 to maintain the distance between the vertical walls 3 and 4 substantially constant, and equivalent to the corresponding dimension of the products 10. In effect, therefore, the two motors 29 and 30 operate synchronously in order to conserve the relative positions of the two walls 3 and 4.
For removal of the products from compartments 2, the relative encoder 38 indicates that the walls 3 first set in motion have covered a prescribed distance, and, in response, the central control unit 9 shuts off the corresponding motor 29 while allowing the remaining motor 30 to run (step 3, FIG. 7) until the relative walls 4 have completed their allotted distance. Evidently enough, the effect of such a step is to spread the walls 3 and 4 to the relative positions occupied at the start of the cycle (position 0, FIG. 7), thereby facilitating the removal of the products 10 from the compartments 2 by means not illustrated in the drawings. The extreme flexibility of the device according to the invention is thus clearly illustrated. Adaptation of the device to a new size of product 10 can be accomplished simply by entering the appropriate values in the central control unit 9 by way of the keyboard 40.
It should also be noted that in the instance that the width of the product happens to be greater than the distance between centers of adjacent compartments 2, then a given number of the L-shaped elements 7 and 8 will be removed and the remaining elements 7 and 8 spaced appropriately apart along the belts 19 and 20 and anchored in new positions.
The foregoing preferred specific embodiment has been shown and described for the purpose of this invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
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At least one compartment capable of movement in a direction substantially perpendicular to that in which the products are fed to the device. Each compartment has a size defined by opposing vertical wall members capable of relative movement therebetween for adjusting the size of the compartment. A drive system first moves the wall members relative to one another to adjust the size of the compartment(s) and then moves the wall members at a substantially equal velocity in the direction substantially perpendicular to that in which the products are fed to the device. A central control unit receives a size value of the product and controls the drive system to move the wall members relative to one another to adjust the size of the compartment to the product size value and then move the wall members at substantially equal velocity to move the compartment in the direction substantially perpendicular to that in which the products are fed to the device.
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BACKGROUND
[0001] Certain software products are able to monitor themselves during execution and produce data points relating to status condition, action, event and other parameters and characteristics of the product or its working environment. These data points may be collected in a data warehouse. A software manufacturer may then query the data warehouse to obtain various metrics regarding its product.
[0002] The general process of data warehousing may include accepting raw data points, e.g., the unprocessed data sent from a software application, and performing some organization of the data points in order to store them in a structured manner within a database so that queries may be efficiently run on the database. However, setting up a data warehouse to accept incoming data points requires a prediction of the types of information that will be requested from the data warehouse.
[0003] Defining data structure prior to querying may result in queries being limited to a range of data and/or having a constrained view of the data, thereby inhibiting ad hoc querying. Moreover, while storing unstructured raw data may provide information to satisfy an ad hoc query, storing unstructured raw day may be prohibitively expensive as reporting applications tend to produce inordinate amounts of data. Also, querying unstructured data is cumbersome and inefficient.
SUMMARY OF THE INVENTION
[0004] The present invention enables ad hoc querying of a data warehouse by dividing received application data into an aggregate data store and one or more raw data stores. A modification of the invention involves a reporting tool that is able to locate the correct data store to respond to queries, extract the data, and generate a report.
DRAWINGS
[0005] FIG. 1 illustrates a block diagram of a computing system that may operate in accordance with the claims;
[0006] FIG. 2 illustrates a general data warehouse process;
[0007] FIG. 3 illustrates a process embodiment of the claims;
[0008] FIG. 4 illustrates a reporting process embodiment of the claims;
[0009] FIG. 5 illustrates data sample clusters over a time horizon; and
[0010] FIG. 6 a - 6 c illustrate graphical reporting examples using the data clusters of FIG. 5 .
DETAILED DESCRIPTION
[0011] Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.
[0012] It should also be understood that, unless a term is expressly defined in this patent using the sentence “As used herein, the term ‘______’ is hereby defined to mean . . . ” or a similar sentence, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term be limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. § 112, sixth paragraph.
[0013] FIG. 1 illustrates an example of a suitable computing system environment 100 on which a system for the blocks of the claimed method and apparatus may be implemented. The computing system environment 100 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the method and apparatus of the claims. Neither should the computing environment 100 be interpreted as having any dependency or requirement relating to any one component or combination of components illustrated in the exemplary operating environment 100 .
[0014] The blocks of the claimed method and apparatus are operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well known computing systems, environments, and/or configurations that may be suitable for use with the methods or apparatus of the claims include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
[0015] The blocks of the claimed method and apparatus may be described in the general context of computer-executable instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. The methods and apparatus may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer storage media including memory storage devices.
[0016] With reference to FIG. 1 , an exemplary system for implementing the blocks of the claimed method and apparatus includes a general purpose computing device in the form of a computer 110 . Components of computer 110 may include, but are not limited to, a processing unit 120 , a system memory 130 , and a system bus 121 that couples various system components including the system memory to the processing unit 120 . The system bus 121 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnect (PCI) bus also known as Mezzanine bus.
[0017] Computer 110 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 110 and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by computer 110 . Communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above should also be included within the scope of computer readable media.
[0018] The system memory 130 includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 131 and random access memory (RAM) 132 . A basic input/output system 133 (BIOS), containing the basic routines that help to transfer information between elements within computer 110 , such as during start-up, is typically stored in ROM 131 . RAM 132 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 120 . By way of example, and not limitation, FIG. 1 illustrates operating system 134 , application programs 135 , other program modules 136 , and program data 137 .
[0019] The computer 110 may also include other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only, FIG. 1 illustrates a hard disk drive 140 that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive 151 that reads from or writes to a removable, nonvolatile magnetic disk 152 , and an optical disk drive 155 that reads from or writes to a removable, nonvolatile optical disk 156 such as a CD ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The hard disk drive 141 is typically connected to the system bus 121 through a non-removable memory interface such as interface 140 , and magnetic disk drive 151 and optical disk drive 155 are typically connected to the system bus 121 by a removable memory interface, such as interface 150 .
[0020] The drives and their associated computer storage media discussed above and illustrated in FIG. 1 , provide storage of computer readable instructions, data structures, program modules and other data for the computer 110 . In FIG. 1 , for example, hard disk drive 141 is illustrated as storing operating system 144 , application programs 145 , other program modules 146 , and program data 147 . Note that these components can either be the same as or different from operating system 134 , application programs 135 , other program modules 136 , and program data 137 . Operating system 144 , application programs 145 , other program modules 146 , and program data 147 are given different numbers here to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer 20 through input devices such as a keyboard 162 and pointing device 161 , commonly referred to as a mouse, trackball or touch pad. Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 120 through a user input interface 160 that is coupled to the system bus, but may be connected by other interface and bus structures, such as a parallel port, game port or a universal serial bus (USB). A monitor 191 or other type of display device is also connected to the system bus 121 via an interface, such as a video interface 190 . In addition to the monitor, computers may also include other peripheral output devices such as speakers 197 and printer 196 , which may be connected through an output peripheral interface 190 .
[0021] The computer 110 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 180 . The remote computer 180 may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer 110 , although only a memory storage device 181 has been illustrated in FIG. 1 . The logical connections depicted in FIG. 1 include a local area network (LAN) 171 and a wide area network (WAN) 173 , but may also include other networks. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
[0022] When used in a LAN networking environment, the computer 110 is connected to the LAN 171 through a network interface or adapter 170 . When used in a WAN networking environment, the computer 110 typically includes a modem 172 or other means for establishing communications over the WAN 173 , such as the Internet. The modem 172 , which may be internal or external, may be connected to the system bus 121 via the user input interface 160 , or other appropriate mechanism. In a networked environment, program modules depicted relative to the computer 110 , or portions thereof, may be stored in the remote memory storage device. By way of example, and not limitation, FIG. 1 illustrates remote application programs 185 as residing on memory device 181 . It will be appreciated that the network-connections shown are exemplary and other means of establishing a communications link between the computers may be used.
[0023] FIG. 2 illustrates the general process of data warehousing. Generally, a reporting application 201 will communicate raw data 202 to a data warehouse processing server 203 where the data warehouse processing server 203 may perform some functions on the data 204 - 206 , and load the manipulated data into a structured database 207 . The process of manipulating raw data into aggregated, or structured, data for storage into a database is called extract 204 , transform 205 , and load 206 (ETL). The data warehouse stores aggregated data after the processing server has completed manipulating, or transforming the data. The raw data file may contain a set of data points. A data point is a basic measurement unit that holds information representing a quantity or measure of a reporting application. Examples of data points include a number of favorites, a length of time that a user keeps the dial-up properties window open, and a screen resolution of a user monitor.
[0024] The data warehouse may comprise more than one storage device. For example, a data warehouse may comprise a storage area network (SAN). The SAN may comprise a set of databases connected by a network. In a SAN, data may be geographically stored in different databases, however, information requests are processed by the SAN without the need for a requestor to be aware of the actual location of the data.
[0025] Creating a data warehouse system generally involves defining a set of cubes. A cube is a specialized type of database that optimizes the manipulation and storage of data. A dimension of a cube is a descriptive or analytical view of numeric data in a cube. For example, when a report is created from a data cube, the data are grouped by dimension. A dimension may also be considered a data label, where the label describes a characteristic of the data.
[0026] The process for creating a data warehouse generally begins by defining a set of dimensions for a set of cubes. In determining the dimensions or parameters of a cube, data warehouse designers typically anticipate the types of information requests that will be demanded of the data warehouse. For example, a designer may anticipate the types of questions or reports a typical business executive may ask of the reporting data for a company's software application. A set of cubes can then be designed in order to facilitate the efficient organization of data. Once the cubes are designed and a database is configured to correspond to the cubes, a data warehouse processing server may configure an ETL process to accept application data and load the transformed data into the cubes. In some existing systems, the ETL is custom code created by a data warehouse designer. After the data is manipulated and loaded into cubes, the data may be called aggregate data. In response to a query, the aggregate data stored in the cubes may be provided in an efficient and structured manner. Aggregated data may represent compilations of raw data into statistically significant sets.
[0027] There may be times when a query is received that cannot be answered by any existing structured data, or cube. For example, a query corresponding to an executive's query regarding two dimensions or variables that have not been predefined by an existing cube would not be able to be answered readily. While a workaround solution may exist to extract the data from existing cubes, this solution may be suboptimal because it requires an inefficient extraction process and may require additional database and/or data warehouse expertise. The workaround solution may also be suboptimal because the solution requires guesswork on the correlateability of dimensions. Furthermore, aggregated data may not contain the necessary data points required to answer a non-defined query. For example, a workaround solution may require creating a new cube and waiting a duration of time for the cube to be populated with new data, and thus, a query cannot be answered for a prior time period. Therefore, additional raw data not captured in an aggregate store may need to be accessed occasionally, in an efficient manner, to answer non-defined, ad hoc queries.
[0028] FIG. 3 illustrates a process embodiment of the claims. A data warehouse processing server receives raw data 301 . Based on a set of criteria 315 , the processing server may decide to perform 304 a regular ETL process 303 , 305 , 306 on the received data and store the processed, or aggregated, data into an aggregate data store 307 . The processing server 302 may-also decide 304 to sample 308 the received data 301 and store the sample portions of the received data in a raw data store 312 - 314 . The sample portions may also be divided based on a set of criteria where certain portions are stored in different raw data stores 312 - 314 .
[0029] As illustrated in FIG. 3 , the raw data store may comprise a set of databases 312 - 314 connected by a network 311 , thereby forming a storage area network. The raw data stores may comprise different types of storage medium. The types of storage medium may be characterized by speed of data access. In an embodiment of the claims, the processing server determines which raw data store to store the information based on certain characteristics of the data. For example, data that is frequently accessed may be stored in a raw data store which has high speed access. Data that is more infrequently accessed may be stored on slower media. Slower media may include devices with slower operation times. Slower media may also include offline media such as computer tapes which must first be loaded (either by machine or manually) in order to access relevant data.
[0030] In an embodiment of the claims, the data warehouse process server may sample received data based on a set of time markers. These markers may coincide with milestone events within a business product cycle, such as a product update. In one embodiment, the received data may be sampled at a greater rate when the data received is closer to a milestone and sampled at a lesser rate when the data received is farther from a milestone. Alternatively, the received data may be sampled at one frequency and the sampled data may be partitioned into data closer to the milestones and farther from the milestones. The data points closer to a milestone may be stored in a high speed access raw data store, while the data points farther from a milestone may be stored in a low speed access raw data store.
[0031] The designation of milestones may be made manually and set by a human operator. Alternatively, the milestones may be calculated automatically by a computer. This calculation may be performed by the data warehouse processing server or by a separate server. In any case, the calculation may monitor changes in metric statistics and designate a milestone based on threshold parameters. For example, as illustrated in FIG. 5 , a common milestone may be a release to manufacture (RTM) date, in which the traffic for a reporting application may dramatically increase (for example, from zero). The calculating function or device may monitor the rate of data received by the process server and trigger the creation of a milestone marker when the amount of traffic increases past a threshold. The milestone may also be manually created based on known product events.
[0032] Sampling based on milestones may be used to partition data into useful versus less useful data, and/or into statistically significant versus insignificant data. In a further embodiment, sampling may involve dividing the received data by dimension and maintaining a constant, or control, set of data points and a variable set of data points, where the variable set is randomly taken while the constant set uses fixed characteristic data points. Sampling the data in this manner may enable the processing server to detect when large, statistically significant deviations or differences occur between the control set and variable set. The processing server may then designate a milestone based on the detection of these deviations.
[0033] Sampling and partitioning of raw data may also be based on the usage patterns of the product, for example the amount of data traffic received. High usage pattern events may also create a time marker, or milestone marker. The usage patterns may also be based on data point dimensions. For example, the sampling may be influenced by the type of data being received by the process server. For example, a peak in data having a dimension indicating a statistically significant metric may trigger higher sampling and storage into a high priority media.
[0034] FIG. 4 illustrates a reporting process embodiment of the claims. A reporting server 402 may accept a user query 401 for a report and determine the type of data needed to fill the request. The reporting server may then access a table or directory 403 to determine whether the information is stored in an aggregate store 405 or one of a set of raw data stores 406 - 408 . If the information can be obtained solely from the aggregate store 405 , then the reporting server may simply query a data processing server for the required information to create the report. If the information is stored in a raw data store 406 - 408 , the server will calculate and/or estimate the amount of time required to access and collect the required data from the raw data stores and return the estimate to the user or user application before executing the process for collecting the information. The reporting server may then extract the data from the raw store directly. Alternatively, the reporting server may initiate the creation of a data warehouse cube that is configured to answer the query and/or the reporting server may create a database table structured to answer the query. The cube or table may then be loaded with information from the set of raw data stores. The query can then be answered using the processing server.
[0035] FIGS. 5 and 6 a - 6 c, illustrate the additional reporting functionality possible from the claimed system and method. FIG. 5 illustrates data clusters received and stored in various medium over a time horizon. The online aggregate data line 501 provides most of the necessary information to accommodate average day to day queries for which the data warehouse was designed, e.g., using cubes. The online raw data 502 may contain a cluster of data points around significant product milestones, such as an RTM or a service pack (SP) release date. The online raw data is stored in a relatively high access medium. Higher sample rate raw data segments 503 may be stored in an offline data store having low speed access. Because dimensions are no longer inhibited and are alterable using the claimed system and method, various reports such as the ones listed below may be generated, such as cross-tab and snap-shot reporting 504 , historical trend reporting 505 , and unrestricted reporting 506 . Examples of these reports are graphically illustrated in FIGS. 6 a - 6 c. FIG. 6 a illustrates a multi-dimensional cross tab report which provides N-dimensional reporting (e.g., allows a user to combine datapoints as dimension or measure) and ad-hoc, multi-variant reporting. This report requires raw data windows or samples. FIG. 6 b illustrates a historical trend report which can be used to perform a trend analysis for a distribution of a few datapoint values. This report provides high performance, but is limited to a few dimensions. Aggregations & aggregation grain must be pre-defined for this report, meaning that more dimensions in aggregation dramatically increases disk usage. FIG. 6 c illustrates a snapshot comparison report. This report provides the capabilities of N-dimensional cross-tab comparisons and ad-hoc analysis between points in time. A limitation to this report may be that it needs raw data windows at points in time that a user desires to compare.
[0036] Existing data warehouse systems are not typically designed to accommodate for alterations in the data warehouse configuration after the data warehouse is released to operation. As discussed above, the configuration of a data warehouse requires the analysis of query type and the design of a set of cubes to accommodate the ETL processing of received data. This configuration may involve the creation of a new set of databases or data stores, and the programming of several functions for manipulating the data and loading it into the data stores. Thus, ad hoc queries have not been easily satisfied with existing data warehouse systems. The claimed method and system enables ad hoc querying to be performed more efficiently and economically. Information required to satisfy ad hoc querying may be obtained quickly based on the strategic loading of raw data based on storage access speed. The claimed method and system reduces the need for additional experts to perform the ad hoc query. Moreover, because strategic sampling is used, storage space is conserved.
[0037] Although the forgoing text sets forth a detailed description of numerous different embodiments, it should be understood that the scope of the patent is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment because describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments may be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.
[0038] Thus, many modifications and variations may be made in the techniques and structures described and illustrated herein without departing from the spirit and scope of the present claims. Accordingly, it should be understood that the methods and apparatus described herein are illustrative only and are not limiting upon the scope of the claims.
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A system for sampling raw data from a reporting application and segmenting portions of the sampled data into at least one of a set of raw data stores. The system enables ad hoc querying to be done against a data warehouse using the set of raw data stores and in conjunction with an aggregate store. A reporting aspect of the system is responsible for locating the appropriate store when responding to a query. The system also segments data based on anticipated usage of the raw data and appropriately places them into a raw data store having an access speed that corresponds to the anticipated usage level of the data.
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FIELD OF THE INVENTION
The present invention relates to a clock generation apparatus and, more particularly, to technology of correctly acquiring VBI data from television signals or the like on which the VBI data are superimposed.
BACKGROUND OF THE INVENTION
FIG. 13 is a block diagram illustrating a semiconductor integrated circuit which constitutes a prior art clock generation apparatus for generating a synchronous clock for a signal which is input at a fixed rate.
As shown in this figure, the semiconductor integrated circuit 1300 constituting the prior art clock generation apparatus comprises an analog input terminal 1301 , a threshold input terminal 1302 , a synchronous signal output terminal 1303 , a synchronous clock output terminal 1304 , a comparator circuit 1305 , a clock supply circuit 1306 , a counter circuit 1307 , a decoder circuit 1308 , an edge detection circuit 1309 and a D-type flipflop 1310 .
The comparator circuit 1305 is a circuit for comparing an analog signal S 1301 with the level of a threshold S 1302 and outputting the result of the comparison as a binarized signal, i.e., a comparison signal S 1305 . The comparator circuit 1305 operates using a clock supplied by an oscillator circuit in the clock supply circuit 1306 as the reference clock.
The clock supply circuit 1306 is realized by a crystal oscillator circuit using a crystal or the like. The frequency of the clock which is output by the clock supply circuit is an integral multiple of the rate at which the analog signal S 1301 is input. In addition, the edge detection circuit 1309 is a circuit for detecting the edge of the comparison signal S 1305 which is output by the comparator circuit 1305 . The signal which has been subjected to the edge detection is supplied to the counter circuit 1307 .
The counter circuit 1307 operates using the clock signal S 1306 from the clock supply circuit 1306 as the reference clock. The count value output by the counter circuit 1307 is supplied to the decoder circuit 1308 . The counter circuit 1307 operates using the output from the edge detection circuit 1309 and the output from the decoder circuit 1308 as the clear signals.
Hereinafter, the operation of the digital PLL device will be described.
Initially, the analog signal S 1301 and the threshold S 1302 are input to the comparator circuit 1305 via the analog input terminal 1301 and the threshold input terminal 1302 , respectively.
The comparator circuit 1305 makes the comparison to see whether the level of the analog signal S 1301 is larger or smaller than the threshold S 1302 , and outputs the result of the comparison.
A binarized comparison signal S 1305 output by the comparator circuit 1305 is input to the edge detection circuit 1309 , and the edge of the comparison signal S 1305 is detected herein. The signal whose edge was detected is supplied to the counter circuit 1307 and clears the counter.
Owing to the series of operations of edge detection and counter clear, the count value of the counter circuit 1307 and the edge, i.e., phase of the comparison signal S 1305 , match.
The count value of the counter circuit 1307 is usually composed of plural bits. Therefore, the decoder circuit 1308 executes decoding so as to output a sample clock signal S 1304 and strobe the analog input signal S 1301 in an appropriate phase. The D-type flipflop 1310 stably latches the comparison signal S 1305 with supply of a sample clock signal S 1304 which is output by the decoder circuit 1308 .
As described above, in the semiconductor integrated circuit 1300 constituting the prior art clock generation apparatus, a clear signal S 1308 for clearing the count value of the counter circuit 1307 decides the frequency division ratio of the counter circuit 1307 . The D-type flipflop 1310 stably latches the comparison signal S 1305 with the sample clock signal S 1304 which is output by the decoder circuit 1308 . Therefore, the semiconductor integrated circuit 1300 outputs a synchronous signal and a synchronous clock, which are stable toward the variations in outside environments, such as the variations in temperature or supply voltage and variations with time.
However, in the semiconductor integrated circuit constituting the prior art clock generation apparatus, the frequency of an oscillated clock S 1306 which is supplied by the clock supply circuit 1306 is an integral multiple of the input rate of the analog signal S 1301 , and the variations in the count value of the counter circuit 1307 directly result in the resolution showing the phase of the input analog signal S 1301 . Therefore, the error in the phase which occurs in the counter circuit 1307 results in the phase error in the case where the signal is captured by the D-type flipflop 1310 . In order to solve this problem, the only way is to increase the frequency of the clock supply circuit 1306 to improve the performance. Further, when this is implemented and an extremely high frequency is selected as the frequency of the clock supply circuit 1306 , unnecessary radiation is generated from the semiconductor integrated circuit.
Further, in the semiconductor integrated circuit constituting the prior art clock generation apparatus, in the case where the oscillated clock s 1306 is not an integral multiple of the input rate of the analog signal S 1301 , when the input signal S 1301 is kept in a certain condition during a period longer than the cycle of the oscillated clock S 1306 (for example, when the high level continues), the phase error for the input signal finally exceeds the tolerance and the input signal is erroneously recognized. This results in limiting the frequency of the oscillated clock which is used in the semiconductor integrated circuit comprising the prior art clock generation apparatus. Accordingly, when the input signal has plural kinds of input rates, plural oscillator circuits which correspond to respective input rates are required.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a clock generation apparatus that generates a synchronous clock on the basis of an input analog signal.
A clock generation apparatus according to a 1st aspect of the present invention comprises: A/D conversion means for converting an input analog signal into a digital signal; arithmetic means for generating a threshold which is used as a reference when the digital signal is binarized to generate a binarized signal and a synchronous clock for sampling the binarized clock, on the basis of the digital signal; binarization means for comparing the digital signal with the threshold generated by the arithmetic means, and outputting a result of the comparison as a binary signal; and latch means for latching the binary signal with the synchronous clock and outputting a synchronous signal, and the arithmetic means comprise threshold detection means for detecting a maximum value and a minimum value of the digital signal in a predetermined period, and outputting an average of the maximum value and the minimum value as the threshold; rise time detection means for detecting a rise time as a time of intersection of the threshold and a line connecting two values of the digital signal, one of which is lower and the other of which is higher than the threshold, when the digital signal changes from the lower value to the higher value; fall time detection means for detecting a fall time as a time of intersection of the threshold and a line connecting two values of the digital signal, one of which is higher and the other of which is lower than the threshold, when the digital signal changes from the higher value to the lower value; input rate detection means for obtaining time intervals between the adjacent rise and the fall times during a predetermined period, and outputting a minimum value of the time intervals as an input rate of the analog signal; and synchronous clock output means for obtaining a half timing of the input rate after an edge of the input analog signal is detected on the basis of the input rate and the rise and fall times and outputting a first one of the synchronous clock at that timing, and obtaining a timing of the input rate after the first synchronous clock is output and outputting a second or later one of the synchronous clock at that timing. Therefore, the input rate is detected from the digital signal which is obtained by subjecting the input analog signal to the A/D conversion, and the synchronous clock is generated on the basis of the input rate. Thereby, when the binarized signal is to be latched, the phase error between the synchronous clock and the binarized signal can be kept within one clock of the synchronous clock. Further, even when the input analog signal has plural kinds of input rates, the plural clock supply circuits are not required.
A clock generation apparatus according to a 2nd aspect of the present invention comprises: A/D conversion means for converting an input analog signal into a digital signal; arithmetic means for generating a threshold which is used as a reference when the digital signal is binarized to generate a binarized signal and a synchronous clock for sampling the binarized clock, on the basis of the digital signal; binarization means for comparing the digital signal with the threshold generated by the arithmetic means, and outputting a result of the comparison as a binary signal; and latch means for latching the binary signal with the synchronous clock and outputting a synchronous signal, and the arithmetic means comprise threshold detection means for detecting integrals of the digital signal in a predetermined period, and outputting an average of the integrals as the threshold; rise time detection means for detecting a rise time as a time of intersection of the threshold and a line connecting two values of the digital signal, one of which is lower and the other of which is higher than the threshold, when the digital signal changes from the lower value to the higher value; fall time detection means for detecting a fall time as a time of intersection of the threshold and a line connecting two values of the digital signal, one of which is higher and the other of which is lower than the threshold, when the digital signal changes from the higher value to the lower value; input rate detection means for obtaining time intervals between the adjacent rise and the fall times during a predetermined period, and outputting a minimum value of the time intervals as an input rate of the analog signal; and synchronous clock output means for obtaining a half timing of the input rate after an edge of the input analog signal is detected on the basis of the input rate and the rise and fall times and outputting a first one of the synchronous clock at that timing, and obtaining a timing of the input rate after the first synchronous clock is output and outputting a second or later one of the synchronous clock at that timing. Therefore, in addition to the effects of the 1st aspect, the clock generation apparatus is hard to be affected by noises or the like in detecting the threshold, thereby detecting the more accurate threshold.
According to 3rd and 4th aspects of the present invention, the clock generation apparatus of the 1st and 2nd aspects, respectively, comprises an oversampling digital filter for interpolating the adjacent digital signals. Therefore, arbitrary frequency characteristics are given to the digital signal, whereby unnecessary signals, such as noises, can be removed. Further, the oversampling increases the number of sample data, whereby the temporal resolution of the digital signal can be increased.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a clock generation apparatus according to a first embodiment of the present invention.
FIG. 2 is a block diagram illustrating an arithmetic circuit in the clock generation apparatus of the first embodiment.
FIG. 3 is a flowchart showing the operation of the arithmetic circuit of the first embodiment.
FIG. 4 is a flowchart showing a threshold detection method according to the first embodiment.
FIG. 5 is a flowchart showing a rise time detection method according to the first embodiment.
FIG. 6 is a timing chart for explaining the rise time detection method of the first embodiment.
FIG. 7 is a flowchart showing a fall time detection method according to the first embodiment.
FIG. 8 is a flowchart showing an input rate detection method according to the first embodiment.
FIG. 9 is a flowchart showing a synchronous clock output method according to the first embodiment.
FIG. 10 is a block diagram illustrating an arithmetic circuit in a clock generation apparatus according to a second embodiment of the present invention.
FIG. 11 is a flowchart showing a threshold detection method according to the second embodiment.
FIG. 12 is a block diagram illustrating a clock generation apparatus according to a third embodiment of the present invention.
FIG. 13 is a block diagram illustrating a semiconductor integrated circuit comprising a prior art clock generation apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, embodiments of the present invention will be described.
[Embodiment 1]
FIG. 1 is a block diagram illustrating a clock generation apparatus according to a first embodiment of the present invention.
The clock generation apparatus 100 according to the first embodiment comprises an analog signal input terminal 101 , a clock signal input terminal 102 , a synchronous signal output terminal 103 , a synchronous clock output terminal 104 , an A/D converter 105 , an arithmetic circuit 106 , a comparator circuit 107 and a latch circuit 108 . The clock generation apparatus 100 receives an analog signal S 101 to which VBI data are superimposed in the blanking interval and a clock signal S 102 , and outputs a synchronous signal S 103 and a synchronous clock S 104 .
The A/D converter 105 samples the analog signal S 101 in accordance with the timing of the clock signal S 102 , thereby outputting a digital signal S 109 as a digital discrete value.
The arithmetic circuit 106 receives the digital signal S 109 and the clock signal S 102 , and outputs a threshold S 106 a as a reference value for binarizing the digital signal S 109 and a synchronous clock S 106 b for latching a binarized signal S 110 . The details will be described later.
The comparator circuit 107 receives the digitally converted signal S 109 and the threshold S 106 a , operates in synchronization with the clock signal S 102 , and makes a comparison to see whether the digital signal S 109 is larger or smaller than the threshold S 106 a . Then, the comparator circuit 107 outputs “1” when the digital signal S 109 is larger than the value of the threshold S 106 a , and outputs “0” when the digital signal S 109 is smaller than the threshold S 106 a , as the binarized signal S 110 .
The latch circuit 108 receives the binarized signal S 110 which is output by the comparator circuit 107 as a D input and the synchronous clock S 106 b as a clock input, and outputs the synchronous signal S 103 .
FIG. 2 is a block diagram illustrating the arithmetic circuit in the clock generation apparatus according to the first embodiment.
The arithmetic circuit 106 of the first embodiment comprises a threshold detection block 200 for detecting the threshold S 106 a , a rise detection block 201 for detecting a rise time as a time of intersection of the threshold S 106 a and an approximated line of two values of the digital signal S 109 when the digital signal S 109 exceeds the threshold S 106 a and, a fall detection block 202 for detecting a fall time as a time of intersection of the threshold S 106 a and an approximated line of two values of the digital signal S 109 when the digital signal S 109 is lower than the threshold S 106 a , an input rate detection block 203 for detecting the rate of the digital signal S 109 using the rise time and the fall time, and a synchronous clock output block 204 for outputting the synchronous clock S 106 b.
Hereinafter, the operation of the clock generation apparatus according to the first embodiment is described.
The analog signal S 101 is input to the A/D converter 105 via the analog signal input terminal 101 . The clock signal S 102 is input to the A/D converter 105 , the arithmetic circuit 106 and the comparator circuit 107 via the clock signal input terminal 102 .
The A/D converter 105 samples the analog signal S 101 in accordance with the timing of the clock signal S 102 , thereby outputting the digital signal S 109 as the digital discrete value to the arithmetic circuit 106 and the comparator circuit 107 .
The arithmetic circuit 106 receives the digital signal S 109 and the clock signal S 102 , and outputs the threshold S 106 a as the reference value for binarizing the digital signal S 109 and the synchronous clock S 106 b for latching the binarized signal S 110 in the latch circuit 108 . The details will be described later.
The comparator circuit 107 receives the digital signal S 109 and the threshold S 106 a , and makes the comparison to see whether the digital signal S 109 is larger or smaller than the threshold S 106 a in synchronization with the clock signal S 102 . The comparator circuit 107 outputs “1” when the digital signal S 109 is larger than the threshold S 106 a , and outputs “0” when the digital signal S 109 is smaller than the threshold S 106 a , as the binarized signal S 110 .
The latch circuit 108 receives the binarized signal S 110 as the D input and the synchronous clock S 106 b as the clock input, and outputs the synchronous signal S 103 as the synchronous signal output.
Hereinafter, the operation of the arithmetic circuit 106 outputting the threshold S 106 a and the synchronous clock S 106 b is described with reference to FIG. 3 .
FIG. 3 is a flowchart showing the operation of the arithmetic circuit of the first embodiment.
Initially, the threshold detection block 200 detects the threshold S 106 a (Step 300 ), and outputs the threshold S 106 a to the rise detection block 201 , the fall detection block 202 and the comparator circuit 107 (Step 301 ). Here, the method for detecting the threshold will be described later.
Next, the rise detection block 201 detects the rise time Rise(j) (Step 302 ), and outputs the rise time Rise(j) to the input rate detection block 203 and the synchronous clock output block 204 (Step 303 ). Similarly, the fall detection block 202 detects the fall time Fall(j), and outputs the fall time Fall(j) to the input rate detection block 203 and the synchronous clock output block 204 . Here, “j” is the argument and shows the order in which the respective times have been detected. The rise time detection method and the fall time detection method will be described later.
Then, the input rate detection block 203 detects a rate (Rate) of the digital signal S 109 on the basis of the rise time Rise(j) and the fall time Fall(j) (Step 304 ), and outputs the rate (Rate) to the synchronous clock output block 204 (Step 305 ). The method for detecting the input rate will be described later.
Then, the synchronous clock output block 204 outputs the synchronous clock S 106 b (Step 306 ). The method for outputting the synchronous clock will be described later.
Hereinafter, the operations in the respective blocks of the arithmetic circuit 106 are described in detail with reference to FIGS. 4 to 9 .
Initially, a threshold detection method in the threshold detection block 200 is described with reference to the flowchart of FIG. 4 .
FIG. 4 is a flowchart showing the threshold detection method according to the first embodiment.
Initially, the digital signal S 109 as the output of the A/D converter 105 is accepted at an arbitrary time as 0th data A 0 , and the data A 0 is set as the initial value (Step 400 ). The data A 0 is input to internal registers Amax and Amin in the arithmetic circuit 106 , respectively, and “1” is input to the internal pointer i as well as a repeat count N is given (Step 401 ). The repeat count N shows the number of the digital signals S 109 . The larger the number, the more the accuracy of the threshold S 106 a is increased.
Then, the digital signals S 109 are accepted in the order pointed by the internal pointer i, and the comparison is made to see whether the accepted data A i is larger or smaller than the data in the internal register Amax (Step 402 ). When the data A i is larger than the data in the internal register Amax, the data in the internal register Amax is replaced with the data A i (Step 403 ). On the other hand, when data Ai is smaller than the data in the internal register Amax, a comparison is made to see whether the data A i is larger or smaller than the data in the internal register Amin (Step 404 ). When the data Ai is smaller than the data in the internal register Amin, the data in the internal register Amin is replaced with the data A i (Step 405 ).
Thereafter, the internal pointer i is incremented (Step 406 ) and whether or not the value of the internal pointer i is equal to the repeat count N is checked (Step 407 ). When the value of the internal pointer i is not equal to the repeat count N, i.e., the value of the internal pointer i is smaller than the repeat count N, the processing proceeds to Step 402 so as to accept the next digital signal S 109 . When the value of the internal pointer i is equal to the repeat count N, the average value of the data in the internal register Amax and the data in the internal register Amin is output as the threshold S 106 a (Step 408 ).
A rise time detection method in the rise detection block 201 is described with reference to the flowchart of FIG. 5 .
FIG. 5 is a flowchart showing the rise time detection method according to the first embodiment.
Initially, “2” is input to the internal pointer i, and further, the internal pointer j is cleared. Then, the digital signal S 109 which is accepted at an arbitrary time is set as data A 0 , the digital signal S 109 which is accepted subsequent to the data A 0 is set as data A 1 , and the input of the repeat count M is accepted (Step 500 ).
Further, the digital signal S 109 is accepted (Step 501 ) When Step 501 is executed for the first time at this time, the digital signal S 109 which is accepted here is data A 2 , because “2” has already been set in the internal pointer i.
Then, it is determined whether the value of data A i−1 is smaller than the threshold S 106 a and the value of data A i is larger than the threshold S 106 a (Step 502 ). When the value of the data Ai−1 is larger than the threshold S 106 a or the value of the data Ai is smaller than the threshold S 106 a , the internal pointer i is incremented and then Step 501 is executed (Step 503 ). When the value of the data Ai−1 is smaller than the threshold S 106 a and the value of the data Ai is larger than the threshold S 106 a , the analog signal S 101 intersects the threshold S 106 a and the rise time occurs. Therefore, the j-th rise time Rise(j) is output (Step 504 ). The details of this arithmetic will be described later.
Then, the internal pointer j is incremented (Step 505 ) and whether or not M pieces of the rise time Rise(j) have been detected is monitored (Step 506 ). When M pieces of the rise time have been detected, the processing is completed. Otherwise, the processing returns to Step 501 and the above-mentioned processing is repeated until M pieces of the rise time are detected.
Here, the details of the method of obtaining the j-th rise time Rise(j) are given with reference to FIG. 6 .
FIG. 6 is a timing chart for explaining the rise time detection method of the first embodiment.
At time T i−1 , the data A i−1 , of the digital signal S 109 as the output of the A/D converter 105 is accepted, and the value of the data is lower than the threshold S 106 a . At time T i , the data A i of the digital signal S 109 is accepted. This data A i is higher than the threshold S 106 a . Therefore, the analog signal S 101 intersects the threshold S 106 a between time T i−1 and time T i .
The dot-dash line 600 shows a straight line which is obtained by linear approximation with the two points of the data. Making the approximation that a time when the analog signal S 101 intersects the threshold S 106 a is a time when the dot-dash line 600 intersects the threshold S 106 a , that time is a time when a period x i−1 , has elapsed from time T −1 . That is, the dot-dash line 600 is an intersection time approximation line and x i−1 , is a rise intersection time correction time.
Assuming that the origin of the time axis of the dot-dash line 600 is a time when the data Ai−1 is input, the parameter of the time axis is x, and the amplitude axis of the input signal is y, their relationship is given by the following equation:
y=A i−1 +( A i −A i−1 ) x
The time X i-1 when the dot-dash line 600 intersects the threshold S 106 a is given by the following equation assuming that the threshold is THR,
THR=A i−1 +( A i −A i−1 ) x i−1
Therefore, when this linear equation is solved to obtain x i−1,
x i−1 =( THR−A i−1 )/(A i −A i−1 )
This x i−1 corresponds to the decimal part of the rise time Rise(j). Therefore, the rise time Rise(j) obtained in Step 504 is given by the following expression.
Rise( j )= i−x i−1
A fall time detection method in the fall detection block 202 is described with reference to FIG. 7 .
FIG. 7 is a flowchart showing the fall time detection method according to the first embodiment.
In FIG. 7 , the same reference numerals as those in FIG. 5 correspond to the same processes in FIG. 5 .
In the fall time detection method as shown in the flowchart of FIG. 7 , whether or not the analog signal became lower than the threshold is detected in Step 702 . Therefore, the determination is made by a criterion opposed to that in Step 502 . The fall time detection method is different from Steps 502 and 504 of the rise time detection method in that it is determined whether the value of the data A i−1 is larger than the threshold S 106 a and the value of the data A i is smaller than the threshold S 106 a , and that an arithmetic result in Step 704 is output as Fall (j), respectively.
An input rate detection method in the input rate detection block 203 is described with reference to the flowchart of FIG. 8 .
The input rate of the input analog signal S 101 can be detected on the basis of the rise time and fall time which are detected by the above-mentioned processing. That is, when the period from a rise time Rise(j) to a fall time Fall(j) occurring subsequently is obtained, this period is always a multiple of the input rate. Therefore, difference values between plural rise times and fall times are obtained, and the minimum value of the difference values is used as the input rate.
FIG. 8 is a flowchart showing the input rate detection method according to the first embodiment.
Initially, an initial value is input to the internal register Rate which holds the input rate of the input signal, the initial value “1” is input to the internal pointer j, and the repeat count M is set (Step 800 ). In this case, M means the number of data of a plurality of the rise times Rise and the fall times Fall obtained in Step 302 .
Next, the time interval between the rise time Rise(j) and the fall time Fall(j) is obtained, and the result is retained in the internal register Temp (Step 801 ). The internal register Temp is a saving register to which the difference between the rise time Rise(j) and the fall time Fall(j) corresponding to the argument provided for convenience of arithmetic is saved.
Then, the value of the internal register Rate is compared with the value of the internal register Temp (Step 802 ). When the value of the internal register Temp is smaller than the value of the internal register Rate, the value of the internal register Temp is input to the internal register Rate to make a replacement of the value (Step 803 ). When the value of the internal register Temp is larger than the value of the internal register Rate, the internal pointer j is incremented and Step 801 is executed again (Step 804 ).
Then, in Step 805 , when the value of the internal pointer j is equal to the repeat count M, i.e., when the prescribed number of times of processing has been completed, the processing is completed. The value of the internal register Rate at this time is used as the input rate. When the prescribed number of times of processing has not been completed, Step 804 is executed.
A method for outputting the synchronous clock in the synchronous clock output block 204 is described with reference to the flowchart of FIG. 9 .
FIG. 9 is a flowchart showing a synchronous clock output method according to the first embodiment.
Initially, the threshold S 106 a detected in Step 300 and the input rate (Rate) detected in Step 305 are accepted, and further, the internal pointer i is cleared (Step 900 ).
Next, the digital signals S 109 are accepted in the order in which the internal pointer i points the signals. The product of the difference between the accepted data A i and the threshold S 106 a and the difference between the previously accepted data A i−1 and the threshold S 106 a is obtained (Step 902 ). When the product is 0 or more, the internal pointer i is incremented (Step 903 ). When the product is less than 0, x i and the edge time Edge(i) as a time when the data intersects the threshold S 106 a are obtained on the same principles in Steps 504 and 704 (Step 904 ). The obtained Edge(i) is composed of an integer part i and a decimal part X i . In addition, Rate/2 is composed of an integer part r and a decimal part r i . The Edge(i) and Rate/2 are added and consequently an integer part Sam and a decimal part x s are obtained (Step 905 ). Owing to the arithmetic in this Step, the first synchronous clock S 106 b is generated at a half timing of the input rate (Rate), i.e., at the middle of one rate of the input signal, after the edge of the signal comes.
Next, it is monitored that the Sam-th data Asam for generating the synchronous clock S 106 b is input (Step 906 ) When it is detected that the data Asam has been input, the synchronous clock S 106 b is generated once (Step 907 ).
Then, the arithmetic for a timing value of the second or subsequent synchronous clock is performed (Step 908 ). The timing for generating the synchronous clock in the middle of the input rate, i.e., Sam+x s has been already obtained in Step 905 when the first synchronous clock is generated. Therefore, in this Step, only the value of the internal register Rate is added to Sam+Xs, whereby the second or subsequent clock can be generated in the middle of the input rate. Thereafter, the above-mentioned processing is repeated, thereby outputting the synchronous clock S 106 b.
In the clock generation apparatus according to the first embodiment, the input rate is detected from the digital signal which is obtained by subjecting the input analog signal to the A/D conversion, and the synchronous clock is generated on the basis of the input rate. Therefore, when the binarized signal is to be latched, the phase error between the synchronous clock and the binarized signal can be within one clock of the synchronous clock. Accordingly, the VBI data can be correctly acquired from analog television signals on which the VBI data are superimposed in the blanking interval.
In addition, the clock generation apparatus of the first embodiment, is usually realized by a semiconductor integrated circuit while, in this case, in order to improve performance of the clock generation apparatus, it is not required to increase the frequency of the supplied clock. Therefore, the unnecessary radiation generated from the semiconductor integrated circuit is not increased. Furthermore, even when the input analog signal has the plural kinds of input rates, the plural clock supply circuits are not required.
[Embodiment 2]
FIG. 10 is a block diagram illustrating an arithmetic circuit of a clock generation apparatus according to a second embodiment of the present invention.
In the clock generation apparatus according to the second embodiment, the arithmetic circuit 106 in the clock generation apparatus of the first embodiment as shown in FIG. 1 is replaced with an arithmetic circuit as shown in FIG. 10 . Other construction is the same as that in the clock generation apparatus according to the first embodiment.
As shown in FIG. 10 , the arithmetic circuit 106 comprises a threshold detection block 1000 for detecting a threshold S 106 a , a rise detection block 201 for detecting a rise time as a time of intersection of the threshold S 106 a and an approximated line of two values of the digital signal S 109 when the digital signal S 109 exceeds the threshold S 106 a , a fall detection block 202 for detecting a fall time as a time of intersection of the threshold S 106 a and an approximated line of two values of the digital signal S 109 when the digital signal S 109 gets lower than the threshold S 106 a , an input rate detection block 203 for detecting a rate of the digital signal S 109 using the rise time and the fall time, and a synchronous clock output block 204 for outputting a synchronous clock S 106 b.
Hereinafter, the operation is described.
Here, the operations of the rise detection block 201 , the fall detection block 202 , the input rate detection block 203 and the synchronous clock output block 204 are the same as those in the first embodiment. Therefore, their descriptions are not given here. Hereinafter, the description is given of the operation of the threshold detection block 1000 detecting the threshold S 106 a , with reference to FIG. 11 .
FIG. 11 is a flowchart showing a threshold detection method according to the second embodiment.
Initially, an internal register Acc and an internal pointer i in the arithmetic circuit 106 are cleared, respectively, and a repeat count N is accepted (Step 1100 ). Here, the repeat count N shows the number of the digital signals S 109 . The larger the number, the more the accuracy of the threshold S 106 a is increased.
Next, the digital signal S 109 is accepted as well as it is monitored whether the value of the internal pointer i is larger than the repeat count N (Step 1101 ). When the value of the internal pointer i is smaller than the repeat count N, data Ai which has been accepted in Step 1101 is successively added to the internal register Acc, and further the internal pointer i is incremented (Step 1102 ). Accordingly, the integral of data A i of (N+1) digital signals S 109 (i.e., data A i of the digital signal S 109 where i=0, i.e., 0-th data, to data A i of the digital signal S 109 where i=N, i.e., N-th data) is stored in the internal register Acc. In addition, when the value of the internal pointer i is larger than the repeat count N, the value of the internal register Acc is divided by the number of the integrated data, i.e., N+1. Then, the obtained value is output as the threshold S 106 a (Step 1103 ).
In the clock generation apparatus according to the second embodiment, the average of the integrals of the digital signals is used as the threshold. Therefore, the effects of the clock generation apparatus according to the first embodiment are obtained, and further effects that the detection of the threshold resists influences by the noises or the like and a more accurate threshold is detected are obtained.
[Embodiment 3]
FIG. 12 is a block diagram illustrating a clock generation apparatus according to a third embodiment of the present invention. In this figure, the same reference numerals as those in FIG. 1 denote the same or corresponding parts, and their descriptions are not given here.
The clock generation apparatus according to the third embodiment comprises an oversampling digital filter 1201 in the subsequent stage of the A/D converter 105 of the clock generation apparatus according to the first embodiment.
The oversampling digital filter 1201 gives an arbitrary frequency characteristic to the input signal as well as performs oversampling and outputs the oversampled signal to the comparator circuit 107 .
In the clock generation apparatus according to the third embodiment, the oversampling digital filter 1201 gives an arbitrary frequency characteristic to the digital signal, whereby unnecessary signals, such as noises, can be removed. Further, the oversampling digital filter performs the oversampling, whereby the number of sample data is increased and the temporal resolution of the digital signal can be increased.
The clock generation apparatus of the third embodiment comprises the oversampling digital filter in the subsequent stage of the A/D converter in the clock generation apparatus of the first embodiment. However, the oversampling digital filter can be provided in the subsequent stage of the A/D converter in the clock generation apparatus of the second embodiment.
In the first to third embodiments, the clock generation apparatus according to the present invention are described taking cases where television signals to which VBI data are superimposed in the blanking interval are input as examples. However, the signals are not restricted to the television signal, and playback signals of CD (Compact Disk) or MD (mini disk) or the like can be input.
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A clock generation apparatus generates a synchronous clock based on an input analog signal. The average of maximum and minimum values of a digital signal in a predetermined period is used as a threshold. Rise and fall times which are times when the threshold and an approximated line of two values of the digital signal crosses are detected. The time intervals between the adjacent rise and fall times are obtained during a predetermined period. The minimum value of the time intervals is used as the input rate. The synchronous clock is output on the basis of the input rate and the rise and fall times. The synchronous clock and a comparison signal which is obtained by comparing the threshold and the digital signal are supplied to a latch circuit, thereby outputting a synchronous signal.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application 61/681,546 filed Aug. 9, 2012, the contents of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to locks, and more particularly, but not exclusively, relates to disc tumbler locks.
BACKGROUND
[0003] Conventional disc-style cylinders suffer from a variety of disadvantages and problems including misalignment of the lock discs and susceptibility to lock-picking. For example, the discs can easily become misaligned, in which case the user must rotate the key back and forth to re-align the discs. Furthermore, there is no indication to the user that the key is fully inserted, and the key and contacted discs will turn through the first portion of their travel (usually 90 degrees) even when the key is only partially inserted. Because the key turns, the user might incorrectly assume that that key has been inserted correctly, but the lock will not open due to the partial insertion of the key. This can lead to user frustration and confusion, and often results in the user applying too much force which may cause the key to break. Additionally, in conventional disc-style cylinders, it is possible for a skilled lock-picker to feel the change in tension as one or more discs rotate. A release of tension typically indicates the correct position for a disc, thereby increasing susceptibility of the lock to be picked.
[0004] There is therefore a need for unique and inventive apparatuses, systems and methods to address various disadvantages and problems associated with conventional disc-style cylinders.
SUMMARY
[0005] Unique locking cylinders are disclosed. In an exemplary embodiment, a locking cylinder includes a locking disc, a driver disc and a catch. The catch selectively prevents rotation of the locking disc. The driver disc is operable to move the catch between a first position in which the catch prevents rotation of the locking disc, and a second position in which the catch does not prevent rotation of the locking disc. In the second position, the catch may apply pressure to the locking disc.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 is an elevational illustration of a lock assembly according to an embodiment of the present invention in a first state or operational configuration.
[0007] FIG. 2 is an elevational illustration of the lock assembly of FIG. 1 in a second state or operational configuration.
[0008] FIG. 3 is a perspective illustration of a subassembly of the lock assembly of FIG. 1 .
DETAILED DESCRIPTION
[0009] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is hereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.
[0010] With reference to FIGS. 1-3 , an illustrative locking system 100 according to one form of the invention generally includes a tumbler system having a locking bar 102 that interacts with disc stack 104 including a plurality of locking discs 110 and at least one driving disc 120 , a plug housing 130 at least partially surrounding the disc stack 104 , a movable catch 140 , and a biasing mechanism 142 that exerts a biasing force against the movable catch 140 to engage the movable catch 140 against the disc stack 104 . Although a particular type of a tumbler system is illustrate in FIGS. 1-3 , it should be understood that other types and configurations of tumbler systems are also contemplated for use in association with the locking system 100 including, for example, a pin tumbler system. Furthermore, while the movable catch 140 is illustrated as a pivoting member that is pivotally movable between one or more operational positions, it should be understood that the movable catch 140 may be movable in additional or alternative directions.
[0011] In the illustrated embodiment, the locking discs 110 and the driving disc 120 are coaxially aligned along an axial centerline or axis C, and together form at least a portion of the disc stack 104 . While five locking discs 110 are shown in the illustrated embodiment, it should be appreciated that the disc stack 104 may include more or fewer locking discs 110 . Each locking disc 110 is generally cylindrical in shape, and may include a circumferential outer surface 111 , a groove or indentation 112 formed in the circumferential outer surface 111 , a keyway 114 positioned generally along the axial centerline C, a radial protrusion 116 projecting radially beyond the circumferential outer surface 111 , and a hooked-shaped recess 118 extending between the circumferential outer surface 111 and the radial protrusion 116 . In the illustrated embodiment, the radial protrusion 116 has a first width w 1 at its radially distal extent (i.e., farthest from the axial centerline C) and a smaller second width w 2 at its radially proximal extent (i.e., closest to the axial centerline C). As should be appreciated, the hooked-shaped recess 118 provides the radial protrusion 116 with an undercut region.
[0012] The groove/indentation 112 is sized and configured to receive the locking bar 102 ( FIG. 2 ), and the keyway 114 is sized and configured to receive a corresponding mechanical key (not shown). In an aligned operational configuration/position of the locking discs 110 , the grooves/indentations 112 are axially aligned with one another and/or are axially aligned with the axial channel 132 in the plug housing 130 . In a misaligned operational configuration/position of the locking discs 110 , the grooves/indentations 112 are not aligned with one another and/or are not aligned with the axial channel 132 in the plug housing 130 . In the illustrated embodiment, the radial protrusion 116 generally includes an arcuate outer surface 115 extending generally in a circumferential direction, and an interference surface 117 extending inwardly from the arcuate outer surface toward the circumferential outer surface 111 .
[0013] In the illustrated embodiment, the driving disc 120 is configured substantially similar to the locking discs 110 , having a generally cylindrical shape and including a circumferential outer surface 121 , a groove or indentation 122 formed in the circumferential outer surface 121 and sized and configured to receive the locking bar 102 , and a keyway 124 positioned generally along the axial centerline C and configured to receive the corresponding mechanical key (not shown). In an aligned operational configuration/position of the driving disc 120 , the groove/indentation 122 is axially aligned with the axial channel 132 in the plug housing 130 . In a misaligned operational configuration/position of the driving disc 120 , the groove/indentation 122 is not axially aligned with the axial channel 132 in the plug housing 130 . The driving disc 120 also includes a radial protrusion 126 projecting radially beyond the circumferential outer surface 121 . The radial protrusion 126 generally includes an arcuate outer surface 125 extending generally in a circumferential direction, and a contact or bearing surface 127 extending inwardly from the arcuate outer surface 125 toward the circumferential outer surface 121 .
[0014] In the illustrated embodiment, each radial protrusion 116 of the locking discs 110 and the radial protrusion 126 of the driving disc 120 defines a generally uniform outer radius. In other words, the distance between the axial centerline C of disc stack 104 and the outermost portion of each radial protrusion 116 , 126 is substantially equal. However, it is also contemplated that one or more of the radial protrusions 116 , 126 may have a greater or lesser outer radius relative to one or more of the other radial protrusions. For example, the outer radius of radial protrusion 126 may be greater than the outer radius of the radial protrusions 116 . Furthermore, while the arcuate outer surfaces 115 , 125 of the radial protrusions 116 , 126 each define a substantially uniform arc radius (corresponding to the outer radius of protrusions 116 , 126 ), in other embodiments, the arcuate outer surfaces 115 , 125 may not necessarily define of a uniform arc radius.
[0015] As described in further detail below, the radial protrusions 116 of the locking discs 110 interact with the movable catch/pivoting member 140 to prevent rotation of the locking discs 110 about the axial centerline C when the pivoting member 140 is in a closed position or operational configuration ( FIG. 1 ), and the radial protrusion 126 of the driving disc 120 is configured to interact with the pivoting member 140 and pivot the pivoting member 140 away from and out of the closed position or operational configuration ( FIGS. 2 and 3 ). In the illustrated embodiment, the driver disc 120 including the groove/indentation 122 provides a more compact system because the component that disengages the alignment mechanism is also one of the discs which interacts with the tumbler system, and no additional cylinder length is necessary to implement the system. However, in other embodiments, the driving disc 120 need not necessarily include the groove/indentation 122 . In such embodiments, the tumbler system may be configured to engage only the locking discs 110 , and not the driving disc 120 .
[0016] In the disc stack 104 , the drive disc 120 may be positioned behind the locking discs 110 . That is to say, when a mechanical key is inserted into the keyway of the locking system 100 , the shank of the key will pass through the keyway 114 of each of the locking discs 110 before entering the keyway 124 of the driving disc 120 . This configuration, combined with the fact that the locking discs 110 cannot rotate unless the driving disc 120 has pivotally displaced the pivoting member 140 away from and out of the closed position, prevents the locking discs 110 from rotating in the absence of full insertion of a properly configured key into the keyway of the locking system 100 . However, in other embodiments, some or all of the locking discs 110 or other locking elements may be positioned behind the driving disc 120 .
[0017] In the illustrated embodiment, the plug housing 130 has a generally cylindrical configuration and is sized and shaped to retain the disc stack 104 within the interior region of the plug housing 130 . Additionally, the plug housing 130 includes an outer surface 131 and an axial channel 132 configured to receive the locking bar 102 . When the plug housing 130 is installed into a corresponding lock shell (not illustrated), the axial channel 132 is aligned with a channel formed in the shell, thereby forming a chamber in which the locking bar 102 is positioned. In embodiments which utilize pin tumblers, the axial channel 132 may be replaced by individual tumbler shafts.
[0018] When at least one of the grooves or indentations 112 , 122 of the discs 110 , 120 is not properly aligned with the axial channel 132 of the plug body 130 , the locking bar 102 will contact the corresponding circumferential outer surface 111 , 121 and will be blocked from radial displacement into the grooves/indentations 112 , 122 . This configuration defines a locked state of the locking system 100 ( FIG. 1 ) in which the locking bar 102 is positioned partially in axial channel 132 , and also protrudes beyond the circumferential outer surface 131 . In the locked state, the locking bar 102 provides an interference between the plug body 130 and the lock shell, thereby preventing the plug body 130 from rotating with respect to the lock shell. Regardless of the type of tumbler system used, if any of the grooves/indentations 112 , 122 are not aligned with the axial channel 132 , a portion of the tumbler system will protrude radially beyond the circumferential outer surface 131 , thereby maintaining the locking system 100 in the locked state.
[0019] When each of the grooves/indentations 112 , 122 are aligned with the axial channel 132 of the plug body 130 , the locking bar 102 is free to travel radially inward into each of the aligned grooves/indentations 112 , 122 . This configuration defines an unlocked state of the locking system 100 ( FIG. 2 ) in which the locking bar 102 is positioned partially in the axial channel 132 , and partially in the aligned grooves/indentations 112 , 122 . In the unlocked state, the locking bar 102 does not provide an interference between the plug body 130 and the lock shell, and the plug body 130 is therefore free to rotate with respect to the lock shell. In embodiments which utilize additional or alternative tumbler systems, the unlocked state will allow the plug body to rotate with respect to the lock shell. For example, if the tumbler system includes pin tumblers, the driven pins will not protrude beyond outer circumferential surface 131 .
[0020] In the illustrated embodiment, the pivoting member 140 rotates about a pivot point or axis 141 that may be arranged generally parallel with the axial centerline C, and is biased toward a closed position ( FIG. 1 ) via the biasing mechanism 142 . The pivot point/axis 141 may be maintained in a stationary position with respect to the plug housing 130 , and may be coupled to the lock shell. In the illustrated embodiment, the biasing mechanism 142 includes a biasing member 143 which exerts a biasing force onto the pivoting member 140 through a connection or bearing member 144 . The bearing member 144 may be integral with, attached to, or positioned in contact with the pivoting member 140 . In some embodiments, the biasing member 143 may directly engage the pivoting member 140 , thereby eliminating the bearing member 144 . In the illustrate embodiment, the pivoting member 140 is constrained to pivotal movement. However, in other embodiments, the pivoting member 140 may additionally or alternatively be movable in another direction.
[0021] The pivoting member 140 may extend generally in an axial direction along disc stack 104 (i.e., along the axial centerline C), and includes an arcuate inner bearing surface 145 , an interference contact surface 147 that terminates at a tip portion 148 , and an extended distal portion 149 . The inner bearing surface 145 is configured to be displaced along the outer surfaces 115 , 125 of the radial protrusions 116 , 126 once the pivoting member 140 has been moved away from and out of the closed position. In the illustrated embodiment, the inner bearing surface 145 is of a constant arc radius that generally corresponds to the outer arc radius of the outer surfaces 115 , 125 of the radial protrusions 116 , 126 . It is also contemplated that the inner bearing surface 145 may have a varying arc radius, for example, if the outer surfaces 115 , 125 of the radial protrusions 116 , 126 do not define a substantially uniform outer arc radius.
[0022] As should be appreciated, the interference surface 147 of the pivoting member 140 is configured to prevent rotation of the locking discs 110 about the axial centerline C when the pivoting member 140 is in the closed position ( FIG. 1 ). In the closed position, the interference surface 147 of the pivoting member 140 is generally radially aligned with the interference surfaces 117 of the locking discs 110 , thereby blocking the rotational travel path of the radial protrusions 116 and preventing rotation of the locking discs 110 . Because the locking discs 110 cannot rotate, they will remain in an aligned position. If a user attempts to rotate one or more of the locking discs 110 , the interference surface 147 will engage the interference surface 117 , thereby preventing rotation of the locking disc. By maintaining the locking discs 110 in the aligned position until a proper key is fully inserted into the keyway of the locking system 100 , the locking system 100 not only alerts the user when the key is not fully inserted, but also obviates the need for a user to turn the key back and forth in order to realign the discs.
[0023] To reduce internal stresses resulting from a user applying excessive force to the key when the pivoting member 140 is in the closed position, it is desirable to increase the area of contact between the interference surfaces 117 and 147 . To this end, the radial protrusions 116 and the pivoting member 140 may be configured such that interference surfaces 117 , 147 are substantially parallel to one another when they are positioned in contact with one another. Additionally, in the illustrated embodiment, each locking disc 110 is configured such that when the pivoting member 140 is in the closed position, the tip portion 148 is positioned at least partially within the hooked recesses 118 of the locking discs 110 , thereby increasing the area of contact between interference surfaces 117 , 147 . It is also contemplated that the hooked recess 118 may be absent in one or more of locking discs 110 , in which case the tip portion 148 may contact the circumferential surface 111 .
[0024] The extension 149 of the pivoting member 140 is generally aligned in the axial direction with the driver disc 120 , and is configured to interact with the radial protrusion 126 of the driver disc 120 . While the extension 149 extends beyond the interference surface 147 substantially only along the curved arc defined by the pivoting member 140 , it is also contemplated that an extension may extend in a direction toward the radial protrusion 126 . When the driver disc 120 is rotated, the contact bearing surface 127 urges the extension 149 away from the axial centerline C, thereby pivotally displacing the pivoting member 140 away from and out of the closed position.
[0025] When the outer surface 115 of the locking discs 110 contacts the inner surface 145 of the pivoting member 140 , the pivoting member 140 will be positioned in an open position ( FIG. 2 ) wherein the interference surface 147 is no longer radially aligned with the interference surfaces 117 of the locking discs 110 , and the locking discs 110 are thereby free to rotate about the axial centerline C. When the pivoting member 140 is positioned in the open position, the biasing mechanism 142 continues to exert a biasing force onto the pivoting member 140 . This biasing force causes the inner bearing surface 145 to exert a radially inward force onto the outer surfaces 115 , 125 of the radial protrusions 116 , 126 , thereby resulting in a corresponding frictional force which resists rotation of the discs 110 , 120 about the axial centerline C. This frictional force continues to resist rotation of the discs 110 , 120 , even when the disc's groove/indentation 112 , 122 is aligned with the axial channel 132 of the plug body 130 . The added frictional force increases the difficulty of sensing a change in resistive force, making it much more difficult for a person attempting to pick the lock to determine when the discs are in the proper position for unlocking of the lock system 100 .
[0026] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described, and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred, or more preferred used in the description indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.
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A lock apparatus including a plurality of locking discs rotatable about a rotational axis between locked and unlocked states and each having a locking engagement surface, at least one driver disc rotatable about the rotational axis and having a driving engagement surface, a movable catch having a catch surface that abuts the locking engagement surface of the locking discs when the movable catch is in a locked position such that rotation of the locking discs is inhibited. The catch surface does not abut the locking engagement surface of the locking discs when the movable catch is in an unlocked position such that rotation of the locking discs is enabled. The driving engagement surface of the driver disc engages a portion of the movable catch upon rotation of the driver disc to thereby displace the movable catch from the locked position to the unlocked position.
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[0001] The present application is a continuation of U.S. provisional application serial number 60/050,225, filed Jun. 19, 1997, incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to methods for treatment of ocular neovascularization and, more particularly, to use of one or more farnesyl-protein transferase inhibitor compounds to treat a subject suffering from or susceptible to ocular neovascularization or a disorder associated therewith.
[0004] 2. Background
[0005] New blood vessel formation or neovascularization occurs in a number of ocular disease processes. In particular, retinal neovascularization can result in occlusion of normal retinal blood vessels which leads to retinal ischemia. These disorders have been collectively referred to as ischemic retinopathies and include proliferative diabetic retinopathy (PDR), retinopathy of prematurity, central and branch retinal vein occlusion, and other systematic vasculopathies that affect retinal vessels. The most common affliction is diabetic retinopathy, a major cause of new blindness in developed countries (H. Kahn, Am. J. Ophthalmol., 78:58-67 (1974)).
[0006] Panretinal laser photocoagulation can improve retinal oxygenation and has caused regression of retinal neovascularization in certain cases. See C. Pomaras et al., Ophthalmology, 97:1329-1333 (1990). In many instances however, laser photocoagulation is not effective. For example, laser photocoagulation can not be delivered to a retina obscured by vitreous hemorrhage. For patients with severe neovascularization, even with clear media, laser treatment alone may not prevent vision loss. See S. deBustros et al., Arch. Ophthalmol., 105:196-199 (1987); H. Flynn et al., Ophthalmology, 97:1329-1333 (1990).
[0007] Choroidal neovascularization occurs in diseases in which there are abnormalities in Bruch's membrane and the surrounding tissues. The most common disease of this type is age-related macular degeneration, a major cause of visual loss in patients over the age of 60 (Macular Photocoagulation Study Group, Arch. Ophthalmol., 109:1109 (1991)). It is estimated that by the year 2000 there will be two million patients in the United States with age-related macular degeneration. Currently, no effective treatment exists for choroidal neovascularization due to age-related macular degeneration.
[0008] The oncogene protein Ras is one of several GTP-binding proteins that are modified by a prenyl group. Farnesyl has been reported to modify Ras, Rab, Rho and other small GTP-binding proteins, and geranylgeranyl has been reported to modify Rab, Rho and other small GTP-binding proteins. A. Garcia et al., J. Biol. Chem., 268:18415-18418 (1993).
[0009] Farnesyl-protein transferase (FTase), the enzyme that catalyzes the lipid modification of Ras, has become a target for anticancer therapies. Inhibition of FTase has been reported to block the growth of Ras-transformed cells in soft agar. It also has been reported that certain inhibitors of FTase block the processing of the Ras oncoprotein intracellularly. N. E. Kohl et al., Science, 260:1934-1937 (1993); G. L. James et al., Science, 260:1937-1942 (1993); N. E. Kohl et al., Proc. Natl. Acad. Sci U.S.A., 91:9141-9145 (1994); and N. E. Kohl et al., Nature Medicine, 1:792-797 (1995). See U.S. Pat. Nos. 5,238,922; 5,571,792; and 5,571,835; WO 94/10138; WO 94/04561; WO 94/10138; WO 96/21456; and WO 97/02817, which report certain compounds that inhibit farnesyl-protein transferase.
SUMMARY OF THE INVENTION
[0010] The present invention includes methods for treatment and prevention of eye disorders and injuries, particularly treatment and prevention of ocular neovascularization and disorders associated therewith such as diabetic retinopathy, retinopathy of prematurity, retinal vein and artery occlusion, age-related macular degeneration, corneal graft rejection, neovascular glaucoma, retrolental fibroplasia, Eales disease, and other vasculopathies that affect retinal or chordial vessels.
[0011] The methods of the invention in general comprise administration of a therapeutically effective amount of a compound that inhibits famesyl-protein transferase (a FTase inhibitor) to a patient in need of treatment, such as a mammal suffering from or susceptible to ocular neovascularization and disorders associated therewith.
[0012] A wide variety of FTase inhibitor compounds can be employed in the methods of the invention. For example, suitable compounds have been reported previously including those in U.S. Pat. Nos. 5,238,922; 5,571,792; and 5,571,835; WO 94/10138; WO 94/04561; WO 94/10138; WO 96/21456; and WO 97/02817.
[0013] Particularly preferred FTase inhibitor compounds for use in the methods of the invention exhibit good activity in a standard in vitro FTase inhibition assay, preferably an IC 50 (concentration required to inhibit FTase activity by 50% relative to control) in such an assay of about 100 nM or less, more preferably an IC 50 about 50 nM or less. A standard assay includes the following steps a) through c):
[0014] a) admixing in a suitable assay solution 1) a potential FTase inhibitor compound, 2) [ 3 H]farnesyl diphosphate, 3) famesyl-protein transferase and 4) H-Ras;
[0015] b) incubating the test mixture for 15 minutes at 37° C.; and
[0016] c) measuring utilization of [ 3 H]farnesyl diphosphate over that time relative to a control mixture that is prepared and incubated under the same conditions as the assay mixture but does not include the potential inhibitor compound. A suitable assay solution includes 50 mM HEPES, pH 7.5, 5 mM MgCl 2 , 5 mM dithiothreitol. References herein to a standard in vitro farnesyl-protein transferase inhibition assay are intended to refer to that protocol. That protocol also has been described in A.M. Garica et al., J. Biol. Chem., 268:18415-18418 (1993).
[0017] Even more preferred are FTase inhibitor compounds that exhibit good activity as defined above, and are also selective for FTase inhibition, i.e. the compounds are relatively poor inhibitors of other prenyl-protein transferases, particularly geranylgeranyl-protein transferase I. Geranylgeranyl protein-transferase I is related to famesyl-protein transferase and catalyzes the prenylation of certain GTP-binding proteins as discussed above. The number of geranylgeranylated proteins in a cell significantly exceeds the number of farnesylated proteins, and therefore preferred compounds for use in the methods of the invention are selective for inhibition of famesylation to avoid undesired pharmacological effects that could arise from inhibition of geranylgeranyl-protein transferase I.
[0018] More specifically, preferred FTase inhibitor compounds exhibit at least about a 20-fold greater inhibition of famesyl-protein transferase relative to inhibition of geranylgeranyl-protein transferase I as measured in standard in vitro famesyl-protein transferase and geranylgeranyl-protein transferase I inhibition assays, more preferably at least about a 30-fold greater inhibition of famesyl-protein transferase relative to inhibition of geranylgeranyl-protein transferase I.
[0019] Preferred selective FTase inhibitor compounds also may exhibit an IC 50 (concentration required to inhibit geranylgeranyl-protein transferase I activity by 50% relative to control) of about 200 nM or greater in a standard in vitro geranylgeranyl-protein transferase I inhibition assay, more preferably an IC 50 of about 500 nM or greater. A standard in vitro geranylgeranyl-protein transferase I inhibition assay includes the following steps a) through c):
[0020] a) admixing in a suitable assay solution 1) a potential inhibitor compound, 2) [ 3 H]geranylgeranyl diphosphate, 3) geranylgeranyl-protein transferase I, and 4) H-Ras;
[0021] b) incubating the test mixture for 15 minutes at 37° C.; and
[0022] c) measuring utilization of [ 3 H]geranylgeranyl diphosphate over that time relative to control mixture that is the prepared and incubated under the same conditions as the assay mixture but does not include the potential inhibitor compound. A suitable assay solution includes 50 mM HEPES, pH 7.5, 5 mM MgCl 2 , 5 mM dithiothreitol. References herein to a standard in vitro geranylgeranyl-protein transferase I inhibition assay are intended to refer that protocol. That protocol also has been described in A. M. Garica et al., J. Biol. Chem., 268:18415-18418 (1993).
[0023] Generally preferred for use in the methods are FTase inhibitor compounds that are competitive with protein substrates for famesyl-protein transferase. Such inhibitors may contain a thiol moiety, although substrate-competitive inhibitors are known that do not contain a thiol group. Some of those compounds are cysteine-containing molecules related in some respect to the “CAAX” motif that is the signal for protein prenylation. That CAAX motif has been defined as C=Cys, A=any aliphatic amino acid, X=any amino acid (N. Kohl et al., Nature Medicine, 1:791 (1995)). Such preferred inhibitor compounds are exemplified by compounds of groups (a) through (z) as those groups are specified below.
[0024] Also suitable for use in the methods of the invention are FTase inhibitors that are competitive with farnesyl pyrophosphate. These compounds may contain e.g. a phosphate functionality, or be free of phosphorous groups, e.g. such as in chaetomellic acids. These compounds are exemplified by compounds of groups (aa) through (gg), as those groups are specified below. Further suitable for use in the methods of the invention are FTase inhibitors that comprise features of both classes of inhibitors, i.e. bi-substrate compounds that are competitive with protein substrates and with farnesyl pyrophosphate for FTase.
[0025] Specifically preferred FTase inhibitor compounds for use in the methods of the invention include the following where the compound is structurally depicted above the chemical name thereof, and pharmaceutically acceptable salts of the compounds.
[0026] (2(S)-[2(S)-[2(R)-amino-3-mercapto]-propylamino-3(S)-methyl]pentyloxy-3-henylpropionyl-methionine-sulphone isopropyl ester).
[0027] (2(S)-[2(S)-[2(R)-amino-3-mercapto]-propylamino-3(S)-methyl]pentyloxy-3-phenylpropionyl-methionine-sulphone).
[0028] (N-[2(S)-[2(R)-amino-3-mercaptopropylamino]-3-methylbutyl]-L-phenylalaninyl-L-methionine).
[0029] (N-[2(S)-N′-(1-(4-cyanophenylrnethyl)-1 H-imidazol-5-yl-acetyl)amino-3(S)-methylpentyl]-N-l-naphthylmethyl-glycl-methionine-sulphone methylester).
[0030] Other aspects of the invention are disclosed infra.
DETAILED DESCRIPTION OF THE INVENTION
[0031] As stated above, the invention provides new therapeutic methods for treatment and prevention of eye disorders and injuries, particularly treatment and prevention of ocular neovascularization and associated disorders. The methods of the invention in general comprise administration of a therapeutically effective amount of a farnesyl-protein transferase inhibitor compound to a patient in need of such treatment.
[0032] The efficacy of any particular farnesyl-protein transferase inhibitors in the therapeutic methods of the invention can be readily determined. For example, compounds with superior intrinsic inhibitory activity against and selectivity for farnesyl-protein transferase can be identified through the in vitro assays discussed above.
[0033] In vivo assays will be useful for the subsequent evaluation of potent FTase inhibitors for use in treatment of ocular neovascularization. A mouse oxygen-induced ischemic retinopathy model is a preferred assay. A suitable protocol provides that seven days after birth mice are placed in a high oxygen environment which inhibits the development of the normal retinal vessels. After 5 days in that oxygen environment, the mice are transferred to the relative hypoxia of room air where the retina becomes ischemic and retinal neovascularization occurs in 100% of the animals. The amount of neovascularization can be suitably quantitatively determined using a selective endothelial cell marker and image analysis.
[0034] For an initial in vivo evaluation of a FTase inhibitor compound, the maximum tolerated dose of the inhibitor compound is given subcutaneously twice a day. Dosing begins as soon as the animals are removed from the high oxygen environment on post natal day 12. The mice are treated for five days with drug or vehicle control alone and then sacrificed. The eyes are frozen in optimal cutting temperature embedding compound (Miles, Elkhart, Ind.) and then 10 μm sections cut and every tenth section stained with an endothelial cell specific lectin. The endothelial cell area on the surface of the retina is suitably measured using a 3 CCD camera, a frame grabber, and Image Pro Plus software. This general protocol has been previously employed for evaluation of α v β 3 integrin inhibitors. J. Luna et al., Lab. Invest., 75:563-573 (1996).
[0035] A second in vivo assay for evaluating efficacy of FTase inhibitor compounds in therapeutic methods of the invention involves overexpression of vascular endothelial growth factor (VEGF) in the photoreceptors resulting in focal intraretinal and subretinal neovascularization. Neovascularization can be quantitatively determined by perfusing animals with fluorescein-labeled dextran and then preparing retinal whole mounts. The neovascularization is quantitated by fluorescence microscopy and image analysis. It has been found that the transgene is turned on at one week after birth, and at three weeks after birth 100% of animals have subretinal neovascularization, the area of which varies by less than 5% from animal to animal.
[0036] In this assay, dosing suitably begins on postnatal day 7 and will continue for two weeks. Control animals are treated with vehicle alone. On post natal day 21 the animals are perfused through the left ventricle with fluorescein labeled dextran and then the eyes are removed, fixed in 10% phosphate-buffered formalin, and the retinas dissected and whole mounted. The retinas are viewed with fluorescence microscopy and neovascularization in the subretinal space is quantitated, e.g. using Image ProPlus software.
[0037] In addition to the above discussed preferred FTase inhibitors, suitable FTase inhibitors compounds for use in the methods of the invention are disclosed below (including those compounds of groups (a) through (gg) as those groups of compounds are defined below, and other compounds defined below). It should be appreciated however that the present invention is not limited by the particular FTase inhibitor, and the invention is applicable to any such FTase inhibitor compound now known or subsequently discovered or developed.
[0038] FTase inhibitor compounds suitable for use in the methods of the invention will include those compounds that incorporate a cysteinyl or sulfhydryl containing moiety at the N-terminus of the molecule. More specifically, the following compounds will be useful in the methods of the invention:
[0039] (a) a peptide that comprises the amino acids CA 1 A 2 X, wherein:
[0040] C=cysteine;
[0041] A 1 =an aliphatic amino acid;
[0042] A 2 =an aliphatic amino acid; and
[0043] X=any amino acid;
[0044] (b) Cys-Xaa 1 -Xaa 2 -Xaa 3 -NRR 1 , wherein Cys=cysteine;
[0045] Xaa 1 =any amino acid in the natural L-isomer form;
[0046] Xaa 2 =any amino acid in the natural L-isomer form; and
[0047] Xaa 3 =NRR 1 =an amide of any amino acid in the natural L isomer form,
[0048] wherein R and R 1 are independently selected from hydrogen, C 1 -C 12 alkyl, aralkyl, or unsubstituted or substituted aryl;
[0049] (c) Cys-Xaa 1 -Xaa 2 -Xaa 3 , wherein Cys=cysteine;
[0050] Xaa 1 =any amino acid;
[0051] Xaa 2 =the amino acid phenyl alanine or a p-fluorophenylalanine; and
[0052] Xaa 3 =any amino acid;
[0053] (d) Cys-Xaa 1 -dXaa 2 -Xaa 3 , wherein
[0054] Cys=cysteine;
[0055] Xaa 1 =any amino acid in the natural L-isomer form;
[0056] dXaa 2 =any amino acid in the natural L-isomer form; and
[0057] Xaa 3 =any amino acid in the natural L-isomer form;
[0058] (e) compounds of the following formula, which compounds are also disclosed in U.S. Pat. No. 5,238,922, incorporated herein by reference,
[0059] wherein:
[0060] X, Y, and Z are independently H 2 or O, provided that at least one of these is H 2 ;
[0061] R 1 is H, an alkyl group, an acyl group, an alkylsulfonyl group or aryl sulfonyl group, wherein alkyl and acyl groups comprise straight chain or branched chain hydrocarbons of 1 to 6 carbon atoms, or in the alternative, R 1 INH may be absent;
[0062] R 2 , R 3 and R 4 are the side chains of naturally occurring amino acids, or in the alternative may be substituted or unsubstituted aliphatic, aromatic or heteroaromatic groups, such as allyl, cyclohexyl, phenyl, pyridyl, imidazolyl or saturated chains of 2 to 8 carbon atoms, wherein the aliphatic substituents may be substituted with an aromatic or heteroaromatic ring; and
[0063] R 5 is H or a straight or branched chain aliphatic group, which may be substituted with an aromatic or heteroaromatic group;
[0064] (f) compounds of the following formula, which compounds are also disclosed in U.S. Pat. No. 5,340,828, incorporated herein by reference,
[0065] wherein:
[0066] X and Y are independently H 2 or O, provided that at least one of these is H 2 ;
[0067] R 1 is H, an alkyl group, an acyl group, an alkylsulfonyl group or aryl sulfonyl group, wherein alkyl and acyl groups comprise straight chain or branched chain hydrocarbons of 1 to 6 carbon atoms, or in the alternative, R 1 NH may be absent;
[0068] R 2 and R 3 are the side chains of naturally occurring amino acids, or in the alternative may be substituted or unsubstituted aliphatic, aromatic or heteroaromatic groups, such as allyl, cyclohexyl, phenyl, pyridyl, imidazolyl or saturated chains of 2 to 8 carbon atoms, wherein the.aliphatic substituents may be substituted with an aromatic or heteroaromatic ring;
[0069] Z is O or S; and
[0070] n is0, 1 or2;
[0071] (g) compounds of the following formula, which compounds are also disclosed in U.S. Pat. No. 5,340,828, incorporated herein by reference,
[0072] wherein:
[0073] X and Y are independently H 2 or O, provided that at least one of these is H 2 ;
[0074] R 1 is H, an alkyl group, an acyl group, an alkylsulfonyl group or aryl sulfonyl group, wherein alkyl and acyl groups comprise straight chain or branched chain hydrocarbons of 1 to 6 carbon atoms, or in the alternative, R 1 NH may be absent;
[0075] R 2 and R 3 are the side chains of naturally occurring amino acids, or in the alternative may be substituted or unsubstituted aliphatic, aromatic or heteroaromatic groups, such as allyl, cyclohexyl, phenyl, pyridyl, imidazolyl or saturated chains of 2 to 8 carbon atoms, wherein the aliphatic substituents may be substituted with an aromatic or heteroaromatic ring;
[0076] Z is O or S; and
[0077] n is 0, 1 or2;
[0078] (h) compounds of the following formula, which compounds are also disclosed in U.S. Pat. No. 5,352,705, incorporated herein by reference,
[0079] wherein:
[0080] X and Y are independently H 2 O or O;
[0081] R 1 is an alkyl group, hydrogen, an acyl group, an alkylsulfonyl group or arylsulfonyl group, wherein alkyl and acyl groups comprise straight chain or branched chain hydrocarbons of I to 6 carbons atoms, which alternatively may be substituted with an aryl group;
[0082] R 2 is the side chains of naturally occurring amino acids, or in the alternative may be substituted or unsubstituted aliphatic, aromatic or heterocyclic groups, such as allyl, cyclohexyl, phenyl. pyridyl, imidazolyl or saturated chains of 2 to 8 carbon atoms which may be branched or unbranched, wherein the aliphatic substituents may be substituted with an aromatic or heteroaromatic ring;
[0083] R 3 is an aromatic or heteroaromatic ring or in the alternative an alkyl group or an aryl or heteroaryl substituted alkane, wherein the aromatic ring is unsubstituted or in the alternative, substituted with one or more groups which may be alkyl, halo, alkoxy, trifluoromethyl, or sulfamoyl groups, and which may be polycyclic;
[0084] (i) compounds of the following formulae, which compounds are also disclosed in U.S. Pat. No. 5,326,773 and PCT Publication No. WO 94/10137, incorporated herein by reference,
[0085] wherein in said formulae I, II, III and IV:
[0086] R 1 and R 5a are independently selected from hydrogen, a C 1 -C 6 alkyl group, a C 1 -C 6 acyl group, an aroyl group, a C 1 -C 6 alkylsulfonyl group, C 1 -C 6 aralkylsulfonyl group or arylsulfonyl group wherein the alkyl group and acyl group is optionally substituted with substituted or unsubstituted aryl or heterocycle; R 2 , R 3 and R 4 are independently selected from:
[0087] a) a side chain of naturally occurring amino acids,
[0088] b) an oxidized form of a side chain of naturally occurring amino acids selected from methionine sulfoxide and methionine sulfone,
[0089] c) substituted or unsubstituted C 1 -C 8 alkyl, C 3 -C 8 cycloalkyl, C 2 -C 8 alkenyl, aryl or heterocycle groups, wherein the aliphatic substituent is optionally substituted with an aryl, heterocycle or C 3 -C 8 cycloalkyl;
[0090] R 5b is a C 1 -C 6 alkyl group, a C 1 -C 6 acyl group, an aroyl group, a C 1 -C 6 alkylsulfonyl group, C 1 -C 6 aralkylsulfonyl group or arylsulfonyl group wherein the alkyl group and acyl group is optionally substituted with substituted or unsubstituted aryl or heterocycle;
[0091] R 6 is a substituted or unsubstituted aliphatic, aryl or heterocyclic group, wherein the aliphatic substituent is optionally substituted with an aryl or heterocyclic ring; and
[0092] n is 0, 1 or 2;
[0093] (j) compounds of the following formulae, which compounds are also disclosed in U.S. Pat. No. 5,504,212, incorporated herein by reference,
[0094] wherein in said formulae I, II, III and IV:
[0095] R 1 is selected from hydrogen, a C 1 -C 6 alkyl group, a C 1 -C 6 acyl group, an aroyl group, a C 1 -C 6 alkylsulfonyl group, C 1 -C 6 aralkylsulfonyl group or arylsulfonyl group wherein the alkyl group and acyl group is optionally substituted with substituted or unsubstituted aryl or heterocycle;
[0096] R 2 , R 3 and R 4 are independently selected from:
[0097] a) a side chain of naturally occurring amino acids,
[0098] b) an oxidized form of a side chain of naturally occurring amino acids selected from methionine sulfoxide and methionine sulfone,
[0099] c) substituted or unsubstituted C 1 -C 8 alkyl, C 3 -C 8 cycloalkyl, C 2 -C 8 alkenyl, aryl or heterocycle groups, wherein the aliphatic substituent is optionally substituted with an aryl, heterocycle or C 3 -C 8 cycloalkyl;
[0100] X is CH 2 CH 2 or trans CH═CH;
[0101] R 6 is a substituted or unsubstituted aliphatic, aryl or heterocyclic group, wherein the aliphatic substituent is optionally substituted with an aryl or heterocyclic ring; and
[0102] n is 0, 1 or 2;
[0103] (k) compounds of the following formulae, which compounds are also disclosed in PCT Publication No. WO 94/10138, incorporated herein by reference,
[0104] wherein in said formulae I, II, III and IV,
[0105] R 1 is hydrogen, an alkyl group, an aralkyl group, an acyl group, an aracyl group, an aroyl group, an alkylsulfonyl group, aralkylsulfonyl group or arylsulfonyl group, wherein alkyl and acyl groups comprise straight chain or branched chain hydrocarbons of 1 to 6 carbon atoms;
[0106] R 2 , R 3 and R 5 are the side chains of naturally occurring amino acids, including their oxidized forms which may be methionine sulfoxide or methionine sulfone, or in the alternative may be substituted or unsubstituted aliphatic, aromatic or heteroaromatic groups, such as allyl, cyclohexyl, phenyl, pyridyl, imidazolyl or saturated chains of 2 to 8 carbon atoms which may be branched or unbranched, wherein the aliphatic substituents may be substituted with an aromatic or heteroaromatic ringf;
[0107] R 4 is hydrogen or an alkyl group, wherein the alkyl group comprises straight chain or branched chain hydrocarbons of 1 to 6 carbon atoms;
[0108] R 6 is a substituted or unsubstituted aliphatic, aromatic or heteroaromatic group such as saturated chains of 1 to 8 carbon atoms, which may be branched or unbranched, wherein the aliphatic substituent may be substituted with an aromatic or heteroaromatic ring,
[0109] T is O or S(O) m ;
[0110] is 0, 1 or 2; and
[0111] n is 0, 1 or 2;
[0112] (1) compounds of the following formulae, which compounds are also disclosed in PCT Publication No. WO 95/00497, incorporated herein by reference,
[0113] wherein in said formulae A, B and C:
[0114] X is O or H 2 ;
[0115] m is 1 or 2;
[0116] n is 0 or 1;
[0117] t is 1 to 4;
[0118] R and R 1 are independently selected from H, C 1-4 alkyl, or aralkyl;
[0119] R 2 , R 3 , R 4 , and Rs are independently selected from H, C 1-8 alkyl, alkenyl,
[0120] alkynyl, aryl, heterocycle, unsubstituted or substituted with one or more of:
[0121] 1) aryl or heterocycle, unsubstituted or substituted with:
[0122] a) C 1-4 alkyl,
[0123] b) (CH 2 ) t OR 6 ,
[0124] c) (CH 2 ) t NR 6 R 7 ,
[0125] d) halogen,
[0126] 2) C 3-6 cycloalkyl,
[0127] 3) OR 6 ,
[0128] 4) SR 6 , S(O)R 6 , SO 2 R 6 ,
[0129] 5) —NR 6 R 7 ,
[0130] and any two of R 2 , R 3 , R 4 , and R 5 are optionally attached to the same carbon atom;
[0131] Y is aryl, heterocycle, unsubstituted or substituted with one or more of:
[0132] 1) C 1-4 alkyl, unsubstituted or substituted with:
[0133] a) C 1-4 alkoxy,
[0134] b) NR 6 R 7 ,
[0135] c) C 3-6 cycloalkyl,
[0136] d) aryl or heterocycle,
[0137] e) HO,
[0138] 2) aryl or heterocycle,
[0139] 3) halogen,
[0140] 4) OR 6 ,
[0141] 5) NR 6 R ,
[0142] 6) CN,
[0143] 7) NO 2 , or
[0144] 8) CF 3 ;
[0145] W is H 2 or O;
[0146] Z is aryl, heteroaryl, arylmethyl, heteroarylmethyl, arylsulfonyl, heteroarylsulfonyl, unsubstituted or substituted with one or more of the following:
[0147] 1) C 1-4 alkyl, unsubstituted or substituted with:
[0148] a) C 1-4 alkoxy,
[0149] b) NR 6 R,
[0150] c) C 3-6 cycloalkyl,
[0151] d) aryl or heterocycle, or
[0152] e) HO,
[0153] 2) aryl or heterocycle,
[0154] 3) halogen,
[0155] 4) OR 6 ,
[0156] 5) NR 6 R 7 ,
[0157] 6) CN,
[0158] 7) NO 2 , or
[0159] 8) CF 3 ;
[0160] R 6 , R 7 and R 8 are independently selected from H, C 1-4 alkyl, C 3-6 cycloalkyl, heterocycle, aryl, aroyl, heteroaroyl, arylsulfonyl, heteroarylsulfonyl, unsubstituted or substituted with:
[0161] a) C 1-4 alkoxy,
[0162] b) aryl or heterocycle,
[0163] c) halogen,
[0164] d) HO,
[0165] f) —SO 2 R 9 , or
[0166] g) NRR 1 , wherein
[0167] R 6 and R may be joined in a ring, and
[0168] R and R 1 may be joined in a ring; and
[0169] R 9 is C 1-4 alkyl or aralkyl.
[0170] (m) compounds of the following formulae, which compounds are ,so disclosed in PCT Publication No. WO 96/09821, incorporated herein by reference,
[0171] wherein in said formulae I, II, III and IV:
[0172] R 1 is selected from:
[0173] a) hydrogen,
[0174] b) R 8 S(O) 2 —, R 8 C(O)—, (R 8 ) 2 NC(O)— or R 9 OC(O)—, and
[0175] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, R 8 O—, R 8 S(O) m —, R 8 C(O)NR 8 -, CN, (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , or R 9 OC(O)NR 8 -;
[0176] R 2a and R 2b are independently selected from:
[0177] a) hydrogen,
[0178] b) C 1 -C 6 alkyl unsubstituted or substituted by alkenyl, R 8 O—, R 8 S(O) m —, R 8 C(O)NR—, CN, (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , or R 9 OC(O)NR 8 -,
[0179] c) aryl, heterocycle, cycloalkyl, alkenyl, R 8 O—, R 8 S(O) m —, R 8 C(O)NR 8 -, CN, NO 2 , (R 8 ) 2 NC(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , or R 9 OC(O)NR 8 -, and
[0180] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl;
[0181] R 3 and R 4 are independently selected from:
[0182] a) a side chain of a naturally occurring amino acid,
[0183] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0184] i) methionine sulfoxide, or
[0185] ii) methionine sulfone, and
[0186] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, N(R 8 ) 2 , NO 2 , R 8 O—, R 8 S(O) m —, R 8 C(O)NR 8 -, CN, (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 1 OC(O)—, N 3 , —N(R 8 ) 2 , R 9 OC(O)NR 8 - and C 1 -C 20 alkyl, and
[0187] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl; or
[0188] R 3 and R 4 are combined to form —(CH 2 ) s —;
[0189] R 5a and R 5b are independently selected from:
[0190] a) a side chain of a naturally occurring amino acid,
[0191] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0192] i) methionine sulfoxide, or
[0193] ii) methionine sulfone,
[0194] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocycle group, wherein the substituent is selected from F, Cl, Br, N(R 8 ) 2 , NO 2 , R 8 O—, R 1 S(O) m —, R 8 C(O)NR 8 -, CN, (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , R 9 OC(O)NR 8 - and C 1 -C 20 alkyl, and
[0195] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl; or
[0196] R 5a and R 5b are combined to form —(CH 2 ) s — wherein one of the carbon atoms is optionally replaced by a moiety selected from O, S(O) m , —NC(O)—, and —N(COR 8 )—;
[0197] R 6 is
[0198] a) substituted or unsubstituted C 1 -C 8 alkyl, wherein the substituent on the alkyl is selected from:
[0199] 1) aryl,
[0200] 2) heterocycle,
[0201] 3) —N(R 8 ) 2 ,
[0202] 4) —OR 8 , or
[0203] f) —CH 2 —CH 2 —
[0204] R 7 , is selected from
[0205] a) hydrogen,
[0206] b) unsubstituted or substituted aryl,
[0207] c) unsubstituted or substituted heterocycle,
[0208] d) unsubstituted or substituted cycloalkyl, and
[0209] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
[0210] R 7b is selected from:
[0211] a) hydrogen,
[0212] b) unsubstituted or substituted aryl,
[0213] c) unsubstituted or substituted heterocycle,
[0214] d) unsubstituted or substituted cycloalkyl,
[0215] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl,
[0216] f) a carbonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl, and
[0217] g) a sulfonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
[0218] R 8 is independently selected from hydrogen, C 1 -C 6 alkyl and aryl;
[0219] R 9 is independently selected from C 1 -C 6 alkyl and aryl;
[0220] R 10 is independently selected from hydrogen and C 1 -C 6 alkyl;
[0221] R 11 is independently selected from C 1 -C 6 alkyl;
[0222] Z 1 and Z 2 are independently H 2 or O, provided that Z 1 is not 0 when X—Y is —C(O)N(R 7a );
[0223] m is 0, 1 or 2;
[0224] q is 0, 1 or2;
[0225] s is 4 or 5; and
[0226] t is 3, 4 or 5;
[0227] (n) compounds of the following formulae, which compounds are also disclosed in PCT Publication No. WO 96109820, incorporated herein by reference,
[0228] wherein:
[0229] R 1 is selected from:
[0230] a) hydrogen,
[0231] b) R 5 S(O) 2 —, R 5 C(O)—, (R 5 ) 2 NC(O)— or R 6 OC(O)—, and
[0232] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, R 5 O—, R 5 S(O) m —, R 5 C(O)NR 5 —, CN, (R 5 ) 2 N—R 5 )—, R 5 C(O)—, R 5 OC(O)—, N 3 , —N(R 5 ) 2 , or R 6 OC(O)N 5 —;
[0233] R 2a and R 2b are independently selected from:
[0234] a) hydrogen,
[0235] b) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocycle, cycloalkyl, alkenyl, R 5 O—, R 5 S(O) m —, R 5 C(O)NR 5 -CN, (R 5 ) 2 N—C(NR 5 )—, R 5 C(O)—, R 5 OC(O)—, N 3 , —N(R 5 ) 2 , or R 6 OC(O)Nk 5 -, and
[0236] c) aryl, heterocycle, cycloalkyl, alkenyl, R 5 O—, R 5 S(O)MR 5 C(O)NR 5 —, CN, NO 2 , (R 5 ) 2 N—C(NR 5 )—, R 5 C(O)—. R 1 OC(O)—, N 3 , —N(R 5 ) 2 , or R 6 OC(O)NR 5 —,
[0237] R 3 is selected from:
[0238] a) unsubstituted or substituted aryl,
[0239] b) unsubstituted or substituted heterocycle,
[0240] c) unsubstituted or substituted cycloalkyl, and
[0241] d) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
[0242] X—Y is
[0243] f) —CH 2 —CH 2 —
[0244] R 4a is selected from
[0245] a) hydrogen,
[0246] b) unsubstituted or substituted aryl,
[0247] c) unsubstituted or substituted heterocycle,
[0248] d) unsubstituted or substituted cycloalkyl, and
[0249] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
[0250] R 4b is selected from
[0251] a) hydrogen,
[0252] b) unsubstituted or substituted aryl,
[0253] c) unsubstituted or substituted heterocycle,
[0254] d) unsubstituted or substituted cycloalkyl,
[0255] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl,
[0256] f) a carbonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl, and
[0257] g) a sulfonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
[0258] R 5 is independently selected from hydrogen, C 1 -C 6 alkyl and aryl;
[0259] R 6 is independently selected from C 1 -C 6 alkyl and aryl;
[0260] Z is independently H 2 O or O;
[0261] m is 0, 1 or 2, provided that m is 0 when R 5 =hydrogen;
[0262] n is0, 1, 2, 3 or 4; and
[0263] t is 3, 4 or 5.
[0264] (o) compounds of the following formulae:
[0265] wherein in said formula A, B, C and D:
[0266] X and Y are independently O or H 2 O;
[0267] m is 1 or 2;
[0268] n is O or 1;
[0269] p is 1, 2 or 3;
[0270] q is 0, 1 or 2;
[0271] t is 1 to 4;
[0272] R, R 1 and R 2 are independently selected from H, C 1-6 alkyl, or C 1-6 aralkyl;
[0273] R 3 and R 4 are independently selected from:
[0274] a) hydrogen,
[0275] b) C 1 -C 6 alkyl unsubstituted or substituted by C 2 -C 6 alkenyl, R 6 O—, R 5 S(O) q —, R 7 C(O)NR 6 -, CN, N 3 , R 6 OC(O)NR 6 -, R 6 R 7 N—C(NR 6 R 8 )—, R 6 C(O)—, R 7 R 8 NC(O)O—, R 7 R 8 NC(O)—, R 6 R 7 N-S(0) 2 -, —Nk 6 S(0) 2 R 5 , R 6 OC(0)0-, —Nk 6 R 7 , or R 7 R 8 NC(O)NR 6 ,
[0276] c) unsubstituted or substituted cycloalkyl, alkenyl, R 6 0-, R 5 S(O) q —, R 6 C(O)NR 6 -, CN, NO 2 , R 6 R 7 N—C(NR 8 )—, R 6 C(O)—, N 3 , —NR 6 R 7 , halogen or R 7 OC(O)NR 6 -, and
[0277] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl;
[0278] W is —CHR 9 -or —NR 9 -;
[0279] Z is unsubstituted or substituted C 108 alkyl, unsubstituted or substituted C 2-8 alkenyl, unsubstituted or substituted aryl, unsubstituted or substituted heterocycle; wherein the substituted group is substituted with one or more of:
[0280] 1) C 1-4 alkyl, unsubstituted or substituted with:
[0281] a) C 1-4 alkoxy,
[0282] b) N—R 6 R 7 ,
[0283] c) C 3-6 cycloalkyl,
[0284] d) aryl or heterocycle,
[0285] e) HO,
[0286] 2) aryl or heterocycle,
[0287] 3) halogen,
[0288] 4) OR 6 ,
[0289] 5) NR 6 R 7 ,
[0290] 6) CN,
[0291] 7) NO 2 , or
[0292] 9) CF 3 ;
[0293] R 5 is C 1-4 alkyl or aralkyl;
[0294] R 6 , R 7 and R 8 are independently selected from H, C 1-4 alkyl, C 3-6 cycloalkyl, heterocycle, aryl, aroyl, heteroaroyl, arylsulfonyl, heteroarylsulfonyl, unsubstituted or substituted with:
[0295] a) C 1-4 alkoxy,
[0296] b) aryl or heterocycle,
[0297] c) halogen,
[0298] d) HO,
[0299] f) —SO 2 R 5 , or
[0300] g) —NR 6 R 7 , or
[0301] R 6 and R 7 may be joined in a ring, and
[0302] R 1 and RS may be joined in a ring;
[0303] R 9 is selected from H, Cl, alkyl, C 3-6 cycloalkyl, heterocycle and aryl, unsubstituted, monosubstituted or disubstituted with substituents independently selected from:
[0304] a) C 1-4 alkyl,
[0305] b) C 1-4 alkoxy,
[0306] c) aryl or heterocycle,
[0307] d) halogen,
[0308] e) HO,
[0309] f)
[0310] g) —SO 2 R 3 , and
[0311] h) —NR 6 R 7 ;
[0312] V is selected from —C(R 11 )═C(R 11 )—, C—C—, —C(O)—, —C(R 11 ) 2 —, —C(OR 11 )R 11 -, —CN(R 11 ) 2 R 11 -, —OC(R 11 )2—, —NR 11 C(R 11 ) 2 —, —C(R 11 ) 2 0-, —C(R 11 ) 2 NR 11 -, —C(O)NR 11 -, —NR 11 C(O)—, 0, —NC(O)R 11 -, —NC(O)0R 11 -, —S(O) 2 N(R 11 )—, —N(R 11 )S(O) 2 —, or S(O) m ;
[0313] R 10 and R 11 are independently selected from hydrogen, C 1 -C 6 alkyl, C 2 -C 4 alkenyl, benzyl and aryl; or the pharmaceutically acceptable salt thereof.
[0314] Compounds suitable for use in the methods of the invention also include those farnesyl-protein transferase inhibitors that do not incorporates a cysteinyl or sulfhydryl containing moiety at the N terminus of the molecule. Such compounds may exhibit preferred pharmacological activity, e.g. by avoiding thiol-related reactions in vivo. More specifically, the following compounds may be suitable.
[0315] (p) compounds of the following formulae, which compounds are also disclosed in PCT Publication No. WO 95/09001, incorporated herein by reference,
[0316] wherein in said formulae I, II, III and IV:
[0317] R 1 is selected from:
[0318] a) heterocycle, and
[0319] b) C 1 -C 10 alkyl, which is substituted with heterocycle and which is optionally substituted with one or more of C 1 -C 4 alkyl, hydroxy or amino groups;
[0320] R 2a and R 2b are independently selected from:
[0321] a) a side chain of a naturally occurring amino acid,
[0322] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0323] i) methionine sulfoxide, or
[0324] ii) methionine sulfone,
[0325] c) substituted or unsubstituted C 1 -C alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, NO 2 , R 8 O—, R 9 S(O) m —, R 8 C(O)NR 8 -, CN, (R 8 ) 2 NC(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , R 9 OC(O)NR 8 - and C 1 -C 20 alkyl, and
[0326] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0327] R 2a and R 2b are combined to form —(CH 2 ) s —;
[0328] R 3 and R 4 are independently selected from:
[0329] a) a side chain of a naturally occurring amino acid,
[0330] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0331] i) methionine sulfoxide, or
[0332] ii) methionine sulfone, and
[0333] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, N(R 8 ) 2 , NO 2 , R 8 O—, R 9 S(O) m —, R 8 C(O)NR 8 -, CN, (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , R 9 OC(O)NR 8 - and C 1 -C 20 alkyl, and
[0334] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3-10 cycloalkyl; or
[0335] R 3 and R 4 are combined to form —(CH 2 ) s —;
[0336] R 5a and R 5b are independently selected from:
[0337] a) a side chain of a naturally occurring amino acid,
[0338] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0339] i) methionine sulfoxide, or
[0340] ii) methionine sulfone,
[0341] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocycle group, wherein the substituent is selected from F, Cl, Br, N(R 8 ) 2 , NO 2 , R 8 O—, R 9 S(O) m —, R 8 C(O)NR 8 -, CN, (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , R 9 OC(O)NR 8 - and C 1 -C 20 alkyl, and
[0342] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl; or
[0343] R 5a and R 5b are combined to form —(CH 2 ) s — wherein one of the carbon atoms is optionally replaced by a moiety selected from O, S(O) m , —NC(O)—, and —N(COR 8 )—; R 6 is
[0344] a) substituted or unsubstituted C 1 -C 8 alkyl, wherein the substituent on the alkyl is selected from:
[0345] 1) aryl,
[0346] 2) heterocycle,
[0347] 3) —N(R 9 ) 2 ,
[0348] 4) —OR 8 or
[0349] f) —CH 2 —CH 2 —;
[0350] R 7a is selected from
[0351] a) hydrogen,
[0352] b) unsubstituted or substituted aryl,
[0353] c) unsubstituted or substituted heterocyclic,
[0354] d) unsubstituted or substituted cycloalkyl, and
[0355] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl;
[0356] R 7b is selected from
[0357] a) hydrogen,
[0358] b) unsubstituted or substituted aryl,
[0359] c) unsubstituted or substituted heterocyclic,
[0360] d) unsubstituted or substituted cycloalkyl,
[0361] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl,
[0362] f) a carbonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocyclic, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl, and
[0363] g) a sulfonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocyclic, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl;
[0364] R 8 is independently selected from hydrogen, C 1 -C 6 alkyl and aryl;
[0365] R 9 is independently selected from C 1 -C 6 alkyl and aryl;
[0366] R 10 is independently selected from hydrogen and C 1 -C 6 alkyl;
[0367] R 11 is independently selected from C 1 -C 6 alkyl;
[0368] Z is independently H 2 or O;
[0369] mis 0, 1 or2;
[0370] n is 0, 1 or 2; and
[0371] s is 4 or 5;
[0372] (q) compounds of the following formulae, which compounds are also disclosed in PCT Publication No. WO 95/09000 and U.S. Pat. No. 5,468,773, incorporated herein by reference,
[0373] wherein in said formula I, II, III and IV:
[0374] V is CH 2 , O, S, HN, or R 7 N;
[0375] R 2 , R 3 , R 4 and R 5 are independently the side chains of naturally occurring amino acids, including their oxidized forms which may be methionine sulfoxide or methionine sulfone, or in the alternative may be substituted or unsubstituted aliphatic, aromatic or heteroaromatic groups, such as allyl, cyclohexyl, phenyl, pyridyl, imidazolyl or saturated chains of 2 to 8 carbon atoms which may be branched or unbranched, wherein the aliphatic substituents may be substituted with an aromatic or heteroaromatic ring;
[0376] f) —CH 2 —CH 2 —
[0377] R 6 is a substituted or unsubstituted aliphatic, aromatic or heteroaromatic group such as saturated chains of 1 to 8 carbon atoms, which may be branched or unbranched, wherein the aliphatic substituent may be substituted with an aromatic or heteroaromatic ring;
[0378] R 7 is an alkyl group, wherein the alkyl group comprises straight chain or branched chain hydrocarbons of 1 to 6 carbon atoms, which may be substituted with an aromatic or heteroaromatic group;
[0379] Z is H 2 or O;
[0380] m is 0, 1 or2;
[0381] n is 0, 1 or 2; and
[0382] o is 0, 1, 2 or 3;
[0383] (r) compounds of tbe following formulae, which compounds are also disclosed in PCT Publication No. WO 96/09836, incorporated herein by reference
[0384] wherein in said forrnulae I, II, III and IV:
[0385] R is selected from:
[0386] a) hydrogen,
[0387] b) aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, (R 10 ) 2 N—C(NR 1 )—, R 10 C(O)—, or R 10 OC(O)—, and
[0388] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -;
[0389] R 1b is independently selected from:
[0390] a) hydrogen,
[0391] b) unsubstituted or substituted aryl, cycloalkyl, alkenyl, alkynyl, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, or RROC(O)—, and
[0392] c) C 1 -C 6 alkyl unsubstituted or substituted by unsubstituted or substituted aryl, cycloalkyl, alkenyl, alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -;
[0393] provided that R 1b is not R 10 C(O)NR 10 -when R 1a is alkenyl,
[0394] V is hydrogen and X—Y is C(O)NR 7a ;
[0395] R 2a and R 2b are independently selected from:
[0396] a) a side chain of a naturally occurring amino acid,
[0397] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0398] i) methionine sulfoxide, or
[0399] ii) methionine sulfone,
[0400] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F. Cl, Br,
[0401] NO 2 , R 10 O—, R 1 (O) m —, R 10 C(O)NR 10 O—, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , R 11 OC(O)NR 10 - and C 1 -C 20 alkyl, and
[0402] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0403] R 2a and R 2b are combined to form —(CH 2 ) s —;
[0404] R 3 and R 4 are independently selected from:
[0405] a) a side chain of a naturally occurring amino acid,
[0406] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0407] i) methionine sulfoxide, or
[0408] ii) methionine sulfone,
[0409] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, N(R 10 ) 2 , NO 2 , R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , R 11 OC(O)NR 10 - and C 1 -C 20 alkyl, and
[0410] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0411] R 3 and R 4 are combined to form —(CH 2 ) s —;
[0412] R 5a and R 5b independently selected from:
[0413] a) a side chain of a naturally occurring amino acid,
[0414] b) an oxidized formn of a side chain of a naturally occurring amino acid which is:
[0415] i) methionine sulfoxide, or
[0416] ii) methionine sulfone,
[0417] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, NO 2 , R 10 O—, R 11 S(O) m —, R 10 OC(O)NR 10 -, CN, (R 10 ) 2 N—CNR 10 )—, R 10 C(O)—, R 10 OC(9)—, N 3 , —N(R 10 ) 2 , R 11 C(O)NR 10 - and C 1 -C 20 alkyl, and
[0418] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0419] R 5a and R 5b are combined to form —(CH 2 )s— wherein one of the carbon atoms is optionally replaced by a moiety selected from O, S(O) m , —NC(O)—, and —N(COR 10 )—;
[0420] R 6 is
[0421] a) substituted or unsubstituted C 1 -C 8 alkyl, wherein the substituent on the alkyl is selected from:
[0422] 1) aryl,
[0423] 2) heterocycle,
[0424] 3) —N(R 11 ) 2 ,
[0425] 4) —OR 10 , or
[0426] f) —CH 2 —CH 2 —
[0427] R 7a is selected from
[0428] a) hydrogen,
[0429] b) unsubstituted or substituted aryl,
[0430] c) unsubstituted or substituted heterocyclic,
[0431] d) unsubstituted or substituted cycloalkyl, and
[0432] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl;
[0433] R 7b is selected from:
[0434] a) hydrogen,
[0435] b) unsubstituted or substituted aryl,
[0436] c) unsubstituted or substituted heterocyclic,
[0437] d) unsubstituted or substituted cycloalkyl,
[0438] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl,
[0439] f) a carbonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocyclic, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl, and
[0440] g) a sulfonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocyclic, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl;
[0441] R 8 is independently selected from:
[0442] a) hydrogen,
[0443] b) aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , R 10 2N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0444] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 1 OC(O)NH—, CN, H 2 N—C(NH)—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 8 ) 2 , or R 11 OC(O)NH—;
[0445] R 9 is selected from:
[0446] hydrogen, C 1 -C 6 alkyl, R 10 O—, R 11 S(O) m —, R 1 OC(O)NR 10 -, CN, NO 2 , N 3 , —N(R 10 ) 2 , and R 11 OC(O)NR 10 -;
[0447] provided that R 9 is not R 10 C(O)NR 10 -when R 1a is alkenyl, V is hydrogen and X—Y is —C(O)NR 7 -;
[0448] R 10 is independently selected from hydrogen, C 1 -C 6 alkyl, benzyl and aryl;
[0449] R 11 is independently selected from C 1 -C 6 alkyl and aryl;
[0450] R 12 is independently selected from hydrogen and C 1 -C 6 alkyl;
[0451] R 13 is C 1 -C 6 alkyl;
[0452] V is selected from:
[0453] a) aryl;
[0454] b) heterocycle; or
[0455] c) hydrogen;
[0456] W is —S(O) m —, —O—, —NHC(O)—, —C(O)NH—, —NHSO 2 —, —SO 2 NH—, N(R 7a )— or N[C(O)R 7a ];
[0457] Z is independently H 2 or O;
[0458] m is 0, 1 or 2;
[0459] n is 0, 1, 2, 3 or 4, provided that n is not 0 when V is hydrogen and W is —S(O) m ;
[0460] p is 0, 1, 2, 3 or 4, provided that p=0 when R 9 is not hydrogen or C 1 -C 6 lower alkyl;
[0461] q is 0, 1 or 2;
[0462] r is 0 or 1;
[0463] s is 4 or 5; and
[0464] t is 0, 1 or 2, provided that t=0 when V is hydrogen;
[0465] (s) compounds of the following formulae which compounds are also disclosed in PCT Publication WO 96/10011, incorporated herein by reference,
[0466] wherein in said forrnulae I, II, III and IV:
[0467] R 1 is hydrogen, C 1 -C 6 alkyl or aryl;
[0468] R 2a and R 2b are independently selected from:
[0469] a) a side chain of a naturally occurring amino acid,
[0470] b) an oxidized forrn of a side chain of a naturally occurring amino acid which is:
[0471] i) methionine sulfoxide, or
[0472] ii) methionine sulfone,
[0473] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocycle group, wherein the substituent is selected from F, Cl, Br, NO 2 , R 9 0-, R 10 S(O) m —, R 9 C(O)NR 9 -, CN, (R 9 ) 2 NC(NR 9 )—, R 9 C(O)—, R 9 OC(O)—, N 3 , —N(R 9 ) 2 , R 10 OC(O)NR 9 - and C 1 -C 20 alkyl, and
[0474] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0475] R 2a and R 2b are combined to form —(CH 2 ) s —;
[0476] R 3 and R 4 are independently selected from:
[0477] a) a side chain of a naturally occurring amino acid,
[0478] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0479] i) methionine sulfoxide, or
[0480] ii) methionine sulfone,
[0481] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocycle group, wherein the substituent is selected from F, Cl, Br, NO 2 , R 9 0-, R 1 OS(O) m —, R 9 C(O)NR 9 -, CN, (R 9 ) 2 NCNR 9 )—, R 9 C(O)—, R 9 OC(O)—, N 3 , —N(R 9 ) 2 , R 10 OC(O)NR 9 - and C 1 -C 20 alkyl, and
[0482] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0483] R 3 and R 4 are combined to form —(CH 2 ) s —;
[0484] R 5a and R 5b are independently selected from:
[0485] a) a side chain of a naturally occurring amino acid,
[0486] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0487] i) methionine sulfoxide, or
[0488] ii) methionine sulfone,
[0489] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocycle group, wherein the substituent is selected from F, Cl, Br, NO 2 , R 9 0-, R 1 OS(O) m —, R 9 C(O)NR 9 -, CN, (R 9 ) 2 N—C(NR 9 )—, R 9 C(O)—, R 9 OC(O)—, N 3 , —N(R 9 ) 2 , R 10 OC(O)NR 9 - and C 1 -C 20 alkyl, and
[0490] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0491] R 5a and R 5b are combined to form —(CH 2 ) s — wherein one of the carbon atoms is optionally replaced by a moiety selected from O, S(O) m , —NC(O)—, and —N(COR 9 )—;
[0492] R 6 is
[0493] a) substituted or unsubstituted C 1 -C 8 alkyl, wherein the substituent on the alkyl is selected from:
[0494] 1) aryl,
[0495] 2) heterocycle,
[0496] 3) —N(R 10 ) 2 ,
[0497] 4) —OR 9 , or
[0498] f) —CH 2 —CH 2 —;
[0499] R 7a is selected from
[0500] a) hydrogen,
[0501] b) unsubstituted or substituted aryl,
[0502] c) unsubstituted or substituted heterocycle,
[0503] d) unsubstituted or substituted cycloalkyl, and
[0504] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
[0505] R 7b is selected from
[0506] a) hydrogen,
[0507] b) unsubstituted or substituted aryl,
[0508] c) unsubstituted or substituted heterocycle,
[0509] d) unsubstituted or substituted cycloalkyl,
[0510] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl,
[0511] f) a carbonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl, and
[0512] g) a sulfonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
[0513] R 8a and R 8b are independently selected from hydrogen, F, Cl, Br, NO 2 , R 11 O—, R 10 S(O) m —, CN, R 9 C(O)NR 9 -, (R 9 ) 2 N—C(NR 9 )—, R 9 C(O)—, R 9 OC(O)—, N 3 , —N(R 9 ) 2 , R 10 OC(O)NR 9 -, C 1 -C 20 alkyl, aryl, heterocycle or C 1 -C 20 alkyl substituted with aryl or heterocycle;
[0514] R 9 is independently selected from hydrogen, C 1 -C 6 alkyl and aryl;
[0515] R 10 is independently selected from C 1 -C 6 alkyl and aryl;
[0516] R 11 is independently selected from hydrogen, C 1 -C 6 alkyl and aryl, provided R 11 is C 1 -C 6 alkyl when n is 0:
[0517] R 12 is independently hydrogen or C 1 -C 6 alkyl;
[0518] R 13 is C 1 -C 6 alkyl;
[0519] is aryl or 1,2,3,4-tetrahydronaphthyl;
[0520] Z is independently H 2 or O;
[0521] m is 0, 1 or 2;
[0522] n is independently 0 to 4;
[0523] p is 0 or 1;
[0524] q is 0, 1 or 2; and
[0525] s is 4 or 5;
[0526] (t) compounds of the following formulae, which compounds are also disclosed in PCT Publication 96/10034, incorporated herein by reference,
[0527] wherein in said formulae I, II, III and IV:
[0528] R 1 is independently selected from:
[0529] a) hydrogen,
[0530] b) aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, R 11 OR 11 S(O) m —, R 11 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 NC(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 11 ) 2 , or R 11 OC(O)NR 10
[0531] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -;
[0532] R 2a and R 2b are independently selected from:
[0533] a) a side chain of a naturally occurring amino acid,
[0534] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0535] i) methionine sulfoxide, or
[0536] ii) methionine sulfone,
[0537] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, NO 2 , R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(R 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , R 11 OC(O)NR 10 - and C 1 -C 20 alkyl, and
[0538] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0539] R 2a and R 2b are combined to form —(CH 2 ) s —;
[0540] R 3 and R 4 are independently selected from:
[0541] a) a side chain of a naturally occurring amino acid,
[0542] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0543] i) methionine sulfoxide, or
[0544] ii) methionine sulfone,
[0545] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, N(R 10 ) 2 , NO 2 , R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , R 11 OC(O)NR 10 - and C 1 -C 20 alkyl, and
[0546] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0547] R 3 and R 4 are combined to form —(CH 2 ) s —;
[0548] R 5a and R 5b are independently selected from:
[0549] a) a side chain of a naturally occurring amino acid,
[0550] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0551] i) methionine sulfoxide, or
[0552] ii) methionine sulfone,
[0553] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocycle group, wherein the substituent is selected from F, Cl, Br, N(R 10 ) 2 , NO 2 , R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , R 11 OC(O)NR 10 - and C 1 -C 20 alkyl, and
[0554] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0555] R 5a and R 5b are combined to form —(CH 2 ) s —wherein one of the carbon atoms is optionally replaced by a moiety selected from O, S(O) m , —NC(O)—, and —N(COR 1 )—;
[0556] R 6 is
[0557] a) substituted or unsubstituted C 1 -C 8 alkyl, wherein the substituent on the alkyl is selected from:
[0558] 1) aryl,
[0559] 2) heterocycle,
[0560] 3) —N(R 11 ) 2 ,
[0561] 4) —OR 10 . or
[0562] f) —CH 2 —CH 2 —;
[0563] R 7a is selected from
[0564] a) hydrogen,
[0565] b) unsubstituted or substituted aryl,
[0566] c) unsubstituted or substituted heterocyclic,
[0567] d) unsubstituted or substituted cycloalkyl, and
[0568] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl;
[0569] R 7b is selected from
[0570] a) hydrogen,
[0571] b) unsubstituted or substituted aryl,
[0572] c) unsubstituted or substituted heterocyclic,
[0573] d) unsubstituted or substituted cycloalkyl,
[0574] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl,
[0575] f) a carbonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocyclic, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl, and
[0576] g) a sulfonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocyclic, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocyclic and cycloalkyl;
[0577] R 8 is independently selected from:
[0578] a) hydrogen,
[0579] b) aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 11 C(O)NR 10 -, CN, NO 2 , (R 8 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0580] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NH—, CN, H 2 N—C(NH)—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NH—;
[0581] R 9 is selected from:
[0582] a) hydrogen, alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —. R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 NC(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0583] c) C 1 -C 6 alkyl unsubstituted or substituted by perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 )2N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -;
[0584] R 10 is independently selected from hydrogen, C 1 -C 6 alkyl and aryl;
[0585] R 11 is independently selected from C 1 -C 6 alkyl and aryl;
[0586] R 12 is independently selected from hydrogen and C 1 -C 6 alkyl;
[0587] R 13 is independently selected from C 1 -C 6 alkyl;
[0588] A 1 and A 2 are independently selected from a bond, —CH═CH—, —C≡C—, —C(O)—, —C(O)NR 11 -, 0, —N(R 10 )—, —NR 10 C(O)—, -S(0) 2 N(R 10 )—, —N(R 10 )S(O) 2 — or S(O) m ;
[0589] V is selected from:
[0590] a) hydrogen,
[0591] b) heterocycle,
[0592] c) aryl,
[0593] d) C 1 -C 20 alkyl wherein from 0 to 4 non-terminal carbon atoms are replaced with a heteroatom selected from O, S, and N, and
[0594] e) C 2 -C 20 alkenyl;
[0595] provided that V is not hydrogen if A 1 is S(O) m and V is not hydrogen if A 1 is a bond, n is 0 and A 2 is S(O) m or a bond;
[0596] W is a heterocycle;
[0597] z is independently H 2 or O;
[0598] m is 0, 1 or 2;
[0599] n is 0, 1, 2, 3 or 4;
[0600] p is 0, 1, 2, 3 or 4;
[0601] q is 0, 1 or 2;
[0602] r is 0 to 5, provided that r is 0 when V is hydrogen; and
[0603] s is 4or 5;
[0604] (u) compounds of the following formulae, which compounds are also disclosed in PCT Publication No. WO 96/10035, incorporated herein by reference,
[0605] wherein in said formnulae I, II, III and IV:
[0606] R 1a and R 1b are independently selected from:
[0607] a) hydrogen,
[0608] b) aryl, heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -,
[0609] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, C 3 -C 10 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)—NR 10 -;
[0610] R 2a and R 2b are independently selected from:
[0611] a) hydrogen,
[0612] b) C 1 -C 6 alkyl unsubstituted or substituted by C 2 -C 6 alkenyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, N 3 , (R 10 ) 2 N—(NR 10 )—, R 10 C(O)—, R 11 OC(O)—, —N(R 10 ) 2 , or R 10 C(O)NR 10 -,
[0613] c) aryl, heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 6 alkenyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO,, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0614] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl;
[0615] R 3 and R 4 are independently selected from:
[0616] a) a side chain of a naturally occurring amino acid,
[0617] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0618] i) methionine sulfoxide, or
[0619] ii) methionine sulfone,
[0620] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, N(R 10 ) 2 , NO 2 , R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 1 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , R 11 OC(O)NR 10 - and C 1 -C 20 alkyl, and
[0621] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0622] R 3 and R 4 are combined to form —(CH 2 ) s —;
[0623] R 5a and R 5b are independently selected from:
[0624] a) a side chain of a naturally occurring amino acid,
[0625] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0626] i) methionine sulfoxide, or
[0627] ii) methionine sulfone,
[0628] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocycle group, wherein the substituent is selected from F, Cl, Br, CF 3 , N(R 10 ) 2 , NO 2 , R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—CCNR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , R 10 C(O)N—R 10 - and C 1 -C 20 alkyl, and
[0629] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl. heterocycle and C 3 -C 10 cycloalkyl; or
[0630] R 5a and R 5b are combined to form —(CH 2 ) s —wherein one of the carbon atoms is optionally replaced by a moiety selected from O, S(O) m , —NC(O)—, and —N(COR 10 )—;
[0631] R 6 is
[0632] a) substituted or unsubstituted C 1 -C 8 alkyl, substituted or unsubstituted C 1 -C 8 cycloalkyl, or substituted or unsubstituted cyclic amine, wherein the substituted alkyl, cycloalkyl or cyclic amine is substituted with 1 or 2 substituents independently selected from:
[0633] 1) C 1 -C 6 alkyl,
[0634] 2) aryl,
[0635] 3) heterocycle,
[0636] 4) —N(R 11 ) 2 ,
[0637] 5) —OR 10 ,or
[0638] f) —CH 2 —CH 2 —
[0639] R 7a is selected from
[0640] a) hydrogen,
[0641] b) unsubstituted or substituted aryl,
[0642] c) unsubstituted or substituted heterocycle,
[0643] d) unsubstituted or substituted C 3 -C 10 cycloalkyl, and
[0644] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl;
[0645] R 11b is selected from
[0646] a) hydrogen,
[0647] b) unsubstituted or substituted aryl,
[0648] c) unsubstituted or substituted heterocycle,
[0649] d) unsubstituted or substituted C 3 -C 10 cycloalkyl,
[0650] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl,
[0651] f) a carbonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, C 3 -C 10 cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl, and
[0652] g) a sulfonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, C 3 -C 10 cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl;
[0653] R 89 is independently selected from:
[0654] a) hydrogen,
[0655] b) aryl, heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0656] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NH—, CN, H 2 N—C(H)—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or
[0657] R 10 OC(O)NH—;
[0658] R 9 is selected from:
[0659] a) hydrogen,
[0660] b) C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 8 ) 2 N—C-(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0661] c) C 1 -C 6 alkyl unsubstituted or substituted by perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 ;
[0662] R 10 is independently selected from H, C 1 -C 6 alkyl, benzyl, substituted aryl and C 1 -C 6 alkyl substituted with substituted aryl;
[0663] R 11 is independently selected from C 1 -C 6 alkyl and aryl;
[0664] R 12 is hydrogen or C 1 -C 6 alkyl;
[0665] R 13 is C 1 -C 6 alkyl;
[0666] A 1 and A 2 are independently selected from a bond, —CH═CH—, —C≡C—, —C(O)—, —C(O)NR 10 -, —NR 10 C(O)—, O, —N(R 10 )—, —(O) 2 N(R 10 )—, —N(R 10 )S(O) 2 —, or S(O) m ;
[0667] V is selected from:
[0668] a) hydrogen,
[0669] b) heterocycle,
[0670] c) aryl,
[0671] d) C 1 -C 20 alkyl wherein from 0 to 4 carbon atoms are replaced with a heteroatom selected from O, S, and N, and
[0672] e) C 2 -C 20 alkenyl, provided that V is not hydrogen if A 1 is S(O) m and V is not hydrogen if A 1 is a bond, n is 0 and A 2 is S(O) m ;
[0673] W is a heterocycle;
[0674] Z is independently H 2 or O;
[0675] m is 0, 1 or 2;
[0676] n is 0, 1, 2, 3 or 4;
[0677] p is 0, 1, 2, 3 or 4;
[0678] q is 0, 1 or 2;
[0679] r is 0 to 5, provided that r is 0 when V is hydrogen;
[0680] s is 4or 5;
[0681] t is 3, 4 or 5; and
[0682] u is 0 or 1;
[0683] (v) compounds of the following formulae,
[0684] wherein in formulae I, II, III and IV:
[0685] R 1a and R 1b are independently selected from:
[0686] a) hydrogen,
[0687] b) aryl, heterocycle, cycloalkyl, alkenyl, alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -,
[0688] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)—NR 10 -;
[0689] R 2a and R 2b are independently selected from:
[0690] a) hydrogen,
[0691] b) C 1 -C 6 alkyl unsubstituted or substituted by alkenyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, N 3 , (R 10 ) 2 N—C(NiR 10 )—, R 10 C(O)—, R 10 OC(O)—, —N(R 10 ) 2 , or R 11 OC(O)NR 10 -,
[0692] c) aryl, heterocycle, cycloalkyl, alkenyl, R 10 O R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 16 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0693] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl;
[0694] R 3a and R 3b are independently selected from:
[0695] a) a side chain of a naturally occurring amino acid,
[0696] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0697] i) methionine sulfoxide, or
[0698] ii) methionine sulfone, and
[0699] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, N(R 10 ) 2 , NO 2 , R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , R 10 OC(O)N—R 10 - and C 1 -C 20 alkyl, and
[0700] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from, heterocycle and C 3 -C 10 cycloalkyl; or
[0701] R 3a and R 3b are combined to form —(CH 2 ) s —wherein one of the carbon atoms is optionally replaced by a moiety selected from O, S(O) m , —NC(O)—, and —N(COR 10 )—;
[0702] R 4 and R 5 are independently selected from:
[0703] a) hydrogen, and
[0704] R 6 is
[0705] a) substituted or unsubstituted C 1 -C 8 alkyl or substituted or unsubstituted C 3 -C 8 cycloalkyl, wherein the substituent on the alkyl is selected from:
[0706] 1) aryl,
[0707] 2) heterocycle,
[0708] 3) —N(R 11 ) 2 ,
[0709] 4) —OR 10 , or
[0710] R 7 is independently selected from:
[0711] a) hydrogen,
[0712] b) aryl, heterocycle, cycloalkyl, alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0713] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocycle, cycloalkyl, alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NH—, CN, H 2 NC(NH)—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 10 OC(O)NH—;
[0714] R 8 is selected from:
[0715] a) hydrogen,
[0716] b) alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C-(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0717] c) C 1 -C 6 alkyl unsubstituted or substituted by perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -;
[0718] R 10 is independently selected from hydrogen, C 1 -C 6 alkyl, benzyl and aryl;
[0719] R 11 is independently selected from C 1 -C 6 alkyl and aryl;
[0720] R 12 is independently selected from hydrogen and C 1 -C 6 alkyl; R 13 is independently selected from C 1 -C 6 alkyl;
[0721] A 1 and A 2 are independently selected from a bond, —CH═CH—, —C≡C—, —C(O)—, —C(O)NR 10 -, —NR 10 C(O)—, 0,—N(R 10 )—, -S(O) 2 N(R 10 )—, —N(R 10 )S(O) 2 -, or S(O) m ;
[0722] V is selected from:
[0723] a) hydrogen,
[0724] b) heterocycle,
[0725] c) aryl,
[0726] d) C 1 -C 20 alkyl wherein from 0 to 4 carbon atoms are replaced with a heteroatom selected from O, S, and N, and
[0727] e) C 2 -C 20 alkenyl, provided that V is not hydrogen if A 1 is S(O) m and V is not hydrogen if A 1 is a bond, n is 0 and A 2 is S(O) m ;
[0728] W is a heterocycle;
[0729] Z is independently H 2 or O;
[0730] m is 0, 1 or 2;
[0731] n is 0, 1, 2, 3 or 4;
[0732] p is 0, 1, 2, 3 or 4;
[0733] q is 0, 1 or 2;
[0734] r is 0 to 5, provided that r is 0 when V is hydrogen;
[0735] s is 4 or 5; and
[0736] u is 0 or 1;
[0737] (w) compounds of the following formulae,
[0738] wherein in said formulae I, II, III and IV:
[0739] R 1a and R 1b are independently selected from:
[0740] a) hydrogen,
[0741] b) aryl, heterocycle, cycloalkyl, alkenyl, alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -,
[0742] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , N(R 10 )21 or R 11 OC(O)—NR 10 -;
[0743] R 2 and R 1 are independently selected from:
[0744] a) a side chain of a naturally occurring amino acid,
[0745] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0746] i) methionine sulfoxide, or
[0747] ii) methionine sulfone. and
[0748] c) substituted or unsubstituted C 1 -C 20 alkyl. C 1 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocyclic group, wherein the substituent is selected from F, Cl, Br, N(R 10 ) 2 , NO,, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 11 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , R 11 OC(O)NR 10 - and C 1 -C 20 alkyl, and
[0749] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or R 2 and R 3 are combined to form —(CH 2 ) s —; or R 2 or R 1 are combined with R 6 to form a ring such that
[0750] R 4a , R 4b , R 7a and R 7b are independently selected from:
[0751] a) hydrogen,
[0752] b) C 1 -C 6 alkyl unsubstituted or substituted by alkenyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, N 3 , (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, —N(R 10 ) 2 , or R 11 OC(O)NR 10 -,
[0753] c) aryl, heterocycle, cycloalkyl, alkenyl, R 10 O—, R 11 S(O) m -, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0754] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl;
[0755] R 5a and R 5b are independently selected from:
[0756] a) a side chain of a naturally occurring amino acid,
[0757] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0758] i) methionine sulfoxide, or
[0759] ii) methionine sulfone,
[0760] c) substituted or unsubstituted C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 10 cycloalkyl, aryl or heterocycle group, wherein the substituent is selected from F, Cl, Br, N(R 10 ) 2 , NO 2 , R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , R 10 C(O)NR 10 - and C 1 -C 20 alkyl,
[0761] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0762] R 5a and R 5b are combined to form —(CH,) s —wherein one of the carbon atoms is optionally replaced by a moiety select from O, S(O) m , —NC(O)—, and —N(COR 10 )—;′
[0763] R 6 is independently selected from hydrogen or C 1 -C 6 alkyl;
[0764] R 8 is independently selected from:
[0765] a) hydrogen,
[0766] b) aryl, heterocycle, cycloalkyl, alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 10 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0767] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocycle, cycloalkyl, alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 10 S(O) m —, R 10 C(O)NH—, CN, H 2 NC(NH)—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 10 OC(O)NH—;
[0768] R 9 is selected from:
[0769] a) hydrogen,
[0770] b) alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C—(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 10 OC(O)NR 10 -, and
[0771] c) C 1 -C 6 alkyl unsubstituted or substituted by perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -;
[0772] R 10 is independently selected from hydrogen, C 1 -C 6 alkyl, benzyl and aryl;
[0773] R 11 is independently selected from C 1 -C 6 alkyl and aryl; R 12 is
[0774] a) substituted or unsubstituted C 1 -C 8 alkyl or substituted or unsubstituted C 3 -C 8 cycloalkyl, wherein the substituent on the alkyl or cycloalkyl is selected from:
[0775] 1) aryl,
[0776] 2) heterocycle,
[0777] 3) —N(R 11 ) 2 ,
[0778] 4) —OR 10 , or
[0779] R 13 is independently selected from hydrogen and C 1 -C 6 alkyl;
[0780] R 14 is independently selected from C 1 -C 6 alkyl;
[0781] A 1 and A 2 are independently selected from a bond, —CH═CH—, —C≡C—, —C(O)—, —C(O)NR 10 -, —NR 10 C(O)—, O, —N(R 10 )—, -S(O) 2 N(R 10 )—, —N(R 10 )S(O) 2 —, or S(O) m ;
[0782] Q is a substituted or unsubstituted nitrogen-containing C 4 -C 9 mono or bicyclic ring system, wherein the non-nitrogen containing ring may be an aromatic ring, a C 5 -C 7 saturated ring or a heterocycle;
[0783] V is selected from:
[0784] a) hydrogen,
[0785] b) heterocycle,
[0786] c) aryl,
[0787] d) C 1 -C 20 alkyl wherein from 0 to 4 carbon atoms are replaced with a heteroatom selected from O, S. and N, and
[0788] e) C 2 -C 20 alkenyl, provided that V is not hydrogen if A 1 is S(O) m and V is not hydrogen if A 1 is a bond, n is 0 and A 2 is S(O) m ;
[0789] W is a heterocycle;
[0790] X, Y and Z are independently H 2 or O;
[0791] m is 0, 1 or 2;
[0792] n is 0, 1, 2, 3 or 4;
[0793] p is 0, 1, 2, 3 or 4;
[0794] qis 0, 1 or 2;
[0795] r is 0 to 5, provided that r is 0 when V is hydrogen;
[0796] s is 4 or 5;
[0797] t is 3, 4 or 5; and
[0798] u is 0 or 1;
[0799] (x) compounds of the following formulae,
[0800] wherein in said formulae A, B and C:
[0801] R 1a and R 1b are independently selected from:
[0802] a) hydrogen,
[0803] b) aryl, heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(O)—, R 10 C(O)—, R 10 OC(O)—, N 3 —, —N(RIO) 2 , or R 11 OC(O)NR 10 -,
[0804] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, C 3 -C 10 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)—NR 10 -;
[0805] R 2 and R 3 are independently selected from H; unsubstituted or substituted C,., alkyl, unsubstituted or substituted C 2-8 alkenyl, unsubstituted or substituted C 2 , 8 alkynyl, unsubstituted or substituted aryl, unsubstituted or
[0806] substituted heterocycle, wherein the substituted group is substituted with one or more of:
[0807] 1) aryl or heterocycle, unsubstituted or substituted with:
[0808] a) C, alkyl,
[0809] b) (CH 2 )pOR 6 ,
[0810] c) (CH 2 )pNR 6 R 1 ,
[0811] d) halogen,
[0812] 2) C 3-6 cycloalkyl,
[0813] 3) OR 6 ,
[0814] 4) SR 6 , S(O)R 6 , SO 2 R 6 ,
[0815] 5) —NR 6 R 7
[0816] R 2 and R 3 are attached to the same C atom and are combined to form (CH 2 )u- wherein one of the carbon atoms is optionally replaced by a moiety selected from 0, S(O) m , —NC(O)—, and —N(COR 10 )—;
[0817] R 4 is selected from H and CH 3 ; and any two of R 2 , R 3 and R 4 are optionally attached to the same carbon atom;
[0818] R 6 , R 7 and R 7 are independently selected from H, C 1-4 alkyl, C 3-6 cycloalkyl, heterocycle, aryl, aroyl, heteroaroyl, arylsulfonyl, heteroarylsulfonyl, unsubstituted or substituted with:
[0819] a) C 14 alkoxy,
[0820] b) aryl or heterocycle,
[0821] c) halogen,
[0822] d) HO,
[0823] f) —SO 2 R 11 , or
[0824] g) N(R 10 ) 2 ;or
[0825] R 6 and R 1 may be joined in a ring; R 7 and R 7a may be joined in a ring;
[0826] R 8 is independently selected from:
[0827] a) hydrogen,
[0828] b) aryl, heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 10 C(O)NR 10 -, and
[0829] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m — R 10 C(O)NH—, CN, H 2 N—C(NH)—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 10 OC(O)N—H—;
[0830] R 9 is selected from:
[0831] a) hydrogen,
[0832] b) alkenyl, alkynyl, perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C-(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0833] c) C 1 -C 6 alkyl unsubstituted or substituted by perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O),,-, R 10 C(O)NR 1 k-, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 10 C(O)NR 10 -;
[0834] R 10 is independently selected from hydrogen, C 1 -C 6 alkyl, benzyl and aryl;
[0835] R 11 is independently selected from C 1 -C 6 alkyl and aryl;
[0836] A 1 and A 2 are independently selected from a bond, —CH═CH—, —C≡C—, —C(O)—, —C(O)NR 10 -, —NR 10 C(O)—, O, —N(R 10 )—, —S(O) 2 N(R 10 )—, —N(R 10 )S(O) 2 -, or S(O) m ; G is H 2 or O;
[0837] V is selected from:
[0838] a) hydrogen,
[0839] b) heterocycle,
[0840] c) aryl,
[0841] d) C 1 -C 20 alkyl wherein from 0 to 4 carbon atoms are replaced with a heteroatom selected from O, S, and N, and
[0842] e) C 2 -C 20 alkenyl, provided that V is not hydrogen if A 1 is S(O) m and V is not hydrogen if A 1 is a bond, n is 0 and A 2 is S(O) m ;
[0843] W is a heterocycle;
[0844] X is —CH 2 —, —C(=O)—, or —S(═O) m —;
[0845] Y is aryl, heterocycle, unsubstituted or substituted with one or more of:
[0846] 1) C 1-4 alkyl, unsubstituted or substituted with:
[0847] a) C 1-4 alkoxy,
[0848] b) NR 6 R 7 ,
[0849] c) C 3-6 cycloalkyl,
[0850] d) aryl or heterocycle,
[0851] e) HO,
[0852] f) —S(O) m R 6 , or
[0853] g) —C(O)NR 6 R 7 ,
[0854] 2) aryl or heterocycle,
[0855] 3) halogen,
[0856] 4) OR 6 ,
[0857] 5) NR 6 R 7 ,
[0858] 6) CN,
[0859] 7) NO 2 , CF 3 ,
[0860] 9) —S(O) m R 6 ,
[0861] 10) —C(O)NR 6 R, or
[0862] 11) C 3 -C 6 cycloalkyl;
[0863] Z is aryl, heteroaryl, arylmethyl, heteroarylmethyl, arylsulfonyl, heteroarylsulfonyl, unsubstituted or substituted with one or more of the following:
[0864] 1) C 1-4 alkyl, unsubstituted or substituted with:
[0865] a) C 1-4 , alkoxy,
[0866] b) Nk 6 R − ,
[0867] c) C 3-6 cycloalkyl.
[0868] d) aryl or heterocycle,
[0869] e) HO,
[0870] f) —S(O) m R 6 , or
[0871] g) —C(O)NR 6 R 1 ,
[0872] 2) aryl or heterocycle,
[0873] 3) halogen,
[0874] 4) OR,
[0875] 5) NR 6 R 7 ,
[0876] 6) CN,
[0877] 7) NO 2
[0878] 8) CF 3 ;
[0879] 9) —S(O) m R 6 ,
[0880] 10) —C(O)NR 6 R 7 , or
[0881] 11) C 3 -C 6 cycloalkyl;
[0882] m is 0, 1 or 2;
[0883] n is 0, 1, 2, 3 or 4;
[0884] p is 0, 1, 2, 3 or 4;
[0885] r is 0 to 5, provided that r is 0 when V is hydrogen; is 0 to 1;
[0886] t is 0 to 1; and
[0887] u is 4 or 5;
[0888] (y) compounds of the following formula,
[0889] wherein:
[0890] R 1 a is independently selected from:
[0891] a) hydrogen,
[0892] b) aryl, heterocycle, C 1 -C 10 cycloalkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C,R 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -,
[0893] c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, C 3 -C 10 cycloalkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)—NR 10 -;
[0894] R 1b is independently selected from:
[0895] a) hydrogen,
[0896] b) substituted or unsubstituted aryl, substituted or unsubstituted heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl, R 10 O—, R 11 S(O) m —, CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 or —N(R 10 ) 2 ,
[0897] c) C 1 -C 6 alkyl unsubstituted or substituted by substituted or unsubstituted aryl, substituted or unsubstituted heterocyclic, C 3 -C 10 cycloalkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl, R 10 O—, R 11 S(O) m —, CN, (R 10 ) 2 N—C(NR 0 )—, R 10 C(O)—, R 10 OC(O)—, N 3 or —N(R 10 ) 2 ;
[0898] R 2 and R 3 are independently selected from:
[0899] a) a side chain of a naturally occurring amino acid,
[0900] b) an oxidized form of a side chain of a naturally occurring amino acid which is:
[0901] i) methionine sulfoxide, or
[0902] ii) methionine sulfone, and
[0903] c) substituted or unsubstituted C 1 -C 20 alkyl, substituted or unsubstituted C 2 -C 20 alkenyl, substituted or unsubstituted C 3 -C 10 cycloalkyl, substituted or unsubstituted aryl or substituted or unsubstituted heterocyclic group, wherein the substituent is selected from F, Cl, Br, N(R 10 ) 2 , NO 2 , R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 10 ) 2 N—C(NR 10 )—, R 8 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , R 11 OC(O)NR 10 - and C 1 -C 20 alkyl, and
[0904] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl; or
[0905] R 2 and R 3 are combined to form —(CH 2 ) s —; or
[0906] R 2 or R 3 are combined with R 7 to formn a ring such that
[0907] R 4 , R 5 , R 13a and R 13b are independently selected from:
[0908] a) hydrogen,
[0909] b) C 1 -C 6 alkyl unsubstituted or substituted by C 2 -C 20 alkenyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, N 3 , (R 8 ) 2 N—C(NR 10 )—, R 10 C(O)—, —N(R 11 ) 2 , or R 11 OC(O)NR 10 -,
[0910] c) unsubstituted or substituted aryl, unsubstituted or substituted heterocycle, C 3 -C 10 , cycloalkyl, C 2 -C 20 alkenyl, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C(R 10 )—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0911] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl;
[0912] R 6 is selected from:
[0913] a) hydrogen,
[0914] b) substituted or unsubstituted aryl, substituted or unsubstituted heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl, C 1 -C 20 perfluoroalkyl, allyloxy, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , R 10 2N—C(NR 10 )—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , (R 12 ) 2 NC(O)— or R 11 OC(O)NR 10 -, and
[0915] c) C 1 -C 6 alkyl unsubstituted or substituted by substituted or unsubstituted aryl, substituted or unsubstituted heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl, C 2 -C 20 perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NH—, CN, H 2 N—C(H)—, R 10 C(O)—, N 3 , —N(R 10 ) 2 , or R 10 OC(O)NH—;
[0916] R 1 is independently selected from
[0917] a) hydrogen,
[0918] b) unsubstituted or substituted aryl,
[0919] c) unsubstituted or substituted heterocycle,
[0920] d) unsubstituted or substituted C 3 -C 10 cycloalkyl, and
[0921] e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and C 3 -C 10 cycloalkyl;
[0922] R 8 is selected from:
[0923] a) hydrogen,
[0924] b) substituted or unsubstituted aryl, substituted or unsubstituted heterocycle, C 3 -C 10 cycloalkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl, C 1 -C 20 perfluoroalkyl, allyloxy, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, —S(O) 2 N(R 10 ) 2 , CN, NO 2 , (R 10 ) 2 N—C(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0925] c) C 1 -C 6 alkyl unsubstituted or substituted by substituted or unsubstituted aryl, substituted or unsubstituted heterocycle, C 3 -Cl, cycloalkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkynyl, C 2 -C 20 perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NH—, CN, H 2 N—C(NH)—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 1 or R 10 OC(O)NH—;
[0926] R 9 is selected from:
[0927] a) hydrogen,
[0928] b) C 2 -C 20 alkenyl, C 2 -C 20 alkynyl, C 2 -C 20 perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, NO 2 , (R 10 ) 2 N—C-(NR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -, and
[0929] c) C 1 -C 6 alkyl unsubstituted or substituted by C 2 -C 20 perfluoroalkyl, F, Cl, Br, R 10 O—, R 11 S(O) m —, R 10 C(O)NR 10 -, CN, (R 8 ) 2 N—CiR 10 )—, R 10 C(O)—, R 10 OC(O)—, N 3 , —N(R 10 ) 2 , or R 11 OC(O)NR 10 -;
[0930] R 10 is independently selected from hydrogen, C 1 -C 6 alkyl, benzyl and aryl;
[0931] R 11 is independently selected from C 1 -C 6 alkyl and aryl;
[0932] R 12 is independently selected from hydrogen, C 1 -C 6 alkyl and aryl, or (R 1
[0933] 2) 2 forms —(CH 2 ) s —;
[0934] A 1 , A 2 and A 3 are independently selected from a bond, —CH═CH—, —C≡C—, —C(O)—, —C(O)NR 7 -, —NR 7 C(O)—, O, —N(R 7 )—, —S(O) 2 N(R 7 )—, —N(R 7 )S(O) 2 -, or S(O) m ;
[0935] V is selected from:
[0936] a) hydrogen,
[0937] b) heterocycle,
[0938] c) aryl,
[0939] d) C 1 -C 20 alkyl wherein from 0 to 4 carbon atoms are replaced with a heteroatom selected from O, S, and N, and
[0940] e) C 2 -C 20 alkenyl, provided that V is not hydrogen if A 1 is S(O) m and V is not hydrogen if A 1 is a bond, n is 0 and A 2 is S(O) m ;
[0941] W is a heterocycle;
[0942] Z is independently H 2 or O;
[0943] m is 0, 1 or 2;
[0944] n is 0, 1, 2, 3 or 4;
[0945] p is 0, 1, 2, 3 or 4;
[0946] q is 0, 1, 2, 3 or 4;
[0947] r is 0 to 5, provided that r is 0 when V is hydrogen;
[0948] s is 4or 5; and
[0949] t is 3,4 or 5; and
[0950] (z) compounds of the following formula,
[0951] wherein:
[0952] R 1a and R 1b are independently selected from:
[0953] a) hydrogen,
[0954] b) unsubstituted or substituted aryl, unsubstituted or substituted heterocycle, unsubstituted or substituted C 3 -C 6 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, R 8 O—, R 9 S(O) m —, R 8 C(O)NR 8 -, CN, NO 2 , (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , or R 9 OC(O)N 8 -,
[0955] c) C 1 -C 6 alkyl unsubstituted or substituted by unsubstituted or substituted aryl, unsubstituted or substituted heterocyclic, unsubstituted or substituted C 3 -C 6 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, R 8 0-, R 9 S(O) m —, R 8 C(O)NR 10 -, CN, (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , or R 9 OC(O)—NR 8 -;
[0956] R 2a , R 2b and R 3 are independently selected from:
[0957] a) hydrogen,
[0958] b) C 1 -C 6 alkyl unsubstituted or substituted by C 2 -C 6 alkenyl, R 8 O—, R 9 S(O) m —, R 8 C(O)N 8 -, CN, N 3 , (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, —N(R 8 ) 2 , or R 9 OC(O)NR 8 -,
[0959] c) unsubstituted or substituted aryl, unsubstituted or substituted heterocycle, unsubstituted or substituted cycloalkyl, alkenyl, R 8 O—, R 9 S(O) m —, R 8 C(O)NR 10 -, CN, NO 2 , (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , halogen or R 9 OC(O)Nr 8 -, and
[0960] d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocyclic and C 3 -C 10 cycloalkyl;
[0961] R 4 and R 5 are independently selected from:
[0962] a) hydrogen, and
[0963] R 6 is independently selected from:
[0964] a) hydrogen,
[0965] b) unsubstituted or substituted aryl, unsubstituted or substituted heterocycle, unsubstituted or substituted C 3 -C 6 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 1 -C 6 perfluoroalkyl, F, Cl, is Br, R 8 O—, R 9 S(O) m —, R 8 C(O)NR 8 -, CN, NO 2 , (R 8 ) 2 NC(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , or R 9 OC(O)N 8 -, and
[0966] c) C 1 -C 6 alkyl unsubstituted or substituted by unsubstituted or substituted aryl, unsubstituted or substituted heterocycle, unsubstituted or substituted C 3 -C 6 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 1 -C 6 perfluoroalkyl, F, Cl, Br, R 8 O—, R 9 S(O) m —, R 8 C(O)NH—, CN, H 2 N—C(H)—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , or R 10 C(O)NH—;
[0967] R is selected from:
[0968] a) hydrogen,
[0969] b) C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 1 -C 6 perfluoroalkyl, F, Cl, Br, R 8 O—, R 9 S(O) m —, R 8 C(O)NR 10 -, CN, NO 2 , (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 , —N(R 8 ) 2 , or R 9 OC(O)NR 8 -, and
[0970] c) C 1 -C 6 alkyl unsubstituted or substituted by C 1 -C 6 perfluoroalkyl, F, Cl, Br, R 8 O—, R 9 S(O) m —, R 8 C(O)NR 11 S—, CN, (R 8 ) 2 N—C(NR 8 )—, R 8 C(O)—, R 8 OC(O)—, N 3 —N(R 8 ) 2 , or R 9 OC(O)NR 8 -;
[0971] R 8 is independently selected from hydrogen, C 1 -C 6 alkyl, substituted or unsubstituted C 1 -C 6 aralkyl and substituted or unsubstituted aryl;
[0972] R 9 is independently selected from C 1 -C 6 alkyl and aryl;
[0973] R 10 is independently selected from hydrogen, C 1 -C 6 alkyl, substituted or unsubstituted C 1 -C 6 aralkyl and substituted or unsubstituted aryl;
[0974] A 1 and A 2 are independently selected from a bond, —CH═CH—, —C≡C—, is —C(O)—, —C(O)NR 8 -, —NR 8 C(O)—, O, —N(R 8 )—, —S(O) 2 N(R 8 )—, —N(R 8 )S(O) 2 —, or S(O) m ;
[0975] V is selected from:
[0976] a) hydrogen,
[0977] b) heterocycle,
[0978] c) aryl,
[0979] d) C 1 -C 20 alkyl wherein from 0 to 4 carbon atoms are replaced with a heteroatom selected from O, S, and N, and
[0980] e) C 2 -C 20 alkenyl, provided that V is not hydrogen if A 1 is S(O) m and V is not hydrogen if
[0981] A 1 is a bond, n is 0 and A 2 is S(O) m ;
[0982] W is a heterocycle;
[0983] Y is selected from a bond, —C(R 10 )═C(R 10 )—, —C≡C—, —C(O)—, —C(R 10 ) 2 —, —C(OR 10 )R 10 -, —CN(R 10 ) 2 R 10 -, —OC(R 10 ) 2 -, —NR 10 C(R 10 ) 2 -, —C(R 8 )20-, —C(R 10 ) 2 NR 10 , —C(O)NR 10 -, —NR 10 C(O)—, O, —NC(O)R 10 -, —NC(O)OR 10 -, —S(O) 2 N(R 10 )—, —N(R 10 )s(O) 2 —, or S(O) m ;
[0984] Z is H 2 or O;
[0985] m is 0, or 2;
[0986] nis 0, 1, 2, or 4;
[0987] p is 0, 1, 2, 3 or 4;
[0988] r is 0 to 5, provided that r is 0 when V is hydrogen; and u is 0 or 1;
[0989] or the pharmaceutically acceptable salts thereof.
[0990] Compounds for use in the methods of the invention also may obtained by fermentation of cultures of novel organisms, such as the compounds disclosed in U.S. Pat. No. 5,420,334. Other suitable compounds are disclosed in U.S. Pat. No. 5,420,245; European Patent Publication No. 0618 221; PCT Patent Publication Nos. WO 94/26723; WO 95/10514; WO 95/10515; WO 95/10516; WO 95/08542; WO 95/11917; and WO 95/12612. In certain embodiments of the invention, manomycin is less preferred and may be excluded from preferred aspects of the invention.
[0991] Specifically suitable compounds include the following:
[0992] or the pharmaceutically acceptable salts thereof.
[0993] Other specifically suitable compounds include the following:
[0994] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-n-propyl-3,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[0995] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-methyl-3,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[0996] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[0997] 5(S)-[2(R)-amino-3-mercaptopropylamino] -6(S)-methyl-2(R)-i-propyl-3 ,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[0998] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-n-butyl-3,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[0999] 5(S)-[2(R)-amino-3r-mercaptopropylamino]-6(S)-methyl-2(R)-s-butyl-3 ,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[1000] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-t-butyl-3,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[1001] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-cyclohexyl-3,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[1002] 5(S)-[2(R)-amino-3-mercaptopropylamino] -6(S)-methyl-2(R)-cyclopentyl-3 ,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[1003] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-benzyl-3,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[1004] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-i-propyl-3,4-E-octenoyl-homoserine, and the corresponding homoserine lactone,
[1005] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-2(R)-i-propyl-3 ,4-E-octenoyl-methionine, and the corresponding methyl ester,
[1006] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-n-butyl-3 ,4-E-octenoyl-methionine, and the corresponding methyl ester,
[1007] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-benzyl-3,4-E-octenoyl-methionine, and the corresponding methyl ester,
[1008] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-n-propyl-octenoyl-homoserine, and the corresponding homoserine lactone,
[1009] 5(S)-[2(R)-amino-3-mercaptopropylamino]-6(S)-methyl-2(R)-benzyl-octenoyl-homoserine, and the corresponding homoserine lactone,
[1010] N-(3-phenyl-2(S)-(mercaptopropionylamino)prop-1-yl)isoleucyl-methionine,
[1011] N-(2(R)-amino-3-mercaptopropyl)isoleucyl-phenylalanyl-methionine,
[1012] N-(3-mercaptopropyl)isoleucyl-phenylalanyl-methionine,
[1013] N-(3-mercaptopropyl)valyl-isoleucyl-methionine,
[1014] N-(2(R)-amino-3-mercaptopropyl)valyl-isoleucyl-methionine,
[1015] N-(3-methyl-2(S)-(cysteinylamino)but-1-yl)phenylalanyl-methionine,
[1016] N-(3-methyl-2(S)-(mercaptopropionylamino)butyl)-phenylalanyl-methionine,
[1017] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3(S)methylpentyl]-phenylalanyl-methionine,
[1018] N-[2(S)-(3-mercaptopropylamino)-3-(S)methylpentyl]-phenylalanyl-methionine,
[1019] N-(2(R)-amino-3-mercaptopropyl)isoleucyl-phenylalanyl-(methionine sulfone),
[1020] N-(2(R)-amino-3-mercaptopropyl)isoleucyl)-(p-iodophenylalanyl)-methionine,
[1021] N-[2(R)-(cysteinyl-isoleucylamino)-3(S)-methylpentyl]-methionine,
[1022] N-[2(R)-(N′-(2(R)-amino-3-mercaptopropyl)—isoleucylamino)-3-phenylpropyl]methionine,
[1023] N-[2(R)-(N′-(2(R)-amino-3-mercaptopropyl)—isoleucylamino)-3(S)-methylpentyl]methionine,
[1024] N-(3-mercaptopropyl)valyl-isoleucyl-methionine methyl ester,
[1025] N-(2(R)-amino-3-mercaptopropyl)isoleucyl-phenylalanyl-methionine ethyl ester,
[1026] N-(2(R)-amino-3-mercaptopropyl)isoleucyl-phenylalanyl-methionine benzyl ester,
[1027] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-phenethylamide,
[1028] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-benzylamide,
[1029] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-3-methylbutylamide,
[1030] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-3-phenylpropylamide,
[1031] N-[2(R)-amino-3-mercaptopropyl]-L-isoleuceyl-L-phenylalaninol,
[1032] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-N′-methylbenzylamide,
[1033] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(4-methoxybenzyl)amide,
[1034] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(2,4-dichlorobenzyl)amide,
[1035] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(4-trifluoromethylbenzyl)amide,
[1036] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(2,4-dichlorophenethyl)amino,
[1037] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(2-benzimidazolylmethyl)amide,
[1038] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(1-indanyl)amide,
[1039] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(2,4-dimethylbenzyl)amide,
[1040] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(2,3-dichlorobenzyl)amide,
[1041] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(4-sulfamoylbenzyl)amide,
[1042] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucineanilide,
[1043] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(2,4-dimethylphenyl)amide,
[1044] N-[2(R)-amino-3-mercaptopropyl]-L-isoleucine-(2,3-dimethylphenyl)amide,
[1045] L-cysteinyl-L-isoleucine-phenethylamide,
[1046] N-[2(S)-[2(R)-amino-3-mercaptopropylamino]-3-methylpentyl]phenethylamide,
[1047] N-(2(R)-amino-3-mercaptopropyl)-L-alaninebenzylamide,
[1048] N-benzyl-[2(S)-2(R)-amino-3-mercaptopropyl)-amino]butyramide,
[1049] N-(2(R)-amino-3-mercaptopropyl)-L-norleucinebenzylamide,
[1050] N-(2(R)-amino-3-mercaptopropyl)-L-norvalinebenzylamide,
[1051] N-(2(R)-aino-3-mercaptopropyl)isoleucyl-phenylalanyl-homoserine,
[1052] N-(2(R)-amino-3-mercaptopropyl)isoleucyl-isoleucyl-homoserine,
[1053] N-(2(R)-a:ino-3-mercaptopropyl)isoleucyl-phenylalanyl-homoserine lactone,
[1054] N-(2(R)-amino-3-mercaptopropyl)isoleucyl-isoleucyl-homoserine lactone,
[1055] N-(2(R)-amino-3-mercaptopropyl)isoleucyl-phenylalanyl-homocysteine lactone,
[1056] N-[2(S)-(2(R)-amino-3-mercaptopropyl) -3(S)-methyl pentyl]-isoleucyl homoserine lactone,
[1057] N-[N′-(2(R)-amino-3-mercaptopropyl)isoleucyl-phenylalanyl]-3-(S)amino-tetrahydropyran-2-one,
[1058] N-[N′-(2(R)-amino-3-mercaptopropyl)isoleucyl-isoleucyl]-3-(S)-aminotetrahydropyran-2-one,
[1059] N-(2(R)-amino-3-mercaptopropyl)isoleucyl-isoleucyl-homocysteine lactone,
[1060] N-[2(S)-(2(R)-amino-3-mercaptopropyl)-3(S)-methylpentyl]isoleucyl homoserine,
[1061] N-[N′-(2(R)-amino-3-mercaptopropyl)isoleucyl-phenylalanyl]-3(S)-amino-4-hydroxypentanoic acid,
[1062] N-[N′-(2(R)-amino-3-mercaptopropyl)isoleucyl-isoleucyl]-3-(S)-amino-hydroxypentanoic acid,
[1063] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]—N-methyl-isoleucyl-homoserine,
[1064] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3(S)-methylpentyl]—N-methyl-isoleucyl-homoserine lactone,
[1065] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3(S)-methylpentyl]—N-methylphenylalanyl-homoserine,
[1066] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3(S)-methylpentyl]—N-methylphenylalanyl-homoserine lactone,
[1067] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-methyl-butyl]-N-methylphenylalanyl-homoserine lactone,
[1068] 3(S)-(N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl)-N-methyl-isoleucylamino)-3-methyltetra-hydropyran-2-one,
[1069] 2(S)-(N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3(S)-methylpentyl]—N-methyl-isoleucylamino)-2-methyl-5-hydroxypentanoic acid,
[1070] 2(S)-(N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]—N-methyl-isoleucylamino)-5-methyl-5-hydroxyhexanoic acid,
[1071] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3(S)-methylpentyl]—N-methyl-norvalyl-homoserine,
[1072] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]—N-methyl-norvalyl-homoserine lactone,
[1073] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]—N-methyl-isoleucyl-methionine,
[1074] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]-N-methyl-isoleucyl-methionine methyl ester,
[1075] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]—N-methyl-phenylalanyl-methionine,
[1076] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3(S)-methylpentyl]—N-methyl-phenylalanyl-methionine methyl ester,
[1077] 3(S)-(N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]-N-methyl-isoleucylamino)-6,6-dimethyl-tetrahydropyran-2-one,
[1078] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]—N-methyl-norvalyl-methionine,
[1079] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]-N-methyl-norvalyl-methionine methyl ester,
[1080] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]—N-methyl-D-norvalyl-homoserine,
[1081] N-[2(S)-(2(R)-amino-3-mercaptopropylamino)-3-(S)-methylpentyl]-N-methyl-D-norvalyl-homoserine lactone,
[1082] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-3-phenylpropionyl-homoserine lactone,
[1083] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-3-phenylpropionyl-homoserine,
[1084] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-2-methyl-3-phenylpropionyl-homoserine lactone,
[1085] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-2-methyl-3-phenylpropionyl-homoserine,
[1086] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-4-pentenoyl-homoserine lactone,
[1087] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-4-pentenoyl-homoserine,
[1088] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxypentanoyl-homoserine lactone,
[1089] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxypentanoyl-homoserine,
[1090] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-4-methylpentanoyl-homoserine lactone,
[1091] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-4-methylpentanoyl-homoserine,
[1092] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-3-methylbutanoyl-homoserine lactone,
[1093] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-3-methylbutanoyl-homoserine,
[1094] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-3-phenylbutanoyl-homoserine lactone,
[1095] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylanino-3(S)-methyl]-pentyloxy-3-phenylbutanoyl-homoserine,
[1096] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentylthio-2-methyl-3-phenylpropionyl-homoserine lactone,
[1097] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentylthio-2-methyl-3-phenylpropionyl-homoserine,
[1098] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentylsulfonyl-2-methyl-3-phenylpropionyl-homoserine lactone,
[1099] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentylsulfonyt-2-methyl-3-phenylpropionyl-homoserine,
[1100] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-3-phenylpropionyl-methionine methyl ester,
[1101] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-3-phenylpropionyl-methionine,
[1102] 2(S)-[2(S)-[2 (R)-amino-3-mercapto ]propylam ino-3 (S)-methyl]-pentyloxy-3-phenylpropionyl-methionine sulfone methyl ester,
[1103] 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methvl]-pentyloxy-3-phenylpropionyl-methionine sulfone,
[1104] 2-(S)-[2(S)-[2(R)-amino-3-(S)-methyl]-pentyloxy-3-naphth-2-yl-propionyl-methionine sulfone methyl ester,
[1105] 2-(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-3-naphth-2-yl-propionyl-methionine sulfone,
[1106] 2-(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3-(S)-methyl]pentyloxy-3-naphth-1-yl-propionyl-methionine sulfone methyl ester,
[1107] 2-(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]-pentyloxy-3-naphth-1-yl-propionyl-methionine sulfone,
[1108] 2-(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3-(S)-methyl]pentyloxy-3-methybutanoyl-methionine methyl ester,
[1109] 2-(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3-(S)-methyl]pentyloxy-3-methybutanoyl-methionine,
[1110] Disulfide of 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]pentyloxy-3-phenylpropionyl-homoserine lactone,
[1111] Disulfide of 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]pentyloxy-3-phenylpropionyl-homoserine,
[1112] Disulfide of 2(S)-[2(S)-[2(R)-amino-3-mercapto]propylamino-3(S)-methyl]pentyloxy-3-methylbutanoyl-methionine methyl ester,
[1113] 1-[2-(R)-amino-3-mercaptopropyl]-2(S)-(1-butyl)-4-(2,3-dimethylbenzoyl)piperazine dihydrochloride,
[1114] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-(n-butyl)-4-(1-naphthoyl)piperazine,
[1115] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-benzyl-4-[1-(2,3-dimethyl)benzoyl]piperazine,
[1116] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-(2-methoxy)ethyl-4-[ 1-(2,3-dimethyl)benzoyl]piperazine.,
[1117] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-(2-methylthio)ethyl-4-[1-(2,3-dimethyl)benzoyl]piperazine,
[1118] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-(n-butyl)-4-[7-(2,3-dihydrobenzofuroyl)]piperazine,
[1119] 1-(2(R)-amino-3-mercaptopropyl)-4-(1-naphthoyl)-2(S)-pyridinylcarboxyl-4-piperazine dihydrochloride,
[1120] Methyl 4-(2(R)-amino-3-mercaptopropyl)-1-(1-naphthylmethyl)piperazine-2-carboxylate hydrochloride,
[1121] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-(2-methoxyethyl)-4-(1-naphthoyl)piperazine,
[1122] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-n-butyl-4-(8-quinolinylcarbonyl)piperazine,
[1123] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-(2-(1-propoxy)ethyl)-4-(1-naphthoyl)piperazine,
[1124] 1-[2(R)-amino-3-mercaptopropyl)-2(S)-(3-methoxy-1-propyl)-4-(1-naphthoyl)piperazine,
[1125] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-(2-(1-propoxy)ethyl)-4-(8-quinolinoyl)piperazine,
[1126] 1-[2(R)-amino-3-mercaptopropyl]-2(S)-[(3-pyridyl)methoxyethyl)]-4-(1-naphthoyl)piperazine,
[1127] 1-[2(R)-amino-3-mercaptopropyl]-4-naphthoyl-2(S)-(2-phenylsulfonylethyl)piperazine dihydrochloride,
[1128] bis-1,1′-[2(R)-amino-3-(2(S)-(2-methoxyethyl)-4-naphthoyl-1-piperazinyl)]propyl disulfide tetrahydrochloride,
[1129] bis-1,1′-[2(R)-amino-3-(4-naphthoyl-2(S)-(2-phenylsulfonylethyl)-1-piperazinyl)]propyl disulfide tetrahydrochloride,
[1130] 1-[2(R)-amino-3-mercaptopropyl]-4-naphthoyl-2(S)-(2-cyclopropyloxyethyl)piperazine dihydrochloride,
[1131] 1-[2(R)-amino-3-mercaptopropyl]-4-(1-naphthoyl)-2(S)-(4-acetamidobutyl)piperazine dihydrochloride,
[1132] 1-[2(R)-amino-3-mercaptopropyl]-4-naphthoyl-2(S)-(2-cyclopropylmethylsulfonylethyl)piperazine dihydrochloride,
[1133] Pyroglutamyl-valyl-phenylalanyl-methionine,
[1134] Pyroglutamyl-valyl-phenylalanyl-methionine methyl ester,
[1135] Pyroglutamyl-valyl-isoleucyl-methionine,
[1136] Pyroglutamyl-valyl-isoleucyl-methionine methyl ester,
[1137] Nicotinoyl-isoleucyl-phenylalanyt-methionine,
[1138] Nicotinoyl-isoleucyl-phenylalanyl-methionine methyl ester,
[1139] N-[2(S)-(L-pyroglutamylamino)-3-methylbutyl]phenylalanyl-methionine,
[1140] N-[2(S)-(L-pyroglutamylamino)-3-methylbutyl]phenylalanyl-methioninemethyl ester,
[1141] N-[5(S)-(L-pyroglutamylamino)-6(S)-methyl-2(R)-butyl-3 ,4(E)octenoyl]-methionine,
[1142] N-[5(S)-(L-pyroglutamylamino)-6(S)-methyl-2(R)-butyl-3,4(E)octenoyl]-methionine methyl ester,
[1143] N-[5(S)-((Imidazol-4-yl)acetylamino)-6(S)-methyl-2(R)-butyl-3,4(E)octenoyl]-methionine,
[1144] N-[5(S)-((Imidazol-4-yl)acetylamino)-6(S)-methyl-2(R)-butyl-3,4(E)octenoyl]-methionine methyl ester,
[1145] N-[5(S)-((Imidazol-4-yl-carbonylamino)-6(S)-methyl-2(R)-butyl-3,4(E)octenoyl]-methionine,
[1146] N-[5(S)-((Imidazol-4-yl-carbonylamino)-6(S)-methyl-2(R)-butyl-3,4(E)octenoyl]-methionine methyl ester,
[1147] N-[2(S)-(2(S)-(Imidazol-4-yl)acetylamino)-3(S)-methylpentyloxy)-3-phenylpropionyl]-methionine,
[1148] N-[2(S)-(2(S)-(Imidazol-4-yl)acetylamino)-3(S)-methylpentyloxy)-3-phenylpropionyl]-methionine methyl ester,
[1149] N-[2(S)-(2(S)-Pyroglutamylamino-3(S)-methylpentyloxy)-3-phenylpropionyl]-methionine,
[1150] N-[2(S)-(2(S)-Pyroglutamylamino-3(S)-methylpentyloxy)-3-phenylpropionyl]-methionine methyl ester,
[1151] N-[2(S)-(2(S)-Imidazol-4-yl-carbonyl)amino)-3(S)-methylpentyloxy)-3-phenylpropionyl]-methionine,
[1152] N-[2(S)-(2(S)-Imidazol-4-yl-carbonyl)amino)-3(S)-methylpentyloxy)-3-phenylpropionyl]-methionine methyl ester,
[1153] N-[2(S)-(2(S)-((3-Picolinyl)amino)-3(S)-methylpentyloxy)-3-phenylpropionyl]-methionine,
[1154] N-[2(S)-(2(S)-((3-Picolinyl)amino)-3(S)-methylpentyloxy)-3-phenylpropionyl]-methionine methyl ester,
[1155] N-[2(S)-(2(S)-((Histidyl)amino)-3(S)-methylpentyloxy)-3-phenylpropionyl]-methionine,
[1156] N-[2(S)-(2(S)-((Histidyl)amino)-3 (S)-methylpentyloxy)-3-phenylpropionyl]-methionine methyl ester,
[1157] N-Benzyl-N-[2(S)-((Imidazol-4-yl-carbonyl)amino)-3(S)-methylpentyl]glycyl-methionine,
[1158] N-Benzyl-N-[2(S)-((Imidazol-4-yl-carbonyl)amino)-3(S)-methylpentyl]glycyl-methionine methyl ester,
[1159] N-Benzyl-N-[2(S)-((Imidazol-4-yl-acetyl)amino)-3(S)-methylpentyl]glycyl-methionine,
[1160] N-Benzyl-N-[2(S)-((Imidazol-4-yl-acetyl)amino)-3(S)-methylpentyl]glycyl-methionine methyl ester,
[1161] N-Benzyl-N-[2(S)-((Pyroglutamyl)amino)-3(S)-methylpentyl]-glycylmethionine,
[1162] N-Benzyl-N-[2(S)-((Pyroglutamyl)amino)-3(S)-methylpentyl]-glycylmethionine methyl ester,
[1163] N-(1-Naphthylmethyl)-N-[2(S)-((imidazol-4-yl-carbonyl)amino)-3(S)-methylpentyl]-glycyl-methionine,
[1164] N-(1-Naphthylmethyl)-N-[2(S)-((imidazol-4-yl-carbonyl)amino)-3(S)-methylpentyl]-glycyl-methionine methyl ester,
[1165] N-(1Naphthylmethyl)-N-[2(S)-((imidazol-4-yl-acetyl)amino)-3(S)-methylpentyl]-glycyl-methionine,
[1166] N-(1-Naphthylmethyl)-N-[2(S)-((imidazol-4-yl-acetyl)amino)-3(S)-methylpentyl]-glycyl-methionine methyl ester,
[1167] N-(1-Naphthylmethyl)-N-[2(S)-((pyroglutamyl)amino-3(S)-methylpentyl]-glycyl-methionine,
[1168] N-(1-Naphthylmethyl)-N-[2(S)-((pyroglutamyl)amino-3(S)-methylpentyl]-glycyl-methionine methyl ester,
[1169] N-[1-(Pyroglutamylamino)cyclopent-1-yl-methyl]—N-(1-naphthylmethyl)-glycyl-methionine methyl ester,
[1170] N-[1-(Pyroglutamylamino)-cyclopent-1-yl-methyl]—N-(1-naphthytmethyl)-glycyl-methionine,
[1171] N-(2(S)-L-Histidylamino-3(S)-methylpentyl)-N-(benzylmethyl)-glycylmethionine methyl ester,
[1172] N-(2(S)-L-Histidylamino-3(S)-methylpentyl)-N-(benzylmethyl)glycylmethionine,
[1173] N-(2(S)-L-Histidylamino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycylmethionine methyl ester,
[1174] N-(2(S)-L-Histidylamino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycyl-methionine,
[1175] 2(S)-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyloxy]-3-methylbutanoyl-methionine methyl ester,
[1176] 2(S)-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyloxy]-3-methylbutanoyl-methionine,
[1177] 2(S)-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyloxy]-3-methylbutanoyl-methionine methyl ester,
[1178] 2(S)-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyloxy]-3-methylbutanoyl-methionine,
[1179] N-(Benzyl)-N-[2(S)-(2-oxopyrrolidin-5(R,S)-yl-methyl)amino-3(S)methylpentyl]-glycyl-methionine methyl ester,
[1180] N-(Benzvl)-N-[2(S)-(2-oxopyrrolidin-5(R,S)-yl-methyl)amino-3(S)methylpentyl]-glycyl-methionine,
[1181] N-(Benzyl)-N-(2(S)-[((D,L)-2-thiazolyl)alanyl)amino]-3(S)methylpentyl)-glycyl-methionine methyl ester,
[1182] N-(Benzyl)-N-(2(S)-[((D,L)-2-thiazolyl)alanyl)amino]-3(S)methylpentyl)-glycyl-methionine,
[1183] N-(Benzyl)-N-[2(S)-(3-pyridylmethyl)amino-3(S)-methylpentyl]-glycylmethionine methyl ester,
[1184] N-(Benzyl)-N-[2(S)-(3-pyridylmethyl)amino-3(S)-methylpentyl]-glycylmethionine,
[1185] 2(S)-[2(S)-(2-Oxopyrrolidin-5(S)-yl-methyl)amino-3(S)methylpentyloxy]-3-phenylpropionyl-methionine methyl ester,
[1186] 2(S)-[2(S)-(2-Oxopyrrolidin-S(S)-yl-methyl)amino-3(S)-methyl-pentyloxy]-3-phenylpropionyl-methionine,
[1187] 2(S)-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyloxy]-3-(1-naphthyl)propionyl-methionine sulfone methyl ester,
[1188] 2(S)-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyloxy]-3-(1-naphthyl)propionyl-methionine sulfone,
[1189] 2(S)-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyloxy]-3-(2-naphthyl)propionyl-methionine sulfone methyl ester,
[1190] 2(S)-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyloxy]-3-(2-naphthyl)propionyl-methionine sulfone,
[1191] 2(S)-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyloxy]-3-(1-naphthyl)propionyl-methionine sulfone methyl ester,
[1192] 2(S)-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyloxy]-3-(1-naphthyl)propionyl-methionine sulfone,
[1193] 2(S)-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyloxy]-3-(2-naphthyl)propionyl-methionine sulfone methyl ester,
[1194] 2(S)-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyloxy]-3-(2-naphthyl)propionyl-methionine sulfone,
[1195] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(3-quinolylmethyl)glycyl-methionine methyl ester,
[1196] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(3-quinolylmethyl)glycyl-methionine,
[1197] N-(Benzyl)-N-[2(S)-(tetrazol-1-yl-acetyl)amino-3(S)-methylpentyl]glycyl-methionine methyl ester,
[1198] N-(Benzyl)-N-[2(S)-(tetrazol-1-yl-acetyl)amino-3(S)-methylpentyl]glycyl-methionine,
[1199] N-(Benzyl)-N-[2(S)-nicotinoylamino-3(S)-methylpentyl]-glycylmethionine-methyl ester,
[1200] N-(Benzyl)-N-[2(S)-nicotinoylamino-3(S)-methylpentyl]-glycylmethionine,
[1201] N-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)-glycyl-methionine sulfoxide methyl ester,
[1202] N-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)-glycyl-methionine sulfoxide,
[1203] 2(S)-(2(S)-[2(S,R)-(Imidazol-4-yl)-2-aminoacetyl)amino]-3(S)-methylpentyloxy)-3-phenylpropionyl-methionine sulfone methyl ester,
[1204] 2(S)-(2(S)-[2(S,R)-(Imidazol-4-yl)-2-aminoacetyl)amino]-3(S)-methylpentyloxy)-3-phenylpropionyl-methionine sulfone,
[1205] 2(S)-(2(S)-[2(R,S)-(Imidazol-4-yl)-2-aminoacetyl)amino]-3(S)-methylpentyloxy)-3-phenylpropionyl-methionine sulfone methylester,
[1206] 2(S)-(2(S)-[2(R,S)-(Imidazol-4-yl)-2-aminoacetyl)amino]-3(S)-methylpentyloxy)-3-phenylpropionyl-methionine sulfone,
[1207] N-(2(S)-[2(S,R)-(Imidazol-4-yl)-2-aminoacetyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)-glycyl-methioninemethyl ester,
[1208] N-(2(S)-[2(S,R)-(Imidazol-4-yl)-2-aminoacetyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)-glycyl-methionine,
[1209] N-(2(S)-[2(R,S)-(Imidazol-4-yl)-2-aminoacetyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)-glycyl-methioninemethyl ester,
[1210] N-(2(S)-[2(R,S)-(Imidazol-4-yl)-2-aminoacetyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)-glycyl-methionine,
[1211] N-(2(S)-[(Imidazol-4-yl)methyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)-glycyl-methionine methyl ester,
[1212] N-(2(S)-[(Imidazol-4-yl)methyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)-glycyl-methionine,
[1213] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-methionine isopropyl ester,
[1214] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-methionine t-butyl ester,
[1215] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(4-quinolyl-5-methyl)glycyl-methionine methyl ester,
[1216] N-[2(S)-(L-pyroglutamyl)amino-3 (S)-methylpentyl]-N-(4-quinolylmethyl)glycyl-methionine,
[1217] N-(2(S)-[3-(Imidazol-4-yl)propyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycyl-methionine methyl ester,
[1218] N-(2(S)-[3-(Imidazol-4-yl)propyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycyl-methionine,
[1219] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-norleucine,
[1220] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-norleucine methyl ester,
[1221] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-glutarnine,
[1222] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-glutamine t-butyl ester,
[1223] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-[5-(dimethylamino)naphthylsulfonyl]glycyl-methionine methyl ester,
[1224] N-[2(S)-(3-pyridylmethyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-methionine,
[1225] 2(S)-(2(S)-[2-(Imidazol-4-yl)ethyl]amino-3(S)-methylpentyloxy)-3-phenylpropionyl-methionine sulfone methyl ester,
[1226] 2(S)-(2(S)-[2-(Imidazol-4-yl)ethyl]amino-3(S)-methylpentyloxy)-3-phenylpropionyl-methionine sulfone,
[1227] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-serine methyl ester,
[1228] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-(D,L)-serine,
[1229] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-(L,D)-serine,
[1230] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-homoserine lactone,
[1231] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-homoserine,
[1232] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(cinnamyl)glycyl-methionine methyl ester,
[1233] N-[2(S)-(L-pyroglutamyl)amino-3 (S)-methylpentyl]-N-(cinnamyl)glycyl-methionine,
[1234] N-(2(S)-[2-(Imidazol-4-yl)ethyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycyl-methionine methyl ester,
[1235] N-(2(S)-[2-(Imidazol-4-yl)ethyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycyl-methionine,
[1236] N-[2(S)-(L-pyroglutamyl)amino-3 (S)-methylpentyl]-N-(1-naphthyl-methyl)glycyl-alanine methyl ester,
[1237] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthyl-5-methyl)glycyl-alanine,
[1238] N-[2(S)-(D-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-methionine methyl ester,
[1239] N-[2(S)-(D-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-methionine,
[1240] 2(S)-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyloxy]-3-phenylpropionyl-methionine sulfone methyl ester,
[1241] 2(S)-[2(S)-(L-Pyroglutamyl)amino-3(S)-methylpentyloxy]-3-phenylpropionyl-methionine sulfone,
[1242] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(2,3-methylenedioxybenzyl)glycyl-methionine methyl ester,
[1243] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(2,3-methylenedioxybenzyl)glycyl-methionine,
[1244] N-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyl]-N-(2,3-dihydrobenzofuran-7-yl-methyl)glycyl-methionine methyl ester,
[1245] N-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyl]-N-(2,3-dihydrobenzofuran-7-yl-methyl)glycyl-methionine,
[1246] N-(2(S)-[3-(3-indolyl)propionyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycyl-methionine methyl ester,
[1247] N-(2(S)-[3-(3-indolyl)propionyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycyl-methionine,
[1248] N-(2(S)-[3-(1-indolyl)propionyl]aamino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycyl-methionine methyl ester,
[1249] N-(2(S)-[3-(1-indolyl)propionyl]amino-3(S)-methylpentyl)-N-(1-naphthylmethyl)glycyl-methionine,
[1250] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-histidine methyl ester,
[1251] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-histidine,
[1252] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(cyclopropylmethyl)glycyl-methionine methylester,
[1253] N-[2(S)-(L-pyroglutamyl)amino-3 (S)-methylpentyl]-N-(cyclopropylmethyl)glycyl-methionine,
[1254] N-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyl]-N-(cyclopropylmethyl)glycyl-methionine methylester,
[1255] N-[2(S)-(Imidazol-4-yl-acetyl)amino-3(S)-methylpentyl]-N-(cyclopropylmethyl)glycyl-methionine,
[1256] N-[2(S)-(L-pyroglutarnyl)amino-3(S)-methylpentyl]-N-(2,3-dihydrobenzofuran-7-yl-methyl)glycyl-methionine methyl ester,
[1257] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(2,3-dihydrobenzofuran-7-yl-methyl)glycyl-methionine,
[1258] 2(S)-[2(S)-N-(L-Pyroglutamyl)-N-methylamino-3(S)-methylpentyloxy]-3-phenylpropionyl-methionine methyl ester,
[1259] 2(S)-[2(S)-N-(L-Pyroglutamyl)-N-methylamino-3(S)-methylpentyloxy]-3-phenylpropionyl-methionine,
[1260] N-[2(S)-(L-pyroglutamyl)amino-3 (S)-N-ethylpentyl]-N-(1-naphthylmethyl)glycyl-O-methylserine methyl ester,
[1261] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-O-methylserine,
[1262] N-(1-Naphthylmethyl)-N-[2(S)-(N′-(L-pyroglutamyl)-N′-methylaino)-3(S)-methylpentyl]-glycyl-methionine methyl ester,
[1263] N-(1-Naphthylmethyl)-N-[2(S)-(N′-(L-pyroglutamyl)-N′-methylamino)-3(S)-methylpentyl]-glycyl-methionine,
[1264] N-[1-(Pyroglutamylamino)cyclopent-1-yl-methyl]-N-(1-naphthylmethyl)glycyl-methionine methyl ester,
[1265] N-[1-(Pyroglutamylamino)-cyclopent-1-yl-methyl]-N-(1-naphthylmethyl)glycyl-methionine,
[1266] N-[2(S)-(Pyridin-2-on-6-yl-carbonyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-methionine methyl ester,
[1267] N-[2(S)-(Pyridin-2-on-6-yl-carbonyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-methionine,
[1268] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(3-chlorobenzyl)glycyl-methionine methyl ester,
[1269] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(3-chlorobenzyl)glycyl-methionine,
[1270] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-O-methylhomoserine methyl ester,
[1271] N-[2(S)-(L-pyroglutamyl)amino-3 (S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-O-methylhomoserine,
[1272] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(2,3-dimethylbenzyl)glycyl-methionine methyl ester,
[1273] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(2,3-dimethylbenzyl)glycyl-methionine,
[1274] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-(2-thienyl)alanine methyl ester,
[1275] N-[2(S)-(L-pyroglutamyl)amino-3(S)-methylpentyl]-N-(1-naphthylmethyl)glycyl-(2-thienyl)alanine,
[1276] N-[2(S)-(pyrrolidin-2-on-1-yl)-3-methylbutanoyl]-isoleucyl-methionine,
[1277] N-[2(S)-(piperidin-2-on-1-yl)-3-methylbutanoyl]-isoleucyl-methionine,
[1278] or the pharmaceutically acceptable salts or optical isomers thereof.
[1279] (aa) compounds of the following formulae, which compounds are also disclosed in U.S. Pat. No. 5,260,465, incorporated herein by reference,
[1280] wherein:
[1281] X═X is:
[1282] CH═CH (cis);
[1283] CH═CH (trans); or
[1284] CH 2 CH 2 ;
[1285] R 1 and R 2 are each independently selected from:
[1286] a) H;
[1287] b) C 1-5 alkyl;
[1288] C) C 1-5 alkyl substituted with a member of the group consisting of:
[1289] i) phenyl;
[1290] ii) phenyl substituted with methyl, methoxy, halogen (Cl, Br, F, I) or hydroxy;
[1291] or a pharmaceutically acceptable salt of a compound of formula (I) in which at least one of R 1 and R 2 is hydrogen;
[1292] (bb) compounds of the following formula, which compounds are also disclosed in U.S. Pat. No. 5,420,157, incorporated herein by reference,
[1293] wherein:
[1294] R 1 and R 2 are each independently selected from:
[1295] a) H;
[1296] b) C 1-5 is alkyl;
[1297] c) C 1-5 is alkyl substituted with a member of the group consisting of:
[1298] i) phenyl;
[1299] ii) phenyl substituted with methyl, methoxy, halogen (Cl, Br, F, I) or hydroxy;
[1300] or a pharmaceutically acceptable salt of a compound of formula (I) in which at least one of R 1 and R 2 is hydrogen;
[1301] (cc) compounds of the following formulae, which compounds are also disclosed in U.S. Pat. Nos. 5,245,061 and 5,350,867, incorporated herein by reference,
[1302] wherein:
[1303] X—X is:
[1304] CH═CH(cis);
[1305] CH═CH (trans); or
[1306] CH 2 CH 2 ;
[1307] R 1 and R 2 are each independently selected from:
[1308] a) H;
[1309] b) C 1-3 alkyl;
[1310] c) C 1-5 alkyl substituted with a member of the group consisting of:
[1311] i) phenyl;
[1312] ii) phenyl substituted with methyl, methoxy, halogen (Cl, Br, F, I) or hydroxy;
[1313] or a pharmaceutically acceptable salt of a compound of formula (I) in which at least one of R 1 and R 2 is hydrogen;
[1314] (dd) compounds of the following formula, which compounds are also disclosed in PCT Publication No. WO 96/10037, incorporated herein by reference,
[1315] or the pharmaceutically acceptable salts, hydrates, esters or amides thereof, wherein:
[1316] n is 0 to 4,
[1317] R 1 and R 3 independently are C 1-4 alkyl, substituted with substituents selected from the group consisting of:
[1318] a) aryl, which is defined as phenyl or naphthyl, unsubstituted or substituted with one, two, three or four substituents selected from the group consisting of:
[1319] i) F,
[1320] ii) Cl,
[1321] ii) Br,
[1322] iv) nitro,
[1323] v) cyano,
[1324] vi) C 1-8 alkoxy,
[1325] vii) C 1-8 alkylthio,
[1326] viii) C 1-8 alkylsulfonyl,
[1327] ix) sulfamoyl, or
[1328] x) C 1-8 alkyl; or
[1329] b) heteroaryl, which is defined as indolyl, imidazolyl or pyridyl, unsubstituted or substituted with one, two, three or four substituents selected from the group consisting of:
[1330] i) F,
[1331] ii) Cl,
[1332] iii) Br,
[1333] iv) nitro,
[1334] v) cyano,
[1335] vi) C 1-8 alkoxy,
[1336] vii) C 1-8 alkylthio,
[1337] viii) C 1-8 alkylsulfonyl,
[1338] ix) sulfamoyl, or
[1339] x) C 1-8 alkyl;
[1340] R 2 is: C 1-6 alkyl, which is unsubstituted or substituted with a substituent selected from the group consisting of:
[1341] a) unsubstituted or substituted aryl, as defined in R 1 (a),
[1342] b) unsubstituted or substituted heteroaryl, as defined in R 1 (b),
[1343] c) C 1-8 cycloalkyl,
[1344] d) C 1-8 alkylthio,
[1345] e) C 1-8 alkylsulfonyl,
[1346] f) C 1-8 alkoxy, or
[1347] g) aryl C 1-8 alkyl sulfonyl; and
[1348] R 4 is H;
[1349] (ee) compounds of the following formula, which are also disclosed in U.S. Pat. Nos. 5,298,655 and 5,362,906, incorporated herein by reference,
[1350] wherein:
[1351] X is CH,, CH(OH), C═O, CHCOR, CH(NH 2 ), CH(NHCOR), O, S(O) p , NH, NHCO,
[1352] p is 0, 1 or 2;
[1353] Y is PO 3 RR 1 or CO 2 R;
[1354] R is H, lower alkyl, or CH 2 CH 2 N+Me 3 A-;
[1355] R 1 is H, lower alkyl, or CH 2 CH 2 N+Me 3 A-;
[1356] A is a pharmaceutically acceptable anion; m is 0, 1, 2, or 3; and n is 0, 1, 2, or 3;
[1357] (ff) compounds of the following formula, which compounds are also disclosed in PCT Publication No. WO 96/05169, incorporated herein by reference,
[1358] wherein each of
[1359] which are the same or different, is an aryl group or a heteroaromatic ring group; A is a C 2-8 saturated or unsaturated aliphatic hydrocarbon group which may have substituent(s) selected from the group consisting of a lower alkyl group, a hydroxyl group, a lower hydroxyalkyl group, a lower alkoxy group, a carboxyl group, a lower carboxyalkyl group, an aryl group and an aralkyl group; each of X and Y which are the same or different, is an oxygen atom, a sulfur atom, a carbonyl group or a group of the formula —CHR a - (wherein Ra is a hydrogen atom or a lower alkyl group) or —NR b (wherein Rb is a hydrogen atom or a lower alkyl group), or X and Y together represent
[1360] a vinylene group or an ethynylene group; each of R 1 , R 2 , R 3 , R 8 and
[1361] R 9 which are the same or different, is a hydrogen atom, a halogen atom, a hydroxyl group, a lower alkyl group or a lower alkoxy group;
[1362] each of R 4 and R 5 which are the same or different, is a hydrogen atom. a halogen atom, a hydroxyl group, an amino group, a nitro group, a cyano group, a carboxyl group, a lower alkoxycarbonyl group, a carbamoyl group, a lower alkylcarbamoyl group, a lower alkyl group, a lower hydroxyalkyl group, a lower fluoroalkyl group or a lower alkoxy group; R 6 is a lower alkyl group; and R 7 is a hydrogen atom or a lower alkyl group, provided that when one of X and Y is an oxygen atom, a sulfur atom or a group of the formula —NRb (wherein Rb is as defined above), the other is a carbonyl group or a group of the formula —CHR a - (wherein Ra is as defined above);
[1363] (gg) compounds of the following formula, which compounds are also disclosed in PCT Publication No. WO 96/05168, incorporated herein by reference,
[1364] wherein each of
[1365] which are the same or different, is an aryl group or a heteroaromatic ring group; A is a C 2-8 saturated or unsaturated aliphatic hydrocarbon group which may have substituent(s) selected from the group consisting of a lower alkyl group, a hydroxyl group, a lower hydroxyalkyl group, a lower alkoxy group, a carboxyl group, a lower carboxyalkyl group, an aryl group and an aralkyl group; Q is a group of the formula —(CH 2 ) m - (wherein m is an integer of from 1 to 6) or —(CH 2 ) n —W(CH 2 )p— (wherein W is an oxygen atom, a sulfur atom, a vinylene group or an ethynylene group; and each of n and p which are the same or different, is an integer of from 0 to 3); R 1 is a hydrogen atom, a halogen atom, a hydroxyl group, a lower alkyl group. a lower alkoxy group, or an aryl or heteroaromatic ring group which may have substituent(s) selected from the group consisting of a halogen atom, a lower alkyl group and a lower alkoxy group; each of R 2 , R 7 and R 8 which are the same or different, is a hydrogen atom, a halogen atom, a hydroxyl group, a lower alkyl group or a lower alkoxy group; each of R 3 and R 4 which are the same or different, is a hydrogen atom, a halogen atom, a hydroxyl group, an amino group, a nitro group, a cyano group, a carboxyl group, a lower alkoxycarbonyl group, a carbamoyl group, a lower alkylcarbamoyl group, a lower alkyl group, a lower hydroxyalkyl group, a lower fluoroalkyl group or a lower alkoxy group; R 5 is a lower alkyl group; and R 6 is a hydrogen atom or a lower alkyl group;
[1366] or the pharmaceutically acceptable salts thereof.
[1367] Specifically suitable compounds of the above type include the following:
[1368] 3-Hydroxy-7,11,15-trimethylhexadeca-6,10,14-trienoic acid,
[1369] [2-Oxo-6, 10,1 4-trimethylpentadec-5,9, 1 3-trienyl]phosphonic acid,
[1370] [2-Hydroxy-6,10,14-trimethylpentadec 5,9,13-trienyl]phosphonic acid,
[1371] [1-Acetyl-4,8,12-trimethylpentadeca-3,7,11-trienyl]phosphonic acid,
[1372] [2-[(E,E)-3 ,7,11-Trimethyl-2,6,10-dodecatrienylamino]-2-oxo-ethyl]phosphonic acid,
[1373] [(E,E)-4,8,12-Trimethyl-3,7,11-tridecatrienyl]thiomethyl-phosphonic acid,
[1374] 3-[(E,E)-3 ,7,11-Trimethyl-2,6,10-dodecatrienylamino]-3-oxo-propionic acid,
[1375] [2-[(E,E)-3,7,11-Trimethyl-2,6,10-dodecatrienylamino]-2-oxoethyl]phosphonic acid monomethyl ester,
[1376] [2-[(E,E)-3,7,11-Trimethyl-2,6,10-dodecatrienylamino]-1-oxomethyl]phosphonic acid,
[1377] [1-Hydroxy-(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienyl]-phosphonic acid,
[1378] [1-Hydroxy-(E,E)-5,9,13-trimethyl-4,8,12-tetradecatrienyl]-phosphonic acid,
[1379] [1-Hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]-phosphonic acid,
[1380] [2-Acetamido-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]-phosphonic acid,
[1381] [2-Hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]-phosphonic acid,
[1382] N-((1RS,2RS,4E)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)-carbamoylmethyl succinic acid,
[1383] N-((1RS,2RS,4E)-2-(4-chlorophenyl)-1-methyl-5-(1-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)-carbamoylmethyl succinic acid,
[1384] N-((1RS,2RS)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)pentyl)-N-(2S naphthylmethyl)carbamoylmethyl succinic acid,
[1385] N-((1RS,2RS)-2-(4-chlorophenyl)-1-methyl-4-(2-naphthoxy)butyl)-N(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1386] N-((1RS,2RS)-2-(4-chlorophenyl)-1-methyl-4-(2-naphthyl)butyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1387] N-((1RS,2RS)-2-(4-chlorophenyl)-1-methyl-6-(2-naphthyl)hexyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1388] N-((1RS,2RS)-2-(4-chlorophenyl)-1-methyl-5-phenyl-4-pentynyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1389] N-((1RS ,2RS ,4E)-2-(4-methoxyphenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1390] N-((1RS,2RS,4E)-1-methyl-2-(4-methylphenyl)-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthyl-methyl)carbamoylmethyl succinic acid,
[1391] N-((1RS,2RS,4E)-1-methyl-5-(2-naphthyl)-2-(4-nitrophenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1392] N-((1RS,2RS,4E)-2-(4-fluorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1393] N-((1RS,2RS,4E)-1-methyl-5-(2-naphthyl)-2-(4-trifluoromethylphenyl)4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1394] N-((1RS,2RS,4E)-1-methyl-5-(2-naphthyl)-2-phenyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1395] N-((1RS,2RS,4E)-1-methyl-2-(6-methyl-3-pyridyl)-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1396] N-((1RS,2RS,6E)-2-(4-chlorophenyl)-1-methyl-7-phenyl-6-heptenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1397] N-((1RS,2RS,6E)-2-(4-chlorophenyl)-1-methyl-7-(2-naphthyl)-6-heptenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1398] N-((1RS,2RS,4E)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(3-quinolylmethyl)carbarnoylmethyl succinic acid,
[1399] N-((1RS,2RS,4E)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(3,4-difluorobenzyl)carbamoylmethyl succinic acid,
[1400] N-(2-benzoxazolylmethyl)-N-((1RS,2RS,4E)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)carbamoylmethyl succinic acid,
[1401] N-(2-benzo[b]thienylmethyl)-N-((1RS,2RS,4E)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)carbamoylmethyl succinic acid,
[1402] N-((1RS,2RS,4E)-1-methyl-2-(3 ,4-methylenedioxyphenyl)-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1403] (2R*)-2-[N-((1 S*,2S*,4E)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbarmoylmethyl]succinic acid,
[1404] (2R*)-2-[N-((1R*,2R*,4E)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1405] (2S *)-2-[N-((1R*,2R*,4E)-2-(4-chlorophenyl)--methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbarnoylmethyl]succinic acid,
[1406] (2S *)-2-[N-(( iS*,2S*,4E)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1407] 5-[N-((1RS,2RS,4E)-2-(4-chlorophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]pentanoic acid,
[1408] (2R*)-2-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylrethyl]succinic acid,
[1409] (2R*)-2-[N-((1RS,2RS,4Z)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1410] (2R*)-2-[N-(2-benzo[b]furanylmethyl)-N-((1RS.2RS,4E)-5-(2-benzoxazolyl)-11-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)carbamoylmethyl]succinate,
[1411] (2R*)-2-[N-(2-benzo[b]thienylmethyl)-N-((RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)carbamoylmethyl]succinic acid,
[1412] (2R*)-2-[N-[(1RS,2RS,4E)-5-(2-benzoxazolyl)-2-(3,4-bis(methoxycarbonyl)phenyl)-1-methyl-4-pentenyl]-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1413] (2R*)-2-[N-(2-benzo[b]thienylmethyl)-N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-2-(4-methoxycarbonylphenyl)-1-methyl-4-pentenyl)carbamoylmethyl]succinic acid,
[1414] (2R*)-2-[N-(2-benzo [b]fuiranylmethyl)-N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-25 2-(4-methoxycarbonylphenyl)-1-methyl-4-pentenyl)carbamoylmethyl]succinic acid,
[1415] (2R*)-2-[N-(2-benzo[b]thienylmethyl)-N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-2-(4-cyanophenyl)-1-methyl-4-pentenyl)carbamoylmethyl]succinic acid,
[1416] (2R*)-2-[N-(5-benzo[b]thienylmethyl)-N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-2-(4-methoxycarbonylphenyl)-1-methyl-4-pentenyl)carbamoylmethyl]succinic acid,
[1417] 30 N-((1RS,2RS,4E)-5-(3-chloro-4-methylphenyl)-2-(4-chlorophenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1418] N-((1RS,2RS,4Z)-5-(3-chloro-4-methylphenyl)-2-(4-chlorophenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1419] N-((1RS,2RS,4E)-5-(2-benzo[b]furanyl)-2-(4-chlorophenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1420] N-((1RS,2RS,4Z)-5-(2-benzo[b]furanyl)-2-(4-chlorophenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1421] N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-2-(4-chlorophenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1422] N-((1RS,2RS,4Z)-5-(2-benzoxazolyl)-2-(4-chlorophenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl succinic acid,
[1423] N-((1RS,2RS,4E)-5-(2-benzimidazolyl)-2-(4-chlorophenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1424] N-((1RS,2RS,4E)-2-(4-chlorophenyl)-1-methyl-5-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1425] N-((1RS,2RS ,4E)-5-(2-benzothiazolyl)-2-(4-chlorophenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1426] N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-2-(4-cyanophenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1427] 4-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-1,2,3-butanetricarboxylic acid,
[1428] 3-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]1,2,2-propanetricarboxylic acid,
[1429] (2S,3R)-4-[N-(( I RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl]-3-carboxy-2-hydroxybutanoic acid,
[1430] 4-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-carboxy-4-methioxybutanoic acid,
[1431] 5-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-4-carboxy-3-carboxymethyl pentanoic acid,
[1432] 1-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-2-(4-methoxycarbonylphenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-1,2,3-propanetricarboxylic acid,
[1433] (3R*)-4-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbarnoyl]-3-methoxybutanoic acid,
[1434] (3 S*)-4-[N-(( I RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-methoxybutanoic acid,
[1435] N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-2-(4-carboxyphenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1436] N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(4- (N-methylcarbamoyl)phenyl)-4-pentenyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1437] (2R*)-2-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-2-(4-hydroxy-3-methoxyphenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1438] N-((1RS,2RS,4E)-2-(4-hydroxymethylphenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1439] N-(1RS,2RS,4E)-2-(4-aminophenyl)-1-methyl-5-(2-naphthyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1440] disodium (3RS,4RS)-4-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-carboxy-4-hyroxybutanoate,
[1441] N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)-5-oxotetrahydrofuran-2-carboxyamide,
[1442] sodium 4-[N-((1RS,2Rs,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)]carbamoyl-4-hyroxybutanoate,
[1443] 4-[N-((1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-2-oxotetrahydrofiran-3-yl-acetic acid,
[1444] (2R*)-2-[N-((1R*,2R*, 4 E)-5-(2-benzoxazolyl)-2-(4-methoxycarbonylphenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1445] (2R*)-2-[N-(( i S*,2S*,4E)-5-(2-benzoxazolyl)-2-(4-methoxycarbonylphenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1446] (2R*)-2-[N-(2-benzo[b]thienylmethyl)-N-(1 S*,2S*,4B)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)carbamoylmethyl]succinic acid,
[1447] (2R*)-2-[N-(2-benzo[b]thienylmethyl)-N-((1R*,2R*,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)carbamoylmethyl]succinic acid,
[1448] (2R*)-2-[N-((1RS.2RS)-5-(2-benzoxazolyl)-l -methyl-2-(3,4-methylenedioxyphenyl)pentyl)-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1449] (2R*)-2-[N-(2-benzo[b]thienylmethyl)-N-(( RS,2RS)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)pentyl)carbamoylmethyl]succinic acid,
[1450] (2R*)-2-[N-((1R*,2R*)-5-(2-benzoxazolyl)-2-(4-methoxycarbonylphenyl)-1-methylpentyl)-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1451] disodium (3 S,4S)-4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-carboxy-4-hyroxybutanoate,
[1452] sodium (3S,45)-4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-ethoxycarbonyl-4-hyroxybutanoate,
[1453] 4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-tert-butoxycarbonyl-4-hydroxy-3-butenoic acid,
[1454] 4-[N-((1R,2R,4E)-5-(2-benzoxazo lyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbarnoyl]-4-hydroxy-3-methoxycarbonyl-3-butenoic acid,
[1455] 4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-4-hydroxy-3-isopropoxycarbonyl-3-butenoic acid,
[1456] 4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-cyclohexyloxycarbonyl-4-hydroxy-3-butenoic acid,
[1457] 4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-4-hydroxy-3-(2-methoxyethoxy)carbonyl-3-butenoic acid,
[1458] 4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-benzyloxycarbonyl-4-hydroxy-3-butenoic acid,
[1459] 4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-cyclopentyloxycarbonyl-4-hydroxy-3-butenoic acid,
[1460] 4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-4-hydroxy-3-(3-tetrahydrofuranyloxycarbonyl)-3-butenoic acid,
[1461] 4-[N-(( IR,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-4-hydroxy-3-(2-hydroxy-1-hydroxymethylethoxycarbonyl)-3-butenoic acid,
[1462] 3-allyloxycarbonyl-4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-4-hydroxy-3-butenoic acid,
[1463] 4-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-2-(3,4-methylenedioxyphenyl)-1-methyl-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-carboxymethylcarbonyl-4-hydroxy-3-butenoic acid,
[1464] 5-[N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-4-ethoxycarbonyl-5-hydroxy-4-pentenoic acid,
[1465] 5-N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-4-tert-butoxycarbonyl-5-hydroxy-4-pentenoic acid,
[1466] 4-N-((1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-4-hydroxy-3-hydroxymethyl-3-butenoic acid,
[1467] 4-[N-((1RS,2RS,4E)-6-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-5-hexenyl)-N-(2-naphthylmethyl)carbamoyl]-3-tert-butoxycarbonyl-4-hydroxy-3-butenoic acid,
[1468] (2S*,3R*)-4-[N-(( l R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-1,2,3-butanetricarboxylic acid,
[1469] (2R*,3S*)-4-[N-((1R.2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-1,2,3-butanetricarboxylic acid,
[1470] N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5- (phenylcarbamoyl)-2-furyl)-propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1471] N-[(1RS,2RS)-3-(5-(3,4-dimethoxyphenylcarbamoyl)-2-furyl)-1-methyl-2-(4-nitrophenyl)propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1472] N-[(1RS,2RS)-3-(5-(2-hydroxyphenylcarbamoyl)-2-furyl)-1-methyl-2-(4-nitrophenyl)propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1473] N-[(1RS,2RS)-1-methyl-3-(5- (N-methylphenylcarbamoyl)-2-furyl)-2-(4-nitrophenyl)propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1474] N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5-(3-pyridylcarbamoyl)-2-furyl)-propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1475] N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5-(4-pyridylcarbamoyl)-2-furyl)-propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1476] N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5- (spyrimidinylcarbamoyl)-2-furyl)-propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1477] N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5-(2-thiazolylcarbamoyl)-furyl)-propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid
[1478] N-[(1RS,2RS)-2-(4-chlorophenyl)-1-methyl-3-(5- (phenylcarbamoyl)-2-furyl)-propyl]-N-(2-naphthylmethyl)carbarnoylmethylsuccinic acid,
[1479] N-((1RS,2RS)-2-(4-chlorophenyl)-1-methyl-3-(3-phenylcarbamoylphenyl)propyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1480] N-[(1RS,2RS)-2-(4-chlorophenyl)-1-methyl-3-(3- (phenylcarbamoyl)-5-isoxazolyl)-propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1481] N-[(1RS,2RS)-2-(4-chlorophenyl)-1-methyl-3-(4- (phenylcarbamoyl)-2-pyridyl)-propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1482] (2R*)-2-[N-(2-benzo[b]thienylmethyl)-N-[(1RS,2RS)-1-methyl-2-(3,4-methylenedioxyphenyl)-3-(5- (phenylcarbamoyl)-2-furyl)-propyl]carbamoylmethyl]succinic acid,
[1483] (2R*)-2-[N-(2-benzo[b]thienylmethyl)-N-[(1RS,2RS)-1-methyl-2-(3,4-methylenedioxyphenyl)-3-(5-(3-pyridylcarbamoyl)-2-furyl)propyl]carbamoylmethyl]succinic acid,
[1484] monopivaloyloxymethyl (2R*)-2-[N-(2-benzo[b)thienylmethyl)-N[(1RS,2RS)-1-methyl-2-(3,4-methylenedioxyphenyl)-3-(5-(phenylcarbamoyl)-2-furyl)propyl]carbamoylmethyl]succinate
[1485] (2R*)-2-[N-((1RS,2RS)-2-(4-methoxycarbonylphenyl)-1-methyl-3-(3-phenoxymethylphenyl)propyl)-N-2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1486] (2R*)-2-[N-[(1RS,2RS)-2-(4-methoxycarbonylphenyl)-1-methyl-3-(3-(phenoxymethyl)-5-(1,2,4-oxadiazolyl))propyl]-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1487] (2R*)-2-[N-[(IRS,2RS)-2-(4-methoxycarbonylphenyl)-1-methyl-3- ((E)-3-styrylphenyl)propyl]-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1488] (2R*)-2-[N-[(1RS,2RS)-2-(4-methoxycarbonylphenyl)-1-methyl-3-(3-(2-phenylethyl)phenyl)propyl]-N-(2-naphthylmethyl)carbamoylmethyl]succinic acid,
[1489] N-((1RS,2RS)-2-(4-chlorophenyl)-1-methyl-3-(4-phenylethynylphenyl)propyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1490] N-[(1RS,2RS)-2-(4-chlorophenyl)-1-methyl-3- ((E)-3-styrylphenyl)propyl]-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid
[1491] N-((1RS,2RS)-2-(4-methoxycarbonylphenyl)-1-methyl-3-(5-phenoxymethyl-2-fiuryl)propyl)-N-(2-naphthylmethyl)carbamoylmethylsuccinic acid,
[1492] 4-[N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5- (phenylcarbamoyl)-2-furyl)propyl]-N-(2-naphthylmethyl)carbamoyl]-1,2,3-butanetricarboxylic acid,
[1493] disodium (3RS,4RS)-3-carboxylate-4-hydroxy-4-[N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5- (phenylcarbamoyl)-2-furyl)propyl]-N-(2-naphthylmethyl)carbamoyl]butanoate,
[1494] disodium (3RS,4RS)-3-carboxylate-4-hydroxy-4-[N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5- (phenylcarbamoyl)-2-furyl)propyl]-N-(2-naphthylmethyl)carbamoyl]butanoate,
[1495] 3-tert-butoxycarbonyl-4-hydroxy-4-[N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5- (phenylcarbamoyl)-2-fI )propyl]-N-(2-naphthylmethyl)carbamoyl]-3-butenoic acid,
[1496] 3-tert-butoxycarbonyl-4-hydroxy-4-[N-[(1RS,2RS)-1-methyl-2-(3,4-methylenedioxyphenyl)-3-(5- (phenylcarbanoyl)-2-furyl)propyl]-N-(2-naphthylmethyl)carbamoyl]-3-butenoic acid,
[1497] 3-tert-butoxycarbonyl-4-hydroxy-4-[-((1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(3-phenoxymethylphenyl)propyl)-N-(2-Naphthylmethyl)carbamoyl]-3-butenoic acid,
[1498] 4-hydroxy-3-methoxycarbonyl-4-[N-[(1RS,2RS)-1-methyl-2-(3,4-methylenedioxyphenyl)-3- (S-(phenylcarbamoyl)-2-I)propyl]-N-(2-naphthylmethyl)carbamoyl]-3-butenoic acid,
[1499] 3-allyloxycarbonyl-4-hydroxy-4-[N-[(1RS,2RS)-1-methyl-2-(3,4-methylenedioxyphenyl)-3-(5- (phenylcarbamoyl)-2-furyl)propyl]-N-(2-naphthylmethyl)carbamoyl]-3-butenoic acid,
[1500] 5-hydroxy-4-isopropylcarbonyl-5-[N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5- (phenylcarbamoyl)-2-ftiryl)propyl]-N-(2-naphthylmethyl)carbamoyl]-4-pentenoic acid,
[1501] 3-tert-butoxycarbonyl-4- (N-(2,3-dichlorobenzyl)-N-[(1RS,2RS)-1-methyl-2-(4-nitrophenyl)-3-(5- (phenylcarbanoyl)-2-furyl)propyl]carbamoyl]-4-hydroxy-3-butenoic acid,or
[1502] a pharmaceutically acceptable salt or optical isomer thereof. A further embodiment of the specific farnesyl pyrophosphate-competitive inhibitors includes:
[1503] disodium (3RS.4RS)-4-[N-1(1RS,2RS,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-carboxyl-4-hyroxybutanoate
[1504] and sodium 4-[N-1(1R,2R,4E)-5-(2-benzoxazolyl)-1-methyl-2-(3,4-methylenedioxyphenyl)-4-pentenyl)-N-(2-naphthylmethyl)carbamoyl]-3-tert-butoxycarbonyl-4-hydroxy-3-butenoate
[1505] Other farnesyl-protein transferase inhibitor compounds that are suitable for use in the methods of the invention are disclosed in the following publications: European Patent Publication Nos. 0 537 008; and 0 540 782; PCT Patent Publication Nos. WO 94/1935; WO 95/12572; and WO 95/08546.
[1506] The inhibitor compounds suitable for use in the methods of the invention may have asymmetric centers and occur as racemates,racemic mixtures,and as individual diastereomers,with all possible isomers,including optical isomers,being included in the present invention. Unless otherwise specified,named amino acids are understood to have the natural “L” stereoconfiguration. Further,inhibitor compounds suitable for use in the methods of the invention may have enol form and keto form tautomers, depending upon the form of its substituents. The compounds of the present invention includes such enol form and keto form isomers and their mixtures. Additionally, when a hydroxyl group is present at the γ or δ-position of the terminal carboxyl group or of a carboxyl group when such a carboxyl group or a lower carboxyalkyl group is present on the saturated or unsaturated aliphatic hydrocarbon group represented by A in the formulas (f
[1507] f) and (gg),such a hydroxyl group and a carboxyl group may form an intramolecular ester i.e. a 5-membered or 6-membered lactone ring.
[1508] The following definitions apply to the above-discussed compounds,including those of the above general formulae (a) through (ee):
[1509] “Alkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms. “Cycloalkyl” is intended to include non-aromatic cyclic hydrocarbon groups having the specified number of carbon atoms. Examples of cycloalkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like. “Alkenyl” groups include those groups having the specified number of carbon atoms and having one or several double bonds. Examples of alkenyl groups include vinyl, allyl, isopropenyl, pentenyl, hexenyl, heptenyl, cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclohexenyl, l-propenyl, 2-butenyl, 2-methyl-2-butenyl, isoprenyl, farnesyl, geranyl, geranylgeranyl and the like. As used herein, “aryl” is intended to include any stable monocyclic, bicyclic or tricyclic carbon ring(s) of up to 7 members in each ring, wherein at least one ring is aromatic. Examples of aryl groups include phenyl, naphthyl, anthracenyl, biphenyl, tetrahydronaphthyl, indanyl, phenanthrenyl and the like. The term heterocycle or heterocyclic, as used herein, represents a stable 5 to 7 membered monocyclic or stable 8 to 11 membered bicyclic or stable I 1-membered tricyclic heterocycle ring which is either saturated or unsaturated, and which consists of carbon atoms and from one to four heteroatoms selected from the group consisting of N, O, and S, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached at any heteroatom or carbon atom which results in the creation of a stable structure. Examples of such heterocyclic elements include, but are not limited to, azepinyl, benzimidazolyl, benzisoxazolyl, benzofurazanyl, benzopyranyl, benzothiopyranyl, benzofuryl, benzothiazolyl, benzothienyl, benzoxazolyl, chromanyl, cinnolinyl, dihydrobenzofuryl, dihydrobenzothienyl, dihydrobenzothiopyranyl, dihydrobenzothio-pyranyl sulfone, furyl, imidazolidinyl, imidazolinyl, imidazolyl, indolinyl, indolyl, isochromanyl, isoindolinyl, isoquinolinyl, isothiazolidinyl, isothiazolyl, isothiazolidinyl, morpholinyl, naphthyridinyl, oxadiazolyl, 2-oxoazepinyl, 2-oxopiperazinyl, 2-oxopiperidinyl, 2-oxopyrrolidinyl, piperidyl, piperazinyl, pyridyl, pyridyl N-oxide, pyridonyl, pyrazinyl, pyrazolidinyl, pyrazolyl, pyrimidinyl, pyrrolidinyl, pyrrolyl, quinazolinyl, quinolinyl, quinolinyl N-oxide, quinoxalinyl, tetrahydrofuryl, tetrahydroisoquinolinyl, tetrahydro-quinolinyl, thiamorpholinyl, thiamorpholinyl sulfoxide, thiazolyl, thiazolinyl, thienofuyl, thienothienyl, and thienyl.
[1510] As used herein, the terms “substituted aryl”, “substituted heterocycle” and “substituted cycloalkyl” are intended to include the cyclic group which is substituted with 1 or 2 substituents selected from the group which includes but is not limited to F, Cl, Br, CF 3 , NH2, N(C 1 -C 6 alkyl) 2 , NO 2 , CN, (C 1 -C 6 alkyl)O—, —OH, (C 1 -C 6 alkyl)S(O) m —, (C 1 -C 6 alkyl)C(O)NH—, H 2 N—C(NH)—, (C 1 -C 6 alkyl)C(O)-, (C 1 -C 6 alkyl)OC(O)—, N 3 , (C 1 -C 6 alkyl)OC(O)NR- and C 1 -C 20 alkyl.
[1511] The following structure:
[1512] represents a cyclic amine moiety having 5 or 6 members in the ring, such a cyclic amine which may be optionally fused to a phenyl or cyclohexyl ring. Examples of such a cyclic amine moiety include, but are not limited to, the following specific structures:
[1513] It is also understood that substitution on the cyclic amine moiety by R 2a , R 2 b, R 1a and R 1b may be on different carbon atoms or on the same carbon atom.
[1514] When R 2a and R 2 b, and R 3 and R 4 are combined to form (CH 2 O) m —, cyclic moieties are formed. Examples of such cyclic moieties include, but are not limited to:
[1515] When R 5a and R 5b are combined to form —(CH 2 ) s —, cyclic hereinabove for R 3 and R 4 are formed. In addition, such cyclic moieties may optionally include a heteroatom(s). Examples of such heteroatom-containing cyclic moieties include, but are not limited to:
[1516] As used herein, the phrase “nitrogen containing C 4 -C 9 mono or bicyclic ring system wherein the non-nitrogen containing ring may be a C 6 aromatic ring, a C 5 -C 7 saturated ring or a heterocycle” which defines moiety “Q” includes but is not limited to the following ring systems:
[1517] It is intended that the definition of any substituent or variable (e.g., R 10 , Z, n, etc.) at a particular location in a molecule be independent of its definitions elsewhere in that molecule. Thus, N(R 10 ) 2 represents—NHH, —NHCH 3 , —NHC 2 H 5 , etc. It is understood that substituents and substitution patterns on a particular inhibitor compounds suitable for use in the methods of the invention can be selected by one of ordinary skill in the art to provide compounds that are chemically stable and that can be readily synthesized by known techniques.
[1518] The pharmaceutically acceptable salts of inhibitor compounds for use in the methods of the invention include known non-toxic salts, e.g. pharmaceutically acceptable inorganic or organic acids such as the following acids: hydrochloric, hydrobromic, sulfuric, sulfamic, phosphoric, nitric, acetic, propionic, succinic, glycolic, stearic, lactic, malic, tartaric, citric, ascorbic, pamoic, maleic, hydroxymaleic, phenyl-acetic, glutamic, benzoic, salicylic, sulfanilic, 2-acetoxy-benzoic, fumaric, toluenesulfonic, methanesulfonic, ethane disulfonic, oxalic, isethionic, trifluoroacetic and the like. The pharmaceutically acceptable salts of inhibitor compounds for use in the methods of the invention can be synthesized from the corresponding inhibitor of this invention which contain a basic moiety by conventional chemical methods. Generally, the salts are prepared by reacting the free base with stoichiometric amounts or with an excess of the .desired salt-forming inorganic or organic acid in a suitable solvent or various combinations of solvents.
[1519] The following definitions apply to compounds of the above general formulae (ff) through (gg): The aryl group means a phenyl group, a naphthyl group or an anthryl group. A phenyl group or a naphthyl group is preferred.
[1520] The heteroaromatic ring group means a 5-membered or 6-membered monocyclic aromatic heterocyclic group containing one or two heteroatoms, which are the same or different, selected from the group consisting of an oxygen atom, a nitrogen atom and a sulfur atom, or a fused aromatic heterocyclic group having such a monocyclic aromatic heterocyclic group fused with the above-mentioned aryl group or having the same or different such monocyclic aromatic heterocyclic groups fused with each other, which may, for example, be a pyrrolyl group, an imidazolyl group, a pyrazolyl group, a pyridyl group, a pyrazinyl group, a pyrimidinyl group, a pyridazinyl group, an oxazolyl group, an isoxazolyl group, a furyl group, a thienyl group, a thiazolyl group, an isothiazolyl group, an indolyl group, a benzofuranyl group, a benzothienyl group, a benzimidazolyl group, a benzoxazolyl group, a benzisoxazolyl group, a benzothiazolyl group, a benzisothiazolyl group, an indazolyl group, a purinyl group, a quinolyl group, an isoquinolyl group, a phthalazinyl group, a naphthylidinyl group, a quinoxalinyl group, a quinazolinyl group, a cinnolinyl group or a pteridinyl group. Among them, a furyl group, a thienyl group, a pyridyl group, a pyrimidinyl group, an oxazolyl group, an isoxazolyl group, a thiazolyl group, a benzofuranyl group, a benzothienyl group, a benzimidazolyl group, a benzoxazolyl group, a benzothiazolyl group or a quinolyl group is preferred. The lower alkyl group means a C 1-6 linear or branched alkyl group, which may, for example, be a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a sec-butyl group, a tert-butyl group, a pentyl group or a hexyl group. Among them, a methyl group or an ethyl group is preferred. The lower hydroxyalkyl group means the above-mentioned lower alkyl group having a hydroxyl group, i.e. a C 1-6 hydroxyalkyl group, such as a hydroxymethyl group, a hydroxyethyl group, a hydroxypropyl group or a hydroxybutyl group. Among them, a hydroxymethyl group or a hydroxyethyl group is preferred. The lower alkoxy group means a C 1-6 alkoxy or alkylenedioxy group, which may, for example, be a methoxy group, an ethoxy group, a propoxy group, an isopropoxy group, a butoxy group, a tert-butoxy group, a methylenedioxy group, an ethylenedioxy group or a trimethylenedioxy group. Among them, a methoxy group, an ethoxy group or a methylenedioxy group is preferred. The lower carboxyalkyl group means the above-mentioned lower alkyl group having a carboxyl group, i.e. a C 1-7 carboxyalkyl group, such as a carboxymethyl group, a carboxyethyl group, a carboxypropyl group or a carboxybutyl group. Among them, a carboxymethyl group or a carboxyethyl group is preferred. The aralkyl group means the above-mentioned lower alkyl group having the above-mentioned aryl group, such as a benzyl group, a phenethyl group, a 3-phenylpropyl group, a 1-naphthylmethyl group, a 2-naphthylmethyl group or a 1-(2-naphthyl)ethyl group. Among them, a benzyl group, a phenethyl group or a 2-naphthylmethyl group is preferred. The saturated aliphatic hydrocarbon group may, for example, be an ethylene group, a trimethylene group, a tetramethylene group, a pentamethylene group, a hexamethylene group, a heptamethylene group or an octamethylene group. For example, a trimethylene group, a tetramethylene group or a pentamethylene group is preferred.
[1521] The unsaturated aliphatic hydrocarbon group means an unsaturated aliphatic hydrocarbon group having one or more, preferably one or two double bonds, at optional position(s) on the carbon chain, which may, for example, be a vinylene group, a propenylene group, a 1-butenylene group, a 2-butenylene group, a 1,3-butadienylene group, a 1-pentenylene group, a 2-pentenylene group, a 1,3-pentadienylene group, a 1,4-pentadienylene group, a 1-hexenylene group, a 2-hexenylene group, a 3-hexenylene group, a 1,3-hexadienylene group, a 1,4-hexadienylene group, a 1,5-hexadienylene group, a 1,3,5-hexatrienylene group, a 1-heptenylene group, a 2-heptenylene group, a 3-heptenylene group, a 1,3-heptadienylene group, a 1,4-heptadienylene group, a 1,5-heptadienylene group, a 1,6-heptadienylene group, a 1,3,5-heptatrienylene group, a 1-octenylene group, a 2-octenylene group, a 3-octenylene group, a 4-octenylene group, a 1,3-octadienylene group, a 1,4-octadienylene group, a 1,5-octadienylene group, a 1,6-octadienylene group, a 1,7-octadienylene group, a 2, 4-octadienylene group, a 2, 5-octadienylene group, a 2, 6-octadienylene group, a 3,5-octadienylene group, a 1,3,5-octatrienylene group, a 2, 4, 6-octatrienylene group or a 1,3,5,7-octatetraenylene group. Among them, a propenylene group, a I-butenylene group, a 1,3-butadienylene group or a 1-pentenylene group is preferred. The halogen atom may be a fluorine atom, a chlorine atom, a bromine atom or an iodine atom. For example, a fluorine atom or a chlorine atom is preferred.
[1522] The lower alkoxycarbonyl group means a C 1-7 alkoxycarbonyl group, such as a methoxycarbonyl group, an ethoxycarbonyl group, a propoxycarbonyl group, a butoxycarbonyl group or a tert-butoxycarbonyl group. Among them, a methoxycarbonyl group or an ethoxycarbonyl group is preferred. The lower alkylcarbamoyl group means a carbamoyl group mono-substituted or di-substituted by the above-mentioned lower alkyl group, such as a methylcarbamoyl group, an ethylcarbamoyl group, a dimethylcarbamoyl group or a diethylcarbamoyl group. The lower fluoroalkyl group means the above-mentioned lower alkyl group having fluorine atom(s), i.e. a C 1-6 fluoroalkyl group, such as a fluoromethyl group, a difluoromethyl group, a trifluoromethyl group, a l-fluoroethyl group, a 2-fluoroethyl group, a 2,2,2-trifluoroethyl group or a pentafluoroethyl group.
[1523] The salt of the compound of a formula (ff) or (gg) may be a pharmaceutically acceptable common salt, which may, for example, be a base-addition salt of the terminal carboxyl group or of a carboxyl group when R 4 and/or R 5 or R 3 and/or R 4 is a carboxyl group, or when a carboxyl group or a lower carboxyalkyl group is present on a saturated or unsaturated aliphatic hydrocarbon group represented by A in the formulas (ff) and (gg), or an acid-addition salt of an amino group when R 4 and/or R 5 or R 3 and/or R 4 is an amino group, or of a basic heteroaromatic ring when such a basic heteroaromatic ring is present.
[1524] The base-addition salt may, for example, be an alkali metal salt such as a sodium salt or a potassium salt; an alkaline earth metal salt such as a calcium salt or a magnesium salt; an ammonium salt; or an organic amine salt such as a trimethylamine salt, a triethylamine salt, a dicyclohexylamine salt, an ethanolamine salt, a diethanolamine salt, a triethanolamine salt, a procaine salt or an N,N′-dibenzylethylenediamine salt. The acid-addition salt may, for example, be an inorganic acid salt such as a hydrochloride, a sulfate, a nitrate, a phosphate or a perchlorate; an organic acid salt such as a maleate, a fumarate, a tartrate, a citrate, an ascorbate or a trifluoroacetate; or a sulfonic acid salt such as a methanesulfonate, an isethionate, a benzenesulfonate or a p-toluenesulfonate.
[1525] The ester of a compound of the formula (ff) or (gg) means a pharmaceutically acceptable common ester of the terminal carboxyl group or of a carboxyl group when R 4 and/or Rs or R 3 and/or R 4 is a carboxyl group, or when a carboxyl group or a lower carboxyalkyl group is present on the saturated or unsaturated aliphatic hydrocarbon group represented by A in the formulas (ff) and (gg). It may, for example, be an ester with a lower alkyl group such as a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a sec-butyl group, a tert-butyl group, a cyclopropyl group or a cyclopentyl group, an ester with an aralkyl group such as a benzyl group or a phenethyl group, an ester with a lower alkenyl group such as an allyl group or a 2-butenyl group, an ester with a lower alkoxyalkyl group such as a methoxymethyl group, a 2-methoxyethyl group or a 2-ethoxyethyl group, an ester with a lower alkanoyloxyalkyl group such as an acetoxymethyl group, a pivaloyloxymethyl group or a pivaloyloxyethyl group, an ester with a lower alkoxycarbonylalkyl group such as a methoxycarbonylmethyl group or an isopropoxycarbonylmethyl group, an ester with a lower carboxyalkyl group such as a carboxymethyl group, an ester with a lower alkoxycarbonyloxyalkyl group such as a I -(ethoxycarbonyloxy) ethyl group or a 1-(cyclohexyloxycarbonyloxy)ethyl group, an ester with an lower carbarnoyloxyalkyl group such as a carbamoyloxymethyl group, an ester with a phthalidyl group, or an ester with a (5-substituted-2-oxo-1,3-dioxol-4-yl)methyl group such as a (5-methyl-2-oxo-1,3-dioxol-4yl)methyl group.
[1526] At least some of the inhibitor compounds useful in the methods of the invention can be synthesized from their constituent amino acids by conventional peptide synthesis techniques, and the additional methods described below. Standard methods of peptide synthesis are disclosed, for example, in the following works: Schroeder et al., The Peptides, Vol. 1, Academic Press 1965, or Bodanszky et al., Peptide Synthesis, Interscience Publishers, 1966, or McOmie (ed.) “Protective Groups in Organic Chemistry”, Plenum Press, 1973, or Barany et al., “The Peptides: Analysis, Synthesis, Biology” 2, Chapter 1, Academic Press, 1980, or Stewart et al., “Solid Phase Peptide Synthesis”, Second Edition, Pierce Chemical Company, 1984. Also useful in exemplifying syntheses of specific unnatural amino acid residues are European Patent Application No. 0 350 163 A2 (particularly page 51-52) and J. E. Baldwin et al., Tetrahedron, 50:5049-5066 (1994). With regards to the synthesis of the above discussed compounds containing a (β-acetylamino)alanine residue at the C-terminus, use of the commercially available N-Z-L-2,3-diaminopropionic acid (Fluk
[1527] a) as a starting material is preferred. In general, methods for preparation of the above discussed compounds are known in the art and disclosed e.g. in the above-mentioned publications. Detailed synthetic procedures are also disclosed in PCT/US96/11022. Useful FTase inhibitor compounds are also commercially available.
[1528] In the methods of the invention, an FTase inhibitor compound may be administered to a subject by a variety of routes including parenteral (including subcutaneous, intramuscular and intradermal), topical (including eye drops, buccal, sublingual) oral, nasal and the like. Intraviteal or periocular injection of a compound may be a preferred administration route to provide more direct treatment.
[1529] Inhibitor compounds for use in the methods of the invention can be employed, either alone or in combination with one or more other therapeutic agents, as a pharmaceutical composition in mixture with conventional excipient, i.e., pharmaceutically acceptable organic or inorganic carrier substances suitable for a desired route of administration which do not deleteriously react with the active compounds and are not deleterious to the recipient thereof. Suitable pharmaceutically acceptable carriers include but are not limited to water, salt solutions, alcohol, vegetable oils, polyethylene glycols, gelatin, lactose, amylose, magnesium stearate, talc, silicic acid, viscous paraffin, perfume oil, fatty acid monoglycerides and diglycerides, petroethral fatty acid esters, hydroxymethyl-cellulose, polyvinylpyrrolidone, etc. The pharmaceutical preparations can be sterilized and if desired mixed with auxiliary agents, e.g., lubricants, preservatives, stabilizers, wetting agents, emulsifiers, salts for influencing osmotic pressure, buffers, colorings, flavorings and/or aromatic substances and the like which do not deleteriously react with the active compounds.
[1530] For parenteral application, particularly suitable are solutions, preferably oily or aqueous solutions as well as suspensions, emulsions, or implants, including suppositories. Ampules are convenient unit dosages.
[1531] For enteral application, particularly suitable are tablets, dragees or capsules having talc and/or carbohydrate carrier binder or the like, the carrier preferably being lactose and/or corn starch and/or potato starch. A syrup, elixir or the like can be used wherein a sweetened vehicle is employed. Sustained release compositions can be formulated including those wherein the active component is protected with differentially degradable coatings, e.g., by microencapsulation, multiple coatings, etc.
[1532] It will be appreciated that the actual preferred amounts of active compounds used in a given therapy will vary according to the specific compound being utilized, the particular compositions formulated, the mode of application, the particular site of administration, etc. Optimal administration rates for a given protocol of administration can be readily ascertained by those skilled in the art using conventional dosage determination tests conducted with regard to the foregoing guidelines.
[1533] All documents mentioned herein are incorporated herein by reference.
[1534] This invention has been described in detail with reference to preferred embodiments thereof. However, it will be appreciated that those skilled in the art, upon consideration of this disclosure, may make modifications and improvements within the spirit and scope of the invention.
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The present invention includes methods for treatment and prophylaxis of eye disorders and injuries, particularly treatment and prophylaxis of ocular neovascularization and disorders, especially a vasculopathy that affects retinal or chorodial vessels. The methods of the invention in general comprise administration of a therapeutically effective amount of a compound that inhibits farnesyl-protein transferase to a subject suffering from or susceptible to ocular neovascularization or associated disorder.
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RELATED APPLICATIONS
This application is a national phase application filed under 35 USC §371 of PCT Application No. PCT/IL2012/000334, filing date Sep. 6, 2012, which claims priority to U.S. Provisional Application No. 61/573,120, filing date Sep. 7, 2011. Each of these applications is herein incorporated by reference in its entirety for all purposes.
FIELD OF THE INVENTION
The present invention relates to the field of ophthalmic measurement instruments, especially for use in performing tonometric and refractive measurements of the eye.
BACKGROUND OF THE INVENTION
In multifunction ophthalmic measurements, where each of the measurements has to be performed by a separate instrument, there arises the problem of how to mechanically arrange the instruments such that they can be simply switched from one to the other when changing the measurement to be performed. The optical axis of each measurement instrument must be accurately aligned with the eye to be measured, such that the problem in hand is not only the physical switching between one instrument and the other, but also the alignment of each instrument after it has been switched.
There exist a number of prior art documents which address this problem. For instance in U.S. Pat. No. 7,364,298, U.S. Pat. No. 7,515,321 and U.S. Pat. No. 7,771,050, all assigned to Nidek Co. Ltd., of Japan, there are described arrangements of ophthalmic apparatus capable of performing a plurality of eye characteristic measurements, using two separate measurement instruments stacked one on top of the other, which are moved in a vertical direction by a motion mechanism in order to switch measurements between them. Those patents relate to the combination of a tonometer for the measurement of intraocular pressure in a subject's eye using a unit blowing fluid onto the cornea through a nozzle, and an instrument for measuring the optical characteristics of the eye, in particular the eye's refractive power. In U.S. Pat. No. 7,909,462, assigned to Kabushiki Kaishi Topcon, there is described a similar combination instrument for tonometric and refractive characteristics measurements, in which the measurement heads are aligned side-by-side, and a method is described for switching between them by withdrawing them in a backward direction by a minimum distance, to enable the switch between them to be made in the minimum amount of time.
However, motion of complete measurement heads using linear motion stages can be a slow and mechanically complex technique. Furthermore, motion by means of a vertical lift when a lateral motion mechanism is also required to switch the measurement systems between the subject's left and right eyes may be equally complex. A simpler method of integrating two or more of such measurement modules into one instrument, which overcomes at least some of the disadvantages of prior art systems and methods, would therefore be advantageous.
The disclosures of each of the publications mentioned in this section and in other sections of the specification, are hereby incorporated by reference, each in its entirety.
SUMMARY
The present disclosure describes new exemplary systems for performing multiple function measurements on the eyes of the subject using separate ophthalmic measurement instruments, when it is required to perform the measurements sequentially by mechanically switching between them. In contrast to those prior art systems for this purpose, where the separate measurement instruments are stacked one on top of the other, and transfer between them is performed by mechanically moving the stacked instruments in a vertical direction on a lifting device, in the systems of the present disclosure, the separate measurement instruments are mounted on a base element which is rotatably pivoted around a joint at a location remote from the optical entry apertures of the instruments. When the base element is rotated around such a remote rotation axis, the optical entrance apertures of the separate measurement instruments pass the subject's eye sequentially. Thus a rotational motion around the pivoted joint is transformed into a linear motion at the eye of the subject. Such a rotational motion can be achieved by a mechanism substantially simpler, less costly and more compact than a linear lift mechanism, such as by the use of a stepping motor, or a worm drive, activated by means of an electric motor. A worm drive also has the advantage that it is generally mechanically self locking.
For performing vertical scans across the eye, the rotation may be achieved by means of a horizontal pivot axis, such that the tilt is vertically performed, whereas for a side-by-side configuration, such as is described in U.S. Pat. No. 7,909,462, the tilting motion can be implemented in a horizontal plane by means of a vertically aligned pivot axis. It is to be understood that any other plane of rotation may also be used, though vertical or horizontal tilting motion are the most practical. It is understood however, that although the disclosure is generally described in reference to the vertical tilt motion, it is understood to be applicable to any plane of tilt desired.
Additionally, another implementation of these systems incorporates a novel corneal thickness measurement arrangement, using the known Scheimpflug camera principle, in which the measurement head with the slit beam illuminator and the camera, is tilted as the scan proceeds across the subject's cornea, such that the illuminating slit beam always impinges on the cornea at normal incidence. This ensures that the strong corneal reflection cannot enter the camera and flood out the measurement, and also that any effects arising from oblique passage of the illuminating slit beam across the cornea are also eliminated.
There is therefore provided in accordance with one example implementation, an ophthalmic measurement system, comprising:
(i) a first optical measurement module having a first optical axis, measuring at least a first characteristic of a subject's eye, (ii) a second optical measurement module having a second optical axis, measuring at least a second characteristic of a subject's eye, the second optical measurement module being vertically juxtaposed relative to the first optical measurement module, and (iii) a base element to which the first and the second optical measurement modules are linked,
wherein the base element has a rotatable joint aligned such that angular rotation of the joint around its axis enables either of the first and the second optical measurement modules to be disposed in front of the subject's eye.
In such a system, the axis of the rotatable joint should generally be perpendicular to the first and second optical axes, and perpendicular to a line drawn between the first and second optical axes. The axis of the rotatable joint can be aligned generally horizontally or vertically, depending on the direction in which the measurement modules are to be switched in front of the subject's eye.
Furthermore, in any of the above-described systems, the first optical measurement module may be a tonometer, and the second optical measurement module may be a refractive power measurement system.
Additionally, the first and the second optical axes may be either parallel, or the first and second optical measurement modules may be aligned such that both the first and the second optical axes pass through the center of the rotatable joint axis.
In all of the above described systems, the axis of the rotatable joint should advantageously lie on a line generally parallel to the first and second optical axes, and between them.
Yet another example implementation involves an ophthalmic system for measurement of corneal thickness of an eye, comprising:
(i) a pivotally supported pachymetric measurement head comprising a source generating slit beam illumination and a Scheimpflug camera arranged at mutual angles, such that the camera images the passage of the slit beam through the cornea, (ii) a scanning mechanism for traversing the pivotally supported measurement head across the eye in front of the cornea, and (iii) a control system for rotating the pivotally supported measurement head in co-ordination with its scan position, such that the slit beam impinges generally normally on the cornea independently of the scan position of the measurement head.
In such an ophthalmic system, the scanning mechanism may comprise a linear motion stage traversing the eye, or a rotational motion platform pivoted at a point remote from the measurement head, for traversing the eye. The traversing across the eye may be performed in a plane having a horizontal or vertical angular orientation, or orientation in any other selected plane.
BRIEF DESCRIPTION OF THE DRAWINGS
The presently claimed invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
FIG. 1 illustrates schematically a prior art arrangement for switching between two measurement modules by means of a vertical motion system;
FIGS. 2A and 2B illustrate an exemplary schematic implementation of a system for switching between two ophthalmic measurement instruments by means of a rotational tilt, as shown in this disclosure, with each of the two drawings showing a different rotational alignment of the system;
FIG. 2C shows one example of a drive system suitable for actuating the angular tilt required in the systems of FIGS. 2A and 2B ;
FIG. 3 illustrates schematically another implementation of the system of FIGS. 2A and 2B , but in which the rotational pivot joint is located on a center line equidistant from the optical axes of the two measurement instrument modules;
FIG. 4 illustrates schematically another implementation of the system of FIG. 3 , using a base element situated between the two measurement modules;
FIG. 5 illustrates schematically a further implementation of the systems of FIGS. 3 and 4 , in which the two measurement modules are attached to the base element with each aligned so that the optical axis of each passes through the axis of rotation at the rotary pivot joint; and
FIGS. 6A and 6B illustrate a novel goniometric method, which can use the tilting technique of the present disclosure, in order to simplify a scanning pachymetric measurement over the entire profile of the cornea of the eye.
DETAILED DESCRIPTION
Reference is now made to FIG. 1 , which illustrates schematically a prior art arrangement for switching between two measurement modules by means of a vertical motion system, such as one of those described in the above referenced patents—U.S. Pat. Nos. 7,364,298, 7,515,321 and 7,771,050. The two measurement modules could be an upper module 12 , shown as a tonometric measurement instrument, with the measurement head optical aperture close to and aligned with the eye 19 of the subject 11 being measured, and a lower module 10 , which could be a wavefront measurement instrument for measuring the optical characteristics of the eye. The optical axes of the two modules are also shown in FIG. 1 . The wavefront measurement instrument could also be combined with other measurements which can conveniently be performed in the same module, such as corneal topography or corneal thickness measurements. The two measurement modules are mounted one of top of the other as a single unit, and are moved vertically in order to bring the optical axis of each measurement module to the level of the subject's eye 19 . This motion may conveniently be accomplished by means of a sliding column 17 , mounted within a base section 13 , with the vertical motion provided by a nut and lead screw 16 mechanism, operated by an electric motor 14 . Any other convenient form of vertical mechanical motion may also be used to move the slide 17 along its vertical axis, such as a scissor-jack mechanism. Cable bundles 18 exiting from the two measurement modules are used for providing the power supply for illumination sources within the measurement modules, and for transferring the measurement information back to the control system (not shown, but understood to be present in all of the systems shown in the application, both the prior art system of FIG. 1 and the exemplary systems shown in FIGS. 2A to 6B ). In the above referenced prior art, the tonometer is in the upper position, possibly since it has to operate closer to the eye than the wavefront measurement system, and when the combination system is moved vertically upwards, the tonometer moves towards the forehead area of the subject which is generally more receded from position of the eye than the lower part of the face. However, any combination may be conveniently used.
Although the mechanical lift arrangement shown in FIG. 1 appears to be reasonably compact, since both of the instruments are shown to be of low height, if a corneal topographic measurement facility with a large radius Placido ring illumination system is built into the refractive characteristic measurements instrument, as described in PCT application No. PCT/IL2008/001148 to the assignee of the present application, then the required distance between the lower and upper instrument modules must be larger than that shown schematically in FIG. 1 , leading to a larger range of motion required for the vertical lift assembly to move from one measurement axis to the other.
Reference is now made to FIGS. 2A to 2C , which illustrate an exemplary implementation of a novel system for switching between two ophthalmic measurement modules, such as those shown in FIG. 1 , without the need of the potentially complex prior art mechanical vertical lift mechanism shown in FIG. 1 . FIGS. 2A and 2B show the two measurement modules mounted as previously shown in FIG. 1 , one on top of the other, but instead of the base being moved vertically to switch between one and the other, the base element 20 is equipped at a position remote from the measurement module optical entrance apertures, with a remote rotary tilt joint 22 , which can perform limited rotation. One exemplary method by which this rotary joint can be actuated is shown in FIG. 2C . By means of this rotation, the optical aperture of either of the measurement modules can be brought opposite the subject's eye 19 . In the situation shown in FIG. 2A , the base is aligned such that the upper measurement module 12 , in this example a tonometer, is aligned with its axis opposite the eye 19 of the subject 11 . In the situation shown in FIG. 2B , the rotary tilt joint has been rotated until the system base is aligned such that the lower measurement module 12 , in this case for a measurement of the refractive characteristics of the eye, is aligned with its axis opposite the eye 19 of the subject 11 . It is noted that the eye of each subject is in a fixed vertical position relative to the chin mount 15 , though the eye level of different subjects may be at different heights. Adjustment of the height of the chin support can then be used to align the eye at the same measurement reference height for each subject, as best as can be done by manual adjustment. The exact height adjustment can then be achieved by a fine adjustment of the tilt angle while viewing an image of the eye, in order to center the pupil for the measurement in hand. This centering can be done automatically by using a feedback control system using image processing software to generate the feedback signal to command rotation of the angular tilt axis until the eye is centered in the image. Thus, this tilt motion is used to replace any linear motion fine adjustment for centering the pupil for any measurement.
In FIGS. 2A and 2B , the base of the complete system is not shown in order to show more clearly the way in which the tiltable base element of the measurement modules can operate, but it is to be understood that the chin support 15 and the rotary tilt joint 22 and its drive system may both be mounted on a rigid baseplate for the entire system. A detailed description of an exemplary drive system for the rotary tilt joint 22 as shown in FIG. 2C , is given hereinbelow.
It is observed that in the exemplary alignment shown in FIG. 2B , the axis of the wavefront measurement instrument does not meet the eye normally, and it could be suspected that this may be a disadvantage of the present system compared with the prior art linear motion systems. However, since the subject can roll his/her eye, such an eye rotation action would ensure that the axis of the eye is parallel to the axis of the measurement module. For small angles of rotation of the eye, this effect is done automatically by the eye, so that objects are viewed optimally. This is particularly so since the refractive characteristic measurement module can include a fixation target, in order to control the patient fixation and to eliminate accommodation. It can also be used to enable an accommodation measurement. However any suitable object, preferably imaged at infinity, can be used in either of the instrument modules to ensure that the subject rolls the eye being measured to align its axis with that of each measurement module.
A further problem which arises with the exemplary embodiments shown in FIGS. 2A and 2B is related to the arc traced by the optical input aperture of each instrument, because of the offset location of the rotary joint 22 relative to the axes of the measurement modules. Thus, if the tonometer is correctly distanced from the subject's eye, as in FIG. 2A , then rotation of the base element 20 to align the lower refractive measurement instrument with the eye, as in FIG. 2B , will result in an increase in the distance of the entrance aperture from the subject's eye, such that the entrance aperture may not be at the correct working distance from the subject's eye. This can be compensated for by a predetermined longitudinal adjustment of the position of the two measurement instruments such that they are in the approximately correct focus position for the changed tilt angle, followed by a fine focusing action of the measurement module involved in order to reach a more exact imaging position. A feedback mechanism can be provided which adjusts the focal position of the input lens of the measurement instrument, according to an algorithm which ties the focal position to the angular orientation of the base, such that the measurement instrument is always at its correct working distance regardless of the angle at which the base is aligned.
An alternative and simpler solution which assists in reducing the problem of the dependence of focal distance with angular displacement is to arrange the rotational pivot joint to be located on a center line equidistant from the optical axes of the two measurement instrument modules. Such an implementation is shown in FIG. 3 , where the base element 30 is provided with a bracket to ensure that the center of rotation of the rotary tilt joint 22 is equidistant from the two optical axes of the measurement instrument modules. FIG. 3 shows the measurement modules in the intermediate position, to show that the rotatable tilt joint 22 is aligned level with the subject's eye 19 , and on the center line between the optical axes of the two measurement modules 10 , 12 . When making the two respective measurements, the base 30 will be tilted in either direction to align the optical entrance apertures of the respective instrument modules opposite the subject's eye 19 . Alternatively, and perhaps more simply, the base element could be disposed between the two instruments, as shown in FIG. 4 , such that it is naturally equidistant from the two optical axes. In either of these cases, rotation of the system is symmetrical about the center line between the optical axes of the two measurement modules, such that the need for focal length compensation to maintain each instrument at its correct working distance is minimized. However, patient movement will still necessitate active focus adjustment, such that the implementations suggested here merely reduce the level of refocus required because of the effect of the tilt mechanism.
However, even in the implementations of FIGS. 3 and 4 , when each measurement module is aligned opposite the eye of the subject, there is still need for the subject to implement an eye rotation in order to align the optical axis of the eye with the optical axis of the measurement module. Reference is now made to FIG. 5 , which illustrates schematically an implementation which avoids these effects. In FIG. 5 , the two measurement modules 10 , 12 are not attached to the base element with their optical axes parallel, but rather with each aligned so that the optical axis of each passes through the axis of rotation at the rotary pivot joint 22 . In such a situation, the optical axis of the instrument will always be aligned with the optical axis of the eye under test, regardless of the angle of alignment of the system and the height of the eye, and without the need of the subject to roll his eye to the axis of the measurement module in use at that point of time.
Any of the above described systems using rotary tilt joint motion provides these systems with a number of advantages over the prior art linear motion systems. In the first place a small rotary motion of the rotary tilt joint 22 can provide a significant controlled essentially linear movement of the measurement module's entrance aperture at the subject's eye, the relationship between the angular rotation and the lateral motion depending on the distance L between the tilt axis and the apertures of the measurement modules, as marked in FIG. 5 but as relevant in all of the implementations. Therefore, even measurement instruments having a large height and therefore spaced at an appropriately large distance from each other, can be used with a simple rotary joint implementation as described herewithin. An advantage of such a rotary tilt system is its compactness and simplicity in comparison to the prior art linear lift systems. Therefore, in order to achieve optimum size advantage, the distance L should be kept as small as possible to keep the instrument as compact as possible.
Secondly, rotary motion to a rotary axis may be significantly simpler to provide than the linear motion mechanisms of the prior art systems. Reference is now made back to FIG. 2C , which shows schematically an exemplary implementation in which the rotary motion is provided by means of a worm drive, with the worm gear 26 being attached to the axis of rotation of the rotary tilt joint, and the worm 25 being controllably driven by an electric motor 27 , which could advantageously be a stepping motor. Such a worm drive has the advantage that the gear ratio is generally high, being equal to the “number of teeth on the worm gear-to-1” for a single start worm. Since only a small rotation is required, typically of a few degrees, and the drive motor may have a high rotational speed, such a high gear ratio is advantageous for this application. Furthermore, because of the weight of the combination measurement system including the two measurement modules and their base, a significant torque may be required in order to change its angular orientation, especially to raise the entire system. Therefore, such a worm drive with a high gear ratio also assists in converting the comparatively low torque of the drive motor to a torque suitable for angularly raising the combination measurement system. Finally, since such a worm drive is generally a one-way drive, from the worm to the worm gear (provided, usually, that the tangent of the worm lead angle is less than the coefficient of friction between the drive surfaces), the system is self locking with respect to torque applied from the worm gear, and the weight of the combination measurement system will not generally be able to rotate the rotary tilt joint. However it is to be understood that use of a worm drive is not the only method of providing rotation about an axis, and that this illustrated example is not meant to limit the possible methods of implementing such rotary motion. A directly coupled stepping motor could also be used, or a motor driving a spur gear train, or any other suitable drive mechanism providing controlled angular rotation motion. In any event, any such rotary motion provider is generally simpler and of lower cost than a linear motion system.
The advantages of the use of a rotary tilt joint in maintaining optimum compactness of the system have already been mentioned hereinabove. The reduction in the overall level of motion required by the system, especially with respect to the rear end of the measurement modules at which the operating cables are attached, is significant in maintaining compactness of the system. In addition, the significant reduction of lateral motion at the rear end of the measurement modules results in almost complete elimination of lateral motion of the cable bundle, and hence longer life time and higher reliability. In prior art systems, the cables may be subject to chafing by the constant vertical motion between the two measurement modules. However, the left to right motion in order to switch between the subject's eyes will still need to be maintained and its effect on the cable bundle will therefore not be canceled.
The use of the rotary tilt joint in the above described systems essentially replaces the linear motion along one axis by an angular motion which simulates the linear motion for small angular displacements. This effect can be used in order to simplify the scanning operation required when performing a pachymetric measurement over the entire profile of the cornea of the eye using a Scheimpflug method. However, it is to be emphasized that the measurement technique described can also be performed using direct linear motion of the measurement head, such that it is not limited to use of the tilting configurations of the present disclosure.
Reference is now made to FIGS. 6A and 6B to illustrate this application. In FIG. 6A , there is shown schematically an exemplary optical arrangement for measurement of the thickness of the cornea 60 , by illuminating it with an incident slit beam 62 derived from an illumination source 63 , generally using blue light such as a LED source with a central wavelength of 450 nm. The lens 61 is shown behind the cornea. The light scattered by the cornea is imaged by the camera 64 , and the image information, in particular the length of the slit light scattered by the cornea in its path through the cornea, provides an indication of the corneal thickness. In order to ensure accurate imaging methods, and in particular, accurate measurements of the slit image length, the Scheimpflug principle is used with a tilted camera plane 65 in order to ensure that the image of the slit lamp beam is focused across the entire thickness of the cornea. In order to perform such a pachymetric measurement over the entire surface of the cornea, prior art measurements, such as those described in U.S. Pat. No. 6,286,958 to G. Koest et al for “Device for the Examination of an Eye using a Scheimpflug Camera and a Slit Light Projector for Photographing Slit Images of an Eye”, have used a rotating slit lamp and camera arrangement. However, this is a mechanically complex solution. Another solution is presented in U.S. Pat. No. 5,512,965 to R. K. Snook for “Ophthalmic Instrument and Method of making Ophthalmic Determinations using Scheimpflug Corrections”, where the slit itself is scanned across the corneal area. This solution however suffers from a change in the imaged width of the cornea at different points in the scan due to imaging through different thicknesses of the cornea. If, on the other hand, in order to simplify the technique, a simple linear scan across the cornea is performed, whether by means of a linear motion stage or by means of the tilt mechanism described in this application, because of the different path lengths of the light through the cornea at different lateral points on the eye, the geometry of the measurement becomes complex, since the reflected image is determined both by the corneal thickness which it is desired to measure, and by the different path lengths of the light resulting from the oblique passages of the probe beam through the cornea, as a result of which, the image becomes partially smeared out. For a small part of the scan in the method used in U.S. Pat. No. 5,512,965, the strong reflection of the input beam from the corneal surface will be at such an angle that it will enter the camera thus rendering some of the scanned images unfit for analysis.
In order to avoid this complication, it is necessary to ensure that the slit beam illumination always enters the eye normal to the anterior corneal surface, so that the strong corneal reflection cannot enter the camera. This is shown in FIG. 6B , for several different positions of the incident light beam 62 across the corneal surface. Such a normal incidence scan can be achieved by means of a combination of a linear scan and a rotation of the measurement head such that it always is directed approximately normal to the corneal surface as it scans across the cornea. The base of the measurement head 67 is moved linearly across the height of the eye, as indicated by the vertical double-headed arrows, while the measurement head itself 66 , containing the slit beam source 63 and the imaging camera 64 , is rotated on a pivot 68 , as indicated by the curved arc double-headed arrows, such that the pachymetric imaging measurement is always performed normal to the corneal surface. The rotation is synchronized with the position of the scan relative to the optical axis 69 of the eye and the distance from the eye, to ensure that the correct tilt is obtained at each scanning point. This can be achieved by means of a control system 70 linking the two motions, the control link being schematically shown in FIG. 6B by the connecting arrows to the two motions to be co-ordinated, but being understood to include the elements needed to link the motions in the desired way—such as sensors or encoders to determine the position of the two motions, motion systems such as stepping motors to perform the motion, and the control circuits themselves to maintain the correct relation between the linear and rotational positions. This control system could be part of the main control system for operating the complete instrument.
This description assumes that the scanning motion is performed across the height of the eye, but it is to be understood that the scan can also be performed laterally across the width of the eye, in which case, the measurement head rotation has to be performed around a vertical pivot axis. As previously mentioned, the linear scan can be performed by any method, whether by means of a linear motion stage or by means of the tilt mechanism described in this application, or be another scanning mechanism which provides the necessary motion of the beam across the eye.
Although the combination of ophthalmic measurement instruments described in this disclosure is a commonly used combination, different combinations are also possible, and this disclosure is not intended to be limited by this particular combination of a tonometer, with a wavefront measurement instrument for characterizing refractive properties of the eye, with or without measurement of the topography and thickness of the cornea.
It is appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and subcombinations of various features described hereinabove as well as variations and modifications thereto which would occur to a person of skill in the art upon reading the above description and which are not in the prior art.
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Systems for performing sequential multiple function ophthalmic measurements using separate measurement instruments, by mechanical switching between the instruments. In prior art systems, the separate measurement instruments are stacked, and transfer between them is performed by means of a linear mechanical motion stage. The separate measurement instruments of the present application are mounted on a base which is rotatably pivoted around a joint at a location remote from the optical entry apertures of the instruments. The entrance apertures of the measurement instruments then traverse the eye being measured sequentially. A rotational motion around the pivoted joint is thus transformed into a linear motion at the eye of the subject, without the need for a linear motion stage. A Scheimpflug camera corneal thickness measurement is also described, in which the measurement head is tilted during the corneal scan such that the illuminating slit beam always impinges on the cornea normally.
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BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The invention relates to fuel nozzles for combustors for gas turbine engines. More particularly, the invention relates to the configuration of the vanes of a swirler.
[0003] (2) Description of the Related Art
[0004] As is well known in the gas turbine engine technology it is desirable to operate the combustor at a combination of high efficiency, good lean blowout characteristics, good altitude relight characteristics, low smoke and other pollutant output, long life, and low cost. Scientists and engineers have been experimenting with the designs of the fuel nozzles for many years in attempts to maximize the efficacy of the combustor.
[0005] U.S. Pat. No. 5,966,937 (hereinafter the '937 patent, the disclosure of which is incorporated by reference herein as if set forth at length) discloses a swirler wherein the vanes of the inner duct have a spanwise distributed twist producing a desired swirl angle distribution at the inner duct outlet. The exemplary distribution places the vane chord closer to radial near the outboard/aft wall of the duct than near the inboard/fore wall (in an exemplary implementation, a rearward/aft direction being the downstream flow direction, which may be a rearward direction of the engine).
[0006] Nevertheless, there remains room for improvements in swirler construction.
SUMMARY OF THE INVENTION
[0007] One aspect of the invention involves a swirler vane pack having an array of vanes and means holding the vanes. Each of the vanes may have first and second ends with a span therebetween and a spanwise changing section.
[0008] In various implementations, a spacing between adjacent ones of the vanes may be essentially spanwise constant. The spanwise changing section may comprise a spanwise changing chord. The second end may have a chord that is 25%-75% of a chord of the first end. The spanwise changing section may comprise a spanwise monotonically changing chord. The vanes may be unitarily formed with the means. The vane first ends may be proximal of the means and the vane second ends may be distal of the means. The spanwise changing section may comprise a spanwise monotonically distally decreasing chord. The spanwise changing section may be essentially symmetric across a chord (e.g., to not provide airfoil lift). The spanwise changing section may be characterized by first and second flat facets along a major portion of a chordwise length of the vanes. Each of the vanes may be untwisted.
[0009] Another aspect of the invention involves a method for engineering the vane pack. A target change in swirl angle across a passageway associated with the vane pack is determined. A distribution of the spanwise change in section effective to achieve the target change in swirl angle at a target operating condition is determined. Lean blow out characteristics of a swirler incorporating the vane pack may be measured.
[0010] Another aspect of the invention involves a swirler assembly including a fuel injector. A bearing is coaxial with the fuel injector and has an outer surface forming a first surface of a first passageway from an inlet to an axial outlet. A prefilmer is coaxial with the fuel injector and has an inner surface forming a second surface of the first passageway and an outer surface forming a first surface of a second passageway from an inlet to an axial outlet. A first array of vanes is in the first passageway, each vane extending from a first end proximate the first passageway first surface to a second end proximate the first passageway second surface and having a section characterized by a spanwise decrease in chord of at least 25% from said first end to said second end. A second array of vanes is in the second passageway.
[0011] In various implementations, the first and second passageway inlets may be circumferential inlets. The spanwise decrease in chord may be effective to provide, at a target operating condition, a discharge profile characterized by swirl angle of: a peak value located between 0% and 25% of an exit radius; and a swirl angle of between 15° and 25° at a location between 95% and 100% of the exit radius. The spanwise decrease in chord may be effective to provide, at a target operating condition, a discharge profile characterized by a swirl angle of: a peak value located between 15% and 25% of an exit radius; and a swirl angle of between 18° and 21° at a location between 95% and 100% of the exit radius. The peak value may be in excess of 85°.
[0012] Another aspect of the invention involves a high shear design fuel injector for a combustor of a gas turbine engine. A fuel nozzle is supported at an inlet of the combustor. A first radial inlet swirler is mounted on the fuel nozzle and includes a first passage for flowing air into the combustor and is coaxially disposed relative to the fuel nozzle. A second radial inlet swirler is mounted adjacent to the first radial swirler and includes a second passage for flowing additional air into the combustor and is concentrically disposed relative to the first passage. The first radial inlet swirler has circumferentially disposed vanes. Each of the vanes has a span between first and second ends and has a spanwise change in section effective to change the swirl angle from the first end to the second end to offset the swirl to a higher level than the swirl would be without the change in section so as to produce a Rankine vortex.
[0013] In various implementations, a majority of the air in the first passage and the second passage may be in the first passage. The amount of air in the first passage may be substantially equal to 50%-95% of the total air flow in the first passage and second passage. A bulk swirl angle of air at a discharge of the second passage may be substantially between 60° and 75°.
[0014] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a longitudinal sectional view of a swirler.
[0016] FIG. 2 is an end view of a swirler vane array of the swirler of FIG. 1 .
[0017] FIG. 3 is an enlarged view of two vanes of the array of FIG. 2 .
[0018] FIG. 4 is a medial sectional view of a vane of FIG. 3 , taken along line 4 - 4 .
[0019] FIG. 5 is a leading edge view of a vane of FIG. 3 , taken along line 5 - 5 .
[0020] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0021] FIG. 1 shows a combination of a swirler assembly 20 and a fuel injector nozzle 22 . The nozzle has a distal end outlet 24 discharging a fuel spray 26 into an inner duct or passageway 28 of the swirler. The swirler and injector nozzle share a central longitudinal axis 500 . The fore end of the swirler is formed by a bearing 30 having a cylindrical interior surface 32 that closely accommodates the injector nozzle allowing relative longitudinal movement of the nozzle and swirler. The exemplary bearing has generally aft and fore surfaces 34 , 36 , 38 and 40 , 42 . The aft and fore surfaces extend between a circumferential perimeter rim surface 44 and the cylindrical interior surface 32 . In the exemplary embodiment, the aft surface has a radially-extending outboard portion 34 extending inward from the perimeter rim surface 44 , a curved portion 36 transitioning therefrom to near longitudinal, and an inboard radial rim portion 38 extending to the cylindrical interior surface 32 . The fore surface has a radially-extending outboard portion 40 and a rearwardly/inwardly tapering portion 42 extending to the cylindrical interior surface 32 . Spaced rearwardly of the bearing is a prefilmer 50 having generally aft and fore surfaces 52 , 54 , 56 and 58 , 60 . The aft surface includes a radially-extending outboard portion 52 extending inward from a perimeter rim surface 62 , a longitudinally concavely curved, rearwardly converging, transition portion 54 , and an aft rim portion 56 extending radially inward at the end of the curved portion. The fore surface includes a stepped radially-extending outboard portion 52 extending inward from the rim 62 and a longitudinally convexly curved, rearwardly converging, transition portion 60 extending therefrom to the rim 56 . The bearing aft surface and prefilmer fore surface generally cooperate to define the inner passageway 28 and an inner flowpath 502 extending radially inward from an inlet 64 and curving aft to an outlet 66 at the rim surface 56 . Air 70 entering the inlet 64 mixes with the fuel 26 in a downstream central portion of the inner passageway 28 to be expelled as a mixture from the outlet 66 .
[0022] An outer passageway 72 is formed between the prefilmer aft surface and the fore surface 74 , 76 and divergent rim surface 78 of an outer wall 80 . The outer wall 80 has an aft surface 82 , 84 . The outer wall aft and fore surfaces have radial portions 82 and 74 extending inward from a circumferential outer rim 86 and respectively transitioning to longitudinally concave and convex portions 84 and 76 meeting at the aft rim 78 . The second passageway defines a flowpath 504 from an inlet 90 between the prefilmer and outer wall outer rims 62 and 86 to an outlet 92 at the junction of the outer wall aft surface 84 and rim surface 78 . In the exemplary embodiment, the inner passageway outlet is recessed slightly behind the second passageway outlet so that the two passageways begin to merge at that point.
[0023] Inlet portions of the first and second passageways carry first and second circumferential arrays of vanes 100 and 102 so as to impart swirl to the air flowing therethrough. General operation may be as described in the '937 patent. Whereas the '937 patent discloses achieving a desired swirl profile by an appropriately distributed twist of vanes having otherwise constant section, the exemplary embodiment achieves this by varying blade section without such twist. In the exemplary embodiment, the bearing is formed with a main piece and a vane pack including the vanes 100 . A base portion 104 of the vane pack rides in a rebate in the main piece and has exposed perimeter and aft surfaces respectively forming portions of the perimeter 44 and surface 34 .
[0024] FIG. 2 shows each vane 100 as extending between leading and trailing edges 110 and 112 from a proximal end at the platform 104 to a distal end 114 . The exemplary vanes have first and second side surfaces 116 and 118 having major flat portions converging radially inward at an angle θ 1 . Exemplary θ 1 may be between 0.5° and 5°, more narrowly, 0.5° and 2°. In the exemplary embodiment, the first surface 116 of one vane is nearly parallel to the adjacent second surface 118 of the next vane. With major lengths of these surfaces being straight, a major portion of the space 119 therebetween will have nearly constant width. FIG. 2 further shows a line (or longitudinal plane) 502 extending substantially medially through one of the spaces 119 . A radial line (longitudinal radial plane) 504 intersects the line/plane 502 at a center 506 of the space 119 and is at an angle θ 2 thereto. Non-zero θ 2 is effective to impart swirl. Exemplary θ 2 may be between 5° and 45°, more narrowly, 15° and 30°.
[0025] FIG. 4 shows the vane as tapering in chord length from its proximal end 120 toward its distal end 114 . In the exemplary embodiment, the chord length near the proximal end is shown as S 1ROOT and the chord length at the distal end is shown as S 1TIP with a height from the proximal end to the distal end shown as H. FIG. 5 further shows an exemplary blending or filleting 122 along the vane sides. If such filleting is present along the leading and trailing edge portions, it may affect actual chord length. FIG. 4 further shows the exemplary trailing edge 112 as extending longitudinally. The leading edge 110 is inclined to provide the taper. In the exemplary embodiment, the leading edge (or a major portion thereof) is inclined at an angle θ 3 off vertical as measured in the section of FIG. 4 . In the exemplary embodiments, S 1TIP is ≦75% of S 1ROOT and ≧25%. Exemplary θ 3 may be between 10° and 40°, more narrowly, 15° and 30°. FIG. 3 shows a line (longitudinal plane) 510 extending through the space 119 from the intersection of the flat trailing edge 112 and the adjacent vane second side surface 118 of one adjacent vane and intersecting along the first side 116 of the other adjacent vane. FIG. 3 further shows a line 512 extending normal to that first side surface 116 from the beginning of the flat portion thereof and intersecting the second side 118 of the first vane (at the distal end 114 thereof). FIG. 3 further shows a similar line 514 at the proximal end. A separation (length) between the line/plane 510 and the second line 512 , 514 will progressively vary along the span of the vanes. The separation is shown as S 2 with specific lengths S 2TIP and S 2ROOT shown. FIG. 3 further shows S 3 as the width of the space 119 at the line/plane 510 .
[0026] The effect of the tapering vanes is to reduce the imparted swirl along the reduced chordline length. Such tapering may be used to achieve the same or similar flow properties as are identified in the '937 patent. It is noted that the exemplary embodiment of the '937 patent places the proximal ends of its vanes on the prefilmer whereas the present exemplary embodiment places the proximal ends on or near the bearing for ease of manufacturability. Accordingly, this factor should be remembered to avoid confusion. Thus, whereas the aft (proximal) ends of the '937 patent vanes are at lower angle than the fore (distal) ends the presently-illustrated embodiment has an aft (distal) chord length smaller than a fore (proximal) chord length to achieve a similar fore-to-aft swirl reduction. This, in turn, produces in a downstream portion of the first duct a tailored profile that has both a relatively low swirl value (e.g., less than 25°) near the prefilmer and a peak swirl value at a relatively high radial location inboard thereof (e.g., at least 20% of an exit radius). In the exemplary resulting stretched Rankine vortex, the peak swirl angle (90°) marks the transition between the inboard recirculation zone solid body rotation and the outboard free vortex. An exemplary range for the radius of this transition is 0-25% of the exit radius (e.g., of the surface 60 at the outlet 66 ). As the higher numbers may be more advantageous, narrower ranges of 15-25% or 20-25% may be appropriate. The swirl angle at the prefilmer may best be characterized as just outside of any boundary layer. Typically, this will fall at a radius of at least 95 % of the exit radius. This swirl angle may typically be at least 15° (e.g., 15-25° or, more narrowly, 18-21°).
[0027] The local degree of turning of the flow may be less than θ 2 if, locally, the space 119 does not have sufficient length. For the exemplary vane configuration, the turning has been observed to be substantially θ 2 where the ratio of the length S 2 to the separation S 3 is greater than approximately 0.5. Where less than this value, the turning will be incomplete and only a portion of θ 2 . In exemplary implementations, essentially full turning is desired near the front (proximal) ends of the vanes and, less than full turning is desired near the aft (distal) ends. An exemplary S 2ROOT may be greater than 0.5 and an exemplary S 2TIP may be ≦0.25. An exemplary amount of turning provided at the tip is 35%-60% of θ 2 . For other vane configurations, appropriate relationships may be determined by modeling or measurement.
[0028] One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, when the invention is applied to the reengineering of an existing swirler, details of the existing swirler and/or associated manufacturing techniques may influence details of any associated implementation. Additionally, the invention may be combined with other modifications either presently known or to be developed. Accordingly, other embodiments are within the scope of the following claims.
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A gas turbine engine combustor swirler has vanes with a spanwise chord length distribution providing a desired swirl distribution.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Section 371 of International Application No. PCT/EP2013/069787, filed Sep. 24, 2013, which was published in the German language on Apr. 10, 2014 under International Publication No. WO 2014/053351 A1, which claims the benefit of U.S. Provisional Application No. 61/710,226, filed Oct. 5, 2012, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to the production of noble metal oxalate complexes. Hereinafter, noble metal oxalate complexes shall also be referred to as noble metal oxalates for reasons of simplicity. Specifically, the invention relates to the production of noble metal oxalate complexes from noble metal precursors and oxalic acid and/or oxalic acid salts.
The production of noble metal oxalate complexes from noble metal precursors and oxalic acid and/or oxalic acid salts has been known for a long time. The production of platinum oxalate complexes usually proceeds through the reaction of platinum oxide hydrate (platinum(IV)-hydroxoacid, dihydrogenhexahydroxoplatinate(IV), hydroxoplatinic acid) and oxalic acid at a temperature of 60° C. (K. Krogmann, P. Dodel, Chem. Ber . 99, 3408-3418 (1966)).
EP 0 254 935 A1 describes a method for the production of silver oxalate having a large particle diameter. According to this method, silver salt and oxalic acid or oxalic acid salts are reacted at a pH value of no more than 5. The reaction is carried out at a temperature from 0 to 80° C., preferably at a temperature from 40 to 60° C.
The production of noble metal oxalate complexes from noble metal precursors and oxalic acid and/or oxalic acid salts is an exothermic reaction, in which heat and CO 2 are produced. The temperature can increase above the decomposition point of the noble metal oxalate complexes in the course of the reaction, which simultaneously releases more CO 2 . In this context, see, for example, Sano, Isamu; Bulletin ; 15, p. 196, “On the Catalytic Decomposition of Oxalic Acid by Colloidal Platinum” (1940), and Szabó, Z. G. and Biro-Sugar, E., Zeitschrift für Elektrochemie , vol. 50, no. 8, p. 869-874, “Kinetik der thermischen Zersetzung von Silberoxalat” (1956).
For safety reasons, when the reaction is carried out on a large scale, it is therefore necessary to take into consideration that the product must not be decomposed by heat that is produced during the reaction.
BRIEF SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a method for the production of noble metal oxalate complexes that can be carried out on a large scale. Accordingly, the method enables the course of the reaction to be controlled. It is necessary that the amounts of gas and heat produced during the synthesis can be reliably guided away from the reactor.
These objectives are met by a method for the production of noble metal oxalate complexes which comprises reacting a noble metal precursor with oxalic acid and/or oxalic acid salt, wherein the product noble metal oxalate complexes are also added to the reaction as an auto-catalyst.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
In the drawing:
FIG. 1 is a graph of heat flow as a function of temperature for a platinum oxalate solution.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides a method for the production of noble metal oxalate complexes, in which noble metal precursors are reacted with oxalic acid and/or oxalic acid salts, and in which noble metal oxalate is introduced into the reaction mixture as an auto-catalyst.
According to the invention, noble metal precursors and oxalic acid and/or oxalic acid salts are used as reactants. Many starting substances are conceivable, whereby the noble metal precursor and oxalic acid and/or oxalic acid salt reactants are obviously different from the noble metal oxalate end-product.
The term “noble metal” includes, in particular, the classical noble metals Pt, Pd, Ir, Rh, Os, Ru, Ag, and Au, and also the semi-noble metal Re. Preferred noble metals include silver, palladium, and platinum; platinum is particularly preferred.
Examples of noble metal precursors include noble metal salts and noble metal oxide hydrates. Examples of noble metal salts include noble metal nitrates, noble metal acetates, and mixtures thereof. It is also conceivable to use mixtures of a noble metal oxide hydrate and noble metal salt or salts. However, noble metal oxide hydrate, in particular platinum oxide hydrate, also referred to as platinum(IV) hydroxoacid (see Gmelin, Verlag Chemie GmbH , Berlin p. 47-48 (1940)) has proven to be preferred. The salt which is used also depends on the type of noble metal. For example, silver oxalate can be produced from silver nitrate, and it is preferable to use platinum-(IV) hydroxoacid or any of the salts thereof, such as K 2 Pt(OH) 6 , Na 2 Pt(OH) 6 etc., as starting materials for platinum oxalate. As a matter of rule, the free acid is preferred.
Oxalic acid salts may include, for example, sodium oxalate, ammonium oxalate, potassium oxalate or mixtures thereof. However, it is also feasible to use a mixture of oxalic acid and one or more oxalic acid salt(s). As before, the preferred reactants depend on the type of noble metal. Accordingly, e.g., ammonium oxalate can be used to advantage for the production of silver oxalate. However, as a matter of rule, the use of free oxalic acid is particularly preferred. Accordingly, it is also preferable to use oxalic acid for the production of platinum oxalate.
According to the invention, a combination of noble metal oxide hydrate and oxalic acid reactants is particularly preferred because only carbon dioxide and water are produced in addition to the noble metal oxalate complexes.
It is particularly preferred to add the oxalic acid or oxalic acid salt at a suitable stoichiometric ratio. Referring to the production of platinum oxalate complexes, this means that 1.8 to 2.8 molar equivalents of oxalic acid or oxalic acid salt relative to platinum in the form of the platinum precursor are added. This reaction produces a mixture of different dioxalatoplatinic acids or platinum oxalate complexes. A detailed description of mixtures of this type is in K. Krogmann, P. Dodel, Chem. Ber . 99, pp. 3402-3407 and 3408-3418 (1966).
The form in which the oxalic acid and/or oxalic acid salt is added depends on the noble metal oxalate complex to be produced. Preferably, it is added in the form of an aqueous solution or as a solid. Oxalic acid is preferred and is preferably added as a solid in the form of oxalic acid dihydrate.
The reaction is carried out at a temperature below the decomposition temperature of the noble metal oxalate complexes. For defining the safety margin for the reaction temperature in the present case, a hazard evaluation needs to be considered which takes into account important parameters of process technology, parameters of equipment technology, and considerations and data of safety technology, such as, e.g., the decomposition temperature or decomposition range of the noble metal oxalate complexes. The reaction temperature may then be adjusted to come close to the decomposition temperature as a function of the existing data.
The reaction is therefore preferably performed at a temperature below the decomposition temperature of the noble metal oxalate complexes. In this context, the difference between reaction temperature and decomposition temperature should be at least 1° C., preferably at least 5° C. The decomposition temperature is defined to be the temperature at which decomposition starts, in which the start of decomposition is determined using long-term differential thermal analysis in glass ampules at a heating rate of 0.05 K/min in accordance with DIN 51007. Proven to be preferred for the reaction of noble metal precursors and oxalic acid and/or oxalic acid salts is a temperature range between 0° C. and 56° C., particularly preferably between 30° C. and 52° C., and even more particularly preferably between 35° C. and 45° C.
Referring, in particular, to platinum oxalate complexes already decomposing at a temperature of 57° C. (see FIG. 1 ), it is preferable to carry out the reaction at a temperature of up to 56° C., particularly preferably at up to 52° C., and even more particularly preferably at up to 45° C. The reaction is carried out above 0° C., preferably above 30° C., and particularly preferably at a temperature of 35° C. to 42° C.
According to the invention, the decomposition temperature of the noble metal oxalate complexes is determined by long-term differential thermal analysis (DTA) in accordance with DIN 51007 (June 1994). The determination can be done on solutions of noble metal oxalate complexes that correspond to the product solution, in a closed glass ampule at a heating rate of 0.05 K/min between 0° C. and a temperature above the measured peak trough (see FIG. 1 ). According to the invention, the decomposition temperature shall be understood to be the temperature when the first deviation (see FIG. 1 , 57° C.) of the measuring curve from the starting baseline curve is noted (5.2 DIN 51007).
In the present case, 2934.5 mg of a 10% by weight platinum oxalate solution in water were used. The measurement proceeded in glass ampules at a heating rate of 0.05 K/min. FIG. 1 shows the heat flow W/g as a function of the temperature between 2° C. and 83° C.
In the present description, temperature-equilibrate shall be understood to mean that the reaction mixture is set to a certain temperature. The temperature equilibration can be effected, e.g., with water.
It is advantageous to first produce an aqueous solution or suspension of noble metal oxide hydrate or noble metal salt. Referring to the production of platinum oxalate complexes, it is preferred to first produce an aqueous suspension of platinum oxide hydrate (H 2 [Pt(OH) 6 ] or platinum-(IV) hydroxoacid). It is preferable to produce a 5 to 25% by weight suspension, particularly preferably a 7-15% by weight suspension relative to platinum in water.
Surprisingly, it has been found that the introduction of small amounts of noble metal oxalate complexes into the reaction mixture has an auto-catalytic effect. The addition of noble metal oxalate complexes significantly shortens the induction period of the reaction (very slow starting phase of the reaction). This enables the course of the reaction to be controlled. Therefore, the added noble metal oxalate complexes are also referred to as auto-catalysts hereinafter. According to the invention, a small amount of auto-catalyst is added. Preferably, the amount of auto-catalyst to be added is 1×10 −4 to 5×10 −2 molar equivalents of noble metal relative to the noble metal in the noble metal precursor. Particularly preferably, the amount of auto-catalyst to be added is 5×10 −4 to 1×10 −2 molar equivalents of noble metal relative to the noble metal in the noble metal precursor, and particularly preferably the amount of auto-catalyst to be added is 5×10 −4 to 7×10 −3 molar equivalents of noble metal relative to the noble metal in the noble metal precursor. It is preferable to add the auto-catalyst in aqueous solution. Customary concentrations are 5-20% by weight, e.g. 8-15% by weight.
Expediently, the noble metal oxalate complexes corresponding to the product to be produced are used as auto-catalyst (in line with the meaning of the term, “auto-catalyst”). This means that platinum oxalate is used as an auto-catalyst for the production of platinum oxalate and silver oxalate is used as an auto-catalyst for the production of silver oxalate, etc.
The order in which the noble metal precursor, auto-catalyst, and oxalic acid and/or oxalic acid salt are added is less important. The auto-catalyst may be added to the reaction solution or suspension concurrently with the total amount of oxalic acid and/or oxalic acid salt, concurrently with part of the oxalic acid and/or oxalic acid salt, or before the addition of oxalic acid and/or oxalic acid salt. A solution or a suspension of noble metal precursor may be provided first or added later in this context.
If the noble metal precursor is provided first and the auto-catalyst and oxalic acid are added concurrently, the addition should be made at a temperature below the desired reaction temperature. The addition is preferably made at a temperature of up to 37° C., particularly preferably at up to 32° C. The reaction mixture thus formed is then heated up to the desired reaction temperature. The heating rate is then a function of when the reaction starts.
However, it has proven to be advantageous to first provide the noble metal precursor in solution or suspension, then add the auto-catalyst, and to add at least the major part of the oxalic acid or oxalic acid salt only after the reaction temperature is reached.
The oxalic acid or the oxalic acid salt may be added in one or more aliquots. The aliquots may be equal in size, or multiple aliquots differing in size may just as well be added. If the aliquots differ in size, it is advantageous to first add a larger aliquot and then add one or more smaller aliquots or progressively smaller aliquots. Accordingly, it has proven to be advantageous to first add an aliquot of 0.4 to 1.4 molar equivalents relative to platinum in the form of the platinum precursor and to subsequently add, e.g., multiple equal amounts of the remaining oxalic acid or the remaining oxalic acid salt. This can be done, for example, in a single further addition of e.g., 0.4 to 1.4 molar equivalents, in two further additions of, e.g., 0.2 to 0.9 molar equivalents, in three further additions of, e.g., 0.1 to 0.7 molar equivalents, in four further additions of, e.g., 0.1 to 0.6 molar equivalents, etc. However, it is just as conceivable to add the oxalic acid or the oxalic acid salt evenly and continuously.
It is advantageous to stir the solution or suspension during the reaction. In a preferred embodiment, the oxalic acid or the oxalic acid salt is added as a function of the stirring conditions, concentration of the solution or suspension, and reactor dimensions. As a matter of principle, the rate at which oxalic acid or oxalic acid salt can be added may be set quite well based on the production of CO 2 and on the temperature profile.
Noble metal oxalate complexes produced as specified above may advantageously be used as precursors for noble metal catalysts.
EXAMPLES
The following examples serve purposes of illustration and are not to be construed as to limit the invention.
Measuring Method and Analyses
NMR and UV spectroscopy were used in the qualitative analyses. The UV spectrum was measured at room temperature using a Specord® 200 UV spectrometer made by Analytic Jena AG and 1 cm cuvettes (QS Suprasil® quartz glass cuvettes made by Heraeus Quarzglas GmbH) over a measuring range from 190 nm-1,100 nm at a resolution of 2 nm. The nuclear resonance spectroscopic measurements were carried out using a Bruker Avance 400 MHz NMR spectrometer (Reference Example 1) and a Bruker Avance 600 MHz NMR spectrometer (Example, Reference Examples 2 and 3).
The platinum content was determined by gravimetry.
The reactants used were platinum (IV) hydroxoacid (H 2 [Pt(OH) 6 ]) from in-house production (wt (Pt): 55.51%), oxalic acid dihydrate for analysis EMSURE® ACS, ISO, Reag. Ph Eur made by Merck KGaA, art. no. 100495, and platinum oxalate from in-house production (wt (Pt): 11.72%).
Example 1
Production of Platinum Oxalate at 40° C., in the Presence of Auto-Catalyst, Oxalic Acid Added in 5 Aliquots
A total of 10 g Pt (50 mmol) in the form of 18.01 g H 2 [Pt(OH) 6 ] were placed in 54.29 ml demineralized water (“VEW”) in a 250 ml three-necked round flask. Then, 0.04 g Pt oxalate (0.24 mmol Pt) were added as an auto-catalyst at room temperature (23° C.) while stirring (250 U/min) with a magnetic stirrer. A pale-greenish suspension was thus produced.
Time: 0 min: The suspension was heated in a water bath from room temperature to 40° C. over the course of 20 minutes.
Time 20 min: As soon as the temperature of the suspension had reached 40° C., one of five equal aliquots of 2.568 g (20 mmol) oxalic acid dihydrate was added. Instantaneously gas production was observed, which lasted for a period of 60 minutes. A total of 270 ml CO 2 were captured.
Time 80 min: Once gas production ceased, another aliquot of 2.568 g (20 mmol) oxalic acid dihydrate was added. A total of 40 ml CO 2 were captured.
Time 140 min: Once gas production ceased, another aliquot of 2.568 g (20 mmol) oxalic acid dihydrate was added. The color of the solution changed from green to turquoise-blue after 10 min. A total of 300 ml CO 2 were captured over the course of 60 min.
Time 200 min: Once gas production ceased, another aliquot of 2.568 g (20 mmol) oxalic acid dihydrate was added. A total of 270 ml CO 2 were captured over the course of 60 min.
Time 260 min: Once gas production ceased, another aliquot of 2.568 g (20 mmol) oxalic acid dihydrate was added. A total of 300 ml CO 2 were captured over the course of 110 min. No further gas production was observed during 10 more minutes of stirring at 40° C.
Time 380 min: The heating system was switched off and the solution was stirred until room temperature was reached. The mixture was filtered through a 0.2 μm membrane filter (Sartorius filtration unit). Filtration was carried out within 30 minutes.
A total of 74.49 g of product having a Pt content of 13.40% by weight were obtained with the yield being 99.82% relative to platinum. 13 C-NMR (151 MHz, 299.6 K, DMSO-d 6 capillary): δ=168.70; 167.16 ppm. UV-VIS: 627 nm (A=0.399); 417 nm (0.415).
Reference Example 1
Production of Platinum Oxalate at 50° C.
A total of 10 g Pt (50 mmol) in the form of 18.01 g H 2 [Pt(OH) 6 ] were placed in 54.29 ml demineralized water (“VEW”) in a 250 ml three-necked round flask. Then, 12.93 g (100 mmol) oxalic acid dihydrate were added while stirring (250 U/min) with a magnetic stirrer. A milky, yellowish-white suspension was thus produced.
Time: 0 min: The suspension was heated in a water bath at a rate of approx. 1° C./10 min starting at 19° C.
Time 180 min: The solution started to turn greenish at a temperature of 35° C.
Time 210 min: The solution turned turquoise-blue at a temperature of 38° C.
Time 220 min: The solution turned deep-blue at a temperature of 39° C.
Time 230 min: The temperature of the solution reached 40° C. Gas production was for a period of 50 min, during which the temperature of the solution reached 45° C.
Time 350 min: The temperature reached 50° C. There was no longer any gas production.
Time 510 min: The heating system was switched off, the solution was stirred further until room temperature was reached. The mixture was filtered through a 0.2 μm membrane filter (Sartorius filtration unit). Filtration was carried out within 90 minutes.
A total of 47.82 g of product having a Pt content of 20.75% by weight were obtained with the yield being 99.23% relative to platinum. 13 C-NMR (100.6 MHz, 303 K, DMSO-d 6 capillary): δ=168.43; 166.72 ppm. UV-VIS 664 nm (A=0.731); 417 nm (0.763).
Reference Example 2
Production of Platinum Oxalate at 40° C., No Auto-Catalyst
Reference Example 1 was repeated except that the solution was heated for a period of 210 minutes from 23° C. to a temperature of 40° C. The color of the solution turned greenish after 150 minutes at a temperature of 35° C. After 190 minutes, when the temperature was 37° C., the solution began to turn blueish, and after 230 minutes gas production was observed for a period of 65 minutes.
A total of 80.972 g of product having a Pt content of 12.25% by weight were obtained with the yield being 99.19% relative to platinum. 13 C-NMR (151 MHz, 298 K, DMSO-d 6 capillary): δ=168.16; 166.67 ppm. UV-VIS 641.05 nm (A=0.342); 417 nm (0.374).
Reference Example 3
Production of Platinum Oxalate at 40° C., No Auto-Catalyst, Oxalic Acid Added in 5 Aliquots
A total of 10 g Pt (50 mmol) in the form of 18.01 g H 2 [Pt(OH) 6 ] were placed in 54.29 ml demineralized water (“VEW”) in a 250 ml three-necked round flask.
Time 0 min: The suspension was heated in a water bath from 20° C. to 40° C. over the course of 40 minutes.
Time 40 min: As soon as the temperature of the suspension had reached 40° C., one of five equal aliquots of 2.568 g (20 mmol) oxalic acid dihydrate was added. Neither a color change nor the production of gas was observed. After another 60 minutes, another aliquot of 2.568 g (20 mmol) oxalic acid dihydrate was added. As before, neither a color change nor the production of gas was observed.
Time 160 min: Another 2.568 g (20 mmol) aliquot of oxalic acid dihydrate was added. Ten minutes later, the solution turned greenish. Another 30 minutes later (at 200 minutes), the color of the solution changed from green to turquoise-blue.
Time 220 min: Another 2.568 g (20 mmol) aliquot of oxalic acid dihydrate was added. Ten minutes later, gas production was observed.
Time 280 min: Another 2.568 g (20 mmol) aliquot of oxalic acid dihydrate was added. Gas production continued until the 300 minutes time point. No gas production was observed any longer after this time.
Time 330 min: The heating system was switched off. The solution was stirred further until room temperature was reached. The mixture was filtered through a 0.2 μm membrane filter (Sartorius filtration unit). Filtration was carried out within 30 minutes.
A total of 77.39 g of product having a Pt content of 12.85% by weight were obtained with the yield being 99.45% relative to platinum. 13 C-NMR (151 MHz, 299.6 K, DMSO-d 6 capillary): δ=168.16; 166.66 ppm. UV-VIS 664 nm (A=0.373); 417 nm (0.403).
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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The production of noble metal oxalate complexes from noble metal precursors and oxalic acid and/or oxalic acid salts is an exothermic reaction, in which heat and CO 2 are produced, is described. The temperature can increase above the decomposition point of the noble metal oxalate complexes in the course of the reaction, which simultaneously releases more CO 2 . For safety reasons, when the reaction is carried out on a large scale, it is therefore necessary to take into consideration that the product must not be decomposed by heat that is produced during the reaction. Therefore, according to the invention, a method for the production of noble metal oxalate complexes is provided, in which the product noble metal oxalate complexes are added to the reaction mixture as an auto-catalyst.
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BACKGROUND OF THE INVENTION
The N-methyl-3,4-dimethoxyphenylethylamine, also known under the name of N-methylomoveratrylamine, is an intermediate useful in the synthesis of a drug having coronarodilator activity, internationally known as verapamil (INN), described in the U.S. Pat. No. 3,261,859.
The synthesis of the N-methylomoveratrylamine was described both in patent documents like the unexamined japanese publication JP 77036606, the german publication DE 3338681 and the european publication EP 0233766 and in scientific publications, for instance in J. Med. Chem. 16, (6), 630-3, (1973), in J. Am. Chem. Soc. 104, (3), 877-9 (1982) and in J. Org. Chem. 52, (7), 1309-15, (1987).
In the japanese publication, the N-methylomoveratrylamine is obtained by reducing the corresponding amide by means of a mixture made by an organic acid and by sodium borohydride.
In the german publication, the veratrylcyanide is catalytically hydrogenated, by using a nickel catalyst, in the presence of a strong molar excess (10:1) of methylamine.
In the european publication EP 0233762, the N-methylomoveratrylamine is obtained by acylating the omoveratrylamine with methyl chloroformate and then by reducing the so obtained compound by means of a molar excess of lithium aluminium hydride in anhydrous tetrahydrofuran.
DESCRIPTION OF THE INVENTION
The object of the present invention is a new method for the synthesis of the N-methyl-3,4-dimethoxyphenylethylamine of formula ##STR2## also known as N-methylomoveratrylamine, starting from the 3,4-dimethoxybenzaldehyde of formula ##STR3## also known as veratraldehyde, which is submitted to the Darzens condensation by means of an alkyl ester of an α-haloacetic acid, in the presence of an alcoholate of an alkali metal or of sodium amide or sodium hydride, to give an α,β-epoxyester of formula ##STR4## wherein R represents an alkyl radical, straight or branched, containing from 1 to 6 carbon atoms, which by alkaline hydrolysis gives the alkaline salt of the epoxyacid of formula ##STR5## wherein Me + corresponds to a cation of an alkaline metal, preferably sodium or potassium, which by decarboxylation gives the 3,4-dimethoxy-benzeneacetaldehyde of formula ##STR6## which by treatment first with monomethylamine and then with sodium borohydride furnishes the N-methyl-3,4-dimethoxyphenylethylamine of formula I.
The process object of the present invention is advantageously carried out without isolating and characterizing the various intermediates of the above formulae; however, if it is wanted, the various steps of this process can also be carried out one by one, by isolating and characterizing the relating intermediates.
The process object of the present invention consists in reacting one mole of 3,4-dimethoxybenzaldehyde of formula ##STR7## with from about 1 to about 4 moles of an α-halo-ester of formula
X--CH.sub.2 --COOR VI
wherein X represents a halogen atom, preferably a chlorine atom, and R represents an alkyl radical, straight or branched, containing from 1 to 6 carbon atoms, preferably methyl, ethyl or 2-butyl, in the presence of from about 1 to about 4 moles of a base selected among an alcoholate of an alkaline metal of formula
R.sub.1 O.sup.- Me.sup.+ VII
wherein Me + represents the cation of an alkaline metal, preferably sodium or potassium, and R 1 represents an alkyl radical, straight or branched, containing from 1 to 6 carbon atoms, sodium amide or sodium hydride. Sodium methoxide, potassium tert-butoxide, sodium 2-butoxide, potassium 2-butoxide and potassium n-propoxide are the bases preferably used. The reaction takes place in a period of time comprised between about 1 and about 6 hours at a temperature comprised between about 0° C. and about 40° C. The reaction can take place with or without solvents; the aromatic hydrocarbons, preferably toluene, and the straight or branched alcohols containing from 1 to 6 carbon atoms, preferably 2-butanol, or mixtures thereof, showed to be suitable solvents.
The glycidic ester of formula ##STR8## which forms during the reaction, wherein R has the above seen meaning, generally is not isolated but it is transformed into the alkaline salt of the epoxyacid of formula ##STR9## wherein Me + corresponds to a cation of an alkaline metal, preferably sodium or potassium, through an alkaline hydrolysis carried out by treating the solution containing the epoxyester of formula III with an aqueous solution of sodium or potassium hydroxide, for a period of time comprised between about 6 and about 24 hours, at a temperature comprised between about 10° C. and about 40° C.
The salt of the epoxyacid of formula IV is then decarboxylated in acidic medium, preferably in the presence of monopotassium phosphate, at a temperature comprised between about 10° C. and about 40° C., for a period of time comprised between about 1 and about 8 hours. In this way the 3,4-dimethoxybenzeneacetaldehyde of formula ##STR10## is obtained, which by reaction with from about 1 to about 6 moles of an aqueous solution of monomethylamine, at a temperature comprised between about -10° C. and about 40° C. for a period of time comprised between about 1 and about 6 hours and a subsequent treatment with from about 0.5 to about 1 moles of sodium borohydride at a temperature comprised between about -10° C. and about 80° C. for a period of time comprised between about 2 and about 8 hours, gives the desired N-methyl-3,4-dimethoxyphenylethylamine of formula I.
The so obtained raw product can be purified either by distillation under vacuum or by crystallization of the hydrochloride obtained dissolving the product in a suitable solvent or solvent mixture and treating the solution with gaseous hydrochloric acid.
The examples below reported constitute an illustration of the present invention and are not to be taken as a limitation of it.
EXAMPLE 1
N-methyl-3,4-dimethoxyphenylethylamine
948.4 Ml of a 14.57% (w/v) solution of potassium 2-butoxide (1.23 moles) in 2-butyl alcohol are poured under stirring in about one hour into a solution of 166.2 g (1 mole) of 3,4-dimethoxybenzaldehyde in 205 ml (1.44 moles) of 2-butyl chloroacetate, while keeping the temperature between 15° C. and 20° C. The reaction mixture is kept at room temperature under stirring for another hour and then it is added in about 2 hours to a solution containing 93 g of 90% potassium hydroxide (1.49 moles) in 130 ml of water while keeping the temperature between 15° C. and 20° C. The reaction mixture is kept under stirring at this temperature for three hours, then it is left standing for 12 hours at room temperature and lastly it is cooled to 10° C. and filtered. The solid is washed with 150 ml of 2-butyl alcohol and then with 300 ml of methylene chloride and subsequently it is added portionwise to a mixture made by 500 ml of water, 500 ml of methylene chloride and 140 g of monopotassium phosphate while keeping the reaction mixture under stirring for about 2 hours at room temperature. The two layers are then separated, the aqueous phase is twice extracted with 50 ml of methylene chloride and then it is discarded, while the organic layers are collected, washed with 100 ml of water and dripped under strong stirring on 296 ml of a 33.1% (w/v) aqueous solution of monomethylamine (3.15 moles) while keeping the temperature at about -5° C. for about 2 hours. The layers are separated after addition of 4 g of sodium chloride, the aqueous layer is extracted three times with 50 ml of methylene chloride and then it is discarded while the organic layers are collected and added with 500 ml of methyl alcohol.
The mixture is added, in about one hour, with a solution containing 18.90 g (0.50 moles) of sodium borohydride in 188 ml of water containing 2 drops of a 15% (w/v) aqueous solution of sodium hydroxide while keeping the temperature between 0° C. and 5° C. The reaction mixture is kept under stirring for other 2 hours at a temperature comprised between 0° C. and 10° C. and then is added with 100 ml of a 30% (w/v) aqueous solution of sodium hydroxide and with 500 ml of water. The layers are separated, the aqueous layer is extracted three times with 100 ml of methylene chloride and then is discarded, while the organic layers are collected, washed with 250 ml of water and then are added first with 700 ml of water and then with 114 ml of 86% (w/v) sulfuric acid. The layers are separated, the organic layer is twice extracted with 100 ml of water and then is discarded, while the aqueous layers are collected, added with 600 ml of toluene and 220 ml of a 30% (w/v) aqueous solution of sodium hydroxide. The layers are separated and the aqueous layer is extracted three times with 100 ml of toluene and then is discarded, while the organic layers are collected, dried on anhydrous sodium sulfate and evaporated under vacuum to give 173.5 g of raw product.
The raw product is purified by distillation under vacuum, collecting the portion which distils between 122° C. and 127° C. under a pressure of about 2 mm of mercury. 149.4 Grams of pure product having a HPLC title of 98% are obtained with a yield equal to 76.5% calculated over the starting 3,4-dimethoxybenzaldehyde.
EXAMPLE 2
N-Methyl-3,4-dimethoxyphenylethylamine hydrochloride
910 Ml of a 15.15% (w/v) solution of potassium 2-butoxide (1.23 moles) in 2-butyl alcohol are added under stirring in about 2 hours to a solution containing 166.2 g (1 mole) of 3,4-dimethoxybenzaldehyde in 210 ml (1.48 moles) of 2-butyl chloroacetate while keeping the temperature at about 15° C.
The reaction mixture is kept under stirring at room temperature for further 30 minutes and then is added in 45 minutes with 50 ml of water and in 90 minutes with a solution containing 92 g of 85% potassium hydroxide in 75 ml of water while keeping the temperature at about 20° C. The reaction mixture is kept under stirring at about 20° C. for 15 hours and then it is filtered; the solid is added portionwise under stirring in about one hour to a mixture made by 500 ml of toluene, 500 ml of water, 67.8 g of 85% potassium hydroxide and 70 ml of 85% (w/w) phosphoric acid, while keeping the temperature at about 20° C. and going on with the stirring at this temperature for further two and half hours.
The layers are separated and 175 ml of a 40% (w/v) aqueous solution of monomethylamine (2.25 moles) are added under stirring in about one hour to the organic layer while keeping the temperature at about 10° C. The reaction mixture is kept under stirring at this temperature for another hour and half, then it is cooled to about 5° C., added with 150 ml of methanol, further cooled to -5° C. and added in about one hour with an aqueous solution containing 18.90 g (0.50 moles) of sodium borohydride in 39 ml of water containing 2 drops of a 30% (w/v) aqueous solution of sodium hydroxide. The reaction mixture is kept under stirring another hour at -5° C., then in one hour the temperature is brought to 25° C. The reaction mixture is kept at this temperature for one hour, at 40° C. for one hour, at 50° C. for one hour and at 68° C. for another hour. Subsequently, 250 ml of water are added to the reaction mixture and the layers are separated. The aqueous layer is twice extracted with 60 ml of toluene and then is discarded, the organic layers are collected and added with 250 ml of water and 100 ml of 32% (w/v) aqueous hydrochloric acid. The layers are separated after 30 minutes, the organic layer is discarded while the aqueous layer is concentrated under vacuum until elimination of the methanol present, then it is twice washed with 100 ml of methylene chloride, put again under vacuum in order to eliminate the traces of the organic solvent and lastly added with 240 ml of toluene and 100 ml of a 30% (w/v) aqueous solution of sodium hydroxide. The two layers are separated, the aqueous layer is twice extracted with 80 ml of toluene and then is discarded. The toluene layers are collected and evaporated under vacuum to give a residue which is dissolved in a mixture made by 480 ml of acetone and 24 ml of water. Gaseous hydrochloric acid is added until acidic pH to the resulting solution which subsequently is cooled under stirring to 5° C. for one hour and the resulting suspension is filtered. The solid on the filter is washed with acetone and dried in oven under vacuum.
159 Grams of N-methyl-3,4-dimethoxyphenylethylamine hydrochloride are obtained with a yield of 69% calculated over the starting 3,4-dimethoxybenzaldehyde.
EXAMPLE 3
N-Methyl-3,4-dimethoxyphenylethylamine hydrochloride
The product is prepared according to the same conditions and amounts referred to in example 2, by using the 1,1,1-trichloroethane as solvent instead of the toluene.
152 Grams of product are obtained with a yield of 66% calculated over the starting 3,4-dimethoxybenzaldehyde.
EXAMPLE 4
N-Methyl-3,4-dimethoxyphenylethylamine hydrochloride
948.4 Ml of a 14.57% (w/v) solution of potassium 2-butoxide (1.23 moles) in 2-butyl alcohol are added under stirring in about one hour to a solution of 166.2 g (1 mole) of 3,4-dimethoxybenzaldehyde in 205 ml (1.44 moles) of 2-butyl chloroacetate while keeping the temperature between 15° C. and 20° C. The reaction mixture is kept under stirring for another hour at room temperature and then is added in about 2 hours to a solution containing 93 g of 90% potassium hydroxide (1.49 moles) in 130 ml of water while keeping the temperature between 15° C. and 20° C. The reaction mixture is kept under stirring at room temperature for 15 hours and then is added in about one hour to a mixture made by 780 ml of water, 109.2 ml of 85% (w/w) phosphoric acid, 99.84 g of 90% potassium hydroxide and 100 ml of toluene, keeping the reaction mixture under stirring at about 20° C. for another hour. Subsequently the layers are separated, the aqueous layer is extracted with 50 ml of toluene and then is discarded, while the organic layers are collected, washed with 100 ml of a 10% (w/v) aqueous solution of anhydrous sodium sulfate and added under stirring to 300 ml of a 33.1% (w/v) aqueous solution of monomethylamine (3.19 moles) while keeping the temperature between 10° C. and 15° C.
The reaction mixture is kept under these conditions for one hour, then it is cooled until 0° C. in one hour and is added with an aqueous solution containing 18.90 g (0.5 moles) of sodium borohydride in 39 ml of water alkalinized with two drops of a 30% (w/v) aqueous solution of sodium hydroxide. The reaction mixture is kept one hour at 0° C. under stirring and subsequently it is slowly heated till the temperature of about 78° C. A 32% (w/v) aqueous solution of hydrochloric acid is added to the reaction mixture, cooled to room temperature, until pH 2 and then the layers are separated.
The organic layer is discarded, while the aqueous phase is twice washed with 100 ml of methylene chloride, then it is added with 250 ml of toluene and brought to alkaline pH by adding 100 ml of a 30% (w/v) aqueous solution of sodium hydroxide.
The layers are separated, the aqueous layer is twice extracted with 100 ml of toluene and then is discarded, while the toluene solutions are collected and evaporated under vacuum giving a residue which is dissolved in a mixture of 480 ml of acetone and 24 ml of water where gaseous hydrochloric acid is bubbled till acidic pH. The suspension, after one hour of cooling to 5° C. under stirring, is filtered and the obtained solid is washed with acetone and dried in oven under vacuum. 145.5 Grams of pure product are obtained with a yield of 63% calculated over the starting 3,4-dimethoxybenzaldehyde.
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New process for the synthesis of the N-methyl-3,4-dimetoxyphenylethylamine of formula ##STR1## intermediate in the synthesis of the drug internationally known as verapamil. The process starts from the 3,4-dimethoxybenzaldehyde which, by means of a Darzens condensation, gives an epoxyester that, by alkaline hydrolysis and subsequent decarboxylation, gives the 3,4-dimethoxyphenylacetaldehyde. This aldehyde gives the amine of formula I by reaction with monomethylamine followed by reduction with sodium borohydride.
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[0001] This application claims the benefit of U.S. Ser. No. 60/494,398 filed Aug. 12, 2003, which disclosure is incorporated herein by reference.
BACKGROUND
[0002] Several types of color displays are known for use in mobile devices. These known devices have limitations however, including high power consumption requirements and limited color saturation capabilities. Limited color saturation refers to situations in which the display cannot distinctly display subtle color changes. An example of such a known display is an Organic Light-Emitting Diode (OLED) display. A single pixel 10 of an OLED is shown in FIG. 1 . Each pixel of an OLED has a set of three color emitters 12 : red 12 a , green 12 b , and blue 12 c . Colors other than red, blue and green are generated by illuminating more than one emitter at different intensities. OLED is an emissive display technology, so no backlight is required, but when the OLED is turned off the display is no longer readable. OLED displays generally demonstrate good color saturation, but they consume significant power.
[0003] Another type of known color display is a field sequential liquid crystal display (FS LCD). An illustration of an FS LCD 20 is shown in FIG. 2 . FS LCD technology does not utilize OLED type color emitters or other known types of filters. An FS LCD panel utilizes a tri-color backlight 22 , typically with red 24 , green 26 , and blue 28 colors and a light guide 30 . Behind the light guide 30 is a reflector 32 and in front of the light guide 30 is a liquid crystal layer 34 between top 36 and rear 38 pieces of glass. Liquid crystal layer 34 can be, for example, a monochrome thin film transistor (TFT) display. As illustrated in FIG. 3 , in an FS LCD, the tri-color backlight 22 turns on and off individual colors one by one at a rate higher than the human eye can differentiate so that the viewer perceives a composite color made of the individual colors lit during a cycle. As shown in FIG. 3 , different fields of the liquid crystal layer 34 can be set to pass light as the individual backlights are illuminated. FIG. 3 shows red 40 , blue 42 , and green 44 fields being sequentially formed as the respective backlight is illuminated to form a composite image 46 . A wide array of colors can be created with this technique.
[0004] The rate of the sequence and the time that each backlight is illuminated is a function of, and limited by, the response time of the liquid crystal layer 34 . A sixty (60) Hertz frame rate is achieved in the example shown in FIG. 3 by tripling the frame rate of the liquid crystal to 180 Hertz and displaying each color for one-third of the time or 60 or 180 cycles in a second. By this method the human eye perceives a composite image 46 as shown in the center of FIG. 3 . If the response time of a liquid crystal is slowed, then eventually the user will be able to see the sequence of the backlight colors. When the rate is slow enough for the user to perceive the sequence of backlights, the user will have difficulty perceiving composite colors and will most likely see fragments of color. Color fragmentation also occurs or becomes more severe when the user either moves with respect to the display or experiences certain vibrations, such as on a bumpy car or train ride. Any degree of color fragmentation makes it difficult for the user to perceive the data being displayed, as individual images or characters may appear blurred. An ideal liquid crystal layer 34 for an FS LCD 100 would have a response time fast enough that users would not see the individual sequencing of the primary colors.
[0005] When color fragmentation becomes a problem for the user, one solution is to turn off the multi-color backlight 22 , and use the FS LCD 20 as a black on “white” display. The “white” background in this mode is created by ambient light being reflected off the reflector 32 located at the back of the display. In this mode of operation, however, the black characters created by the liquid crystal have shadows caused by reflections of the characters off the reflector 32 . Due to shadows and the passive nature of reflected ambient light this mode also has a low contrast ratio.
SUMMARY
[0006] A device and a method for establishing a monochromatic background light source in an electronic device with a field sequential liquid crystal display are provided. The device comprises a field sequential liquid crystal display with a liquid crystal layer and a plurality of color backlights, and a control module. To achieve a monochromatic background light source behind the liquid crystal display, the control module controls the continuous illumination of one or more of the plurality of color backlights. The method comprises continuously illuminating one or more of the plurality of color backlights to provide a monochromatic background light behind the liquid crystal display. The intensities of the one or more of the plurality of color backlights may be selected to achieve a user selected color, or the intensities may be chosen to reduce power consumption. The monochromatic mode may be selected while in another mode of operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a diagram illustrating an organic light emitting diode (OLED).
[0008] FIG. 2 is a diagram showing a field sequential liquid crystal display (FS LCD).
[0009] FIG. 3 is a diagram showing a FS LCD scanning sequence.
[0010] FIG. 4 is a block diagram of a FS LCD device using simultaneous rather than sequential backlighting.
[0011] FIG. 5 is a block diagram of the FS LCD device shown in FIG. 4 with only the red backlight active.
[0012] FIG. 6 is a block diagram of a mobile device with an FS LCD display using simultaneous rather than sequential backlighting.
DETAILED DESCRIPTION
[0013] FIG. 4 is a block diagram of a FS LCD device 100 using a continuous monochromatic display mode rather than the standard sequential color FS LCD mode. For simplicity, FIG. 4 shows a liquid crystal layer 102 on top of red 104 , green 106 , and blue 108 backlights. It should be understood, however, that the red 104 , green 106 , and blue 108 backlights may be located remote from each picture element and a light guide may transmit the light components to the picture elements (as shown in FIG. 2 ). Liquid crystal layer 102 can be, for example, a thin film transistor (TFT) display. A control module 110 controls the power levels of each backlight, and also controls the liquid crystal layer 102 using control lines 112 . The control module may be a dedicated unit or may be integrated with other functional components of an electronic device.
[0014] In FIG. 4 , each of the three backlights is outputting a different power level simultaneously, as indicated by the wavelength intensity bars for blue 114 , red 116 , and green 118 . In this embodiment, the blue wavelength intensity bar 114 is the brightest, the green wavelength intensity bar 116 the next brightest, and the red wavelength intensity bar 118 the least brightest. When the intensity of each color is fixed and the backlights are illuminated continuously, the user perceives a single composite color. Under these conditions, characters formed by the liquid crystal layer 102 are contrasted by a monochromatic display color. This continuous mode of operation of the backlights provides a constant background color that does not flicker.
[0015] By adjusting the intensity of the red 104 , green 106 , and blue 108 backlights, the control module 110 can select a wide range of colors to be displayed as a background, and allows the FS LCD 100 to operate in a transmissive monochromatic display mode. The contrast of a transmissive display is significantly higher than the contrast of a reflective display. Additionally, because the backlight is providing the light source, the shadow effect caused by characters formed on the liquid crystal reflecting off a reflector may be eliminated.
[0016] FIG. 5 shows an alternative continuous monochromatic display mode. In FIG. 5 , only the red 116 backlight is active and the user of the display will see a monochromatic red background on the FS LCD screen. In this mode, the control module 110 has only activated the red 116 backlight. By selectively activating a single backlight, power may be conserved. Other power conservation modes are possible by, for example, selectively activating the most power efficient color backlight, lowering the intensity of a single backlight, or by forming a composite color of multiple backlights illuminated at a low intensity. The intensity level of the backlights can be specified by the user. The contrast afforded characters formed on the liquid crystal of the display may depend on the intensity level of the backlights, which may be specified by the user to provide an acceptable contrast level.
[0017] The continuous monochromatic display modes described above can be selected while in another mode of operation. For example, if the user wanted to conserve power in order to extend battery life, he could switch to the continuous monochromatic display mode. Further, if the user was experiencing color separation in a standard FS LCD mode due to movement or vibration, he could switch to the continuous monochromatic display mode.
[0018] The frame rate frequency in the continuous monochromatic display modes described above can be any rate achievable by the liquid crystal. For example, the frame rate frequency in regular sequential color operation of an FS LCD may be 180 Hertz and the monochromatic display mode may continue this frame rate frequency. As a further example, because the backlights are operating continuously rather than sequentially, the frame rate frequency could be reduced. The frame rate frequency of the liquid crystal can be reduced to any level, however, below approximately 24 Hertz the human eye can detect individual frames. Preferably, the frame rate frequency is decreased to between about 24 and about 70 Hertz, more preferably between about 24 and about 40 Hertz, and even more preferably to about 24 Hertz. Reducing the frame rate of the liquid crystal also provides power savings.
[0019] FIG. 6 is a schematic diagram of a mobile device 200 that could be used with an FS LCD 100 as described above. The mobile device 200 may, for example, be a two-way communication device having voice and data communication capabilities. The mobile device may also be operable to communicate with other computer systems on the Internet. Depending on the functionality provided by the device, the device may be referred to as a data messaging device, a two-way pager, a cellular telephone with data messaging capabilities, a wireless Internet appliance, a data communication device, or by other names
[0020] Where the mobile device 200 is enabled for two-way communications, it incorporates a communication subsystem 202 , including a receiver 204 and a transmitter 206 , as well as associated components such as one or more, preferably embedded or internal, antenna elements 208 and 210 , local oscillators (LOs) 212 , and a processing module such as a digital signal processor (DSP) 214 . The particular design of the communication subsystem 202 may be dependent upon the communication network in which the device is intended to operate. For example, a mobile device 200 may include a communication subsystem 202 designed to operate within the Mobitex™ mobile communication system, the DataTAC™ mobile communication system, a CDMA network, an iDen network, or a GPRS network.
[0021] Network access requirements may also vary depending upon the type of network 216 . For example, in the Mobitex and DataTAC networks, mobile devices 200 are registered on the network using a unique identification number associated with each mobile device. In GPRS networks however, network access is associated with a subscriber or user of a mobile device 200 . A GPRS mobile device therefore requires a subscriber identity module, commonly referred to as a SIM card, in order to operate on a GPRS network. Without a valid SIM card, a GPRS mobile device may not be fully functional. Local or non-network communication functions, as well as legally required functions (if any) such as “911” emergency calling, may be operable, but the mobile device 200 may be unable to carry out any other functions involving communications over the network 216 .
[0022] When required network registration or activation procedures have been completed, a mobile device 200 may send and receive communication signals over the network 216 . Signals received by the antenna 208 through a communication network 216 are input to the receiver 204 , which may perform such common receiver functions as signal amplification, frequency down conversion, filtering, channel selection and the like, and in the example system shown in FIG. 6 , analog to digital conversion. Analog to digital conversion of a received signal allows more complex communication functions, such as demodulation and decoding, to be performed in the DSP 214 . In a similar manner, signals to be transmitted are processed by the DSP 214 and input to the transmitter 206 for digital to analog conversion, frequency up conversion, filtering, amplification and transmission over the communication network 216 via the antenna 210 .
[0023] The DSP 214 may also provide receiver and transmitter control. For example, the gains applied to communication signals in the receiver 204 and transmitter 206 may be adaptively controlled through automatic gain control algorithms implemented in the DSP 214 .
[0024] The mobile device 200 may include a microprocessor 222 , which controls the overall operation of the device. Communication functions, such as data and voice communications, are performed through the communication subsystem 202 . The microprocessor 222 also interacts with further device subsystems such as the FS LCD 100 , flash memory 224 , random access memory (RAM) 226 , auxiliary input/output (I/O) subsystems 228 , serial port 230 , keyboard 232 , speaker 234 , microphone 236 , a short-range communications subsystem 238 and any other device subsystems generally designated as 240 .
[0025] Some of the subsystems shown in FIG. 6 perform communication-related functions, whereas other subsystems may provide “resident” or on-device functions. Some subsystems, such as keyboard 232 and FS LCD 100 , may be used for both communication-related functions, such as entering a text message for transmission over a communication network, and device-resident functions such as a calculator or task list.
[0026] Operating system software used by the microprocessor 222 may be stored in a persistent store, such as flash memory 224 , a read only memory (ROM), or similar storage element. The operating system, specific device applications, or parts thereof, may be temporarily loaded into a volatile store such as RAM 226 . Received communication signals may also be stored to RAM 226 .
[0027] As shown, the flash memory 224 can be segregated into different areas for computer programs and program data storage 242 . These different PIM storage types indicate that each program can allocate a portion of flash memory 224 for its database requirements. The microprocessor 222 , in addition to its operating system functions, may enable execution of software applications on the mobile device. A predetermined set of applications that control basic operations, such as data and voice communication applications may normally be installed on the mobile device 200 during manufacturing. For example, one software application may be a personal information manager (PIM) application operable to organize and manage data items relating to the user of the mobile device such as, but not limited to, e-mail, calendar events, voice mails, appointments, task items, or others. One or more memory stores may be available on the mobile device to facilitate storage of PIM data items. Such PIM application may have the ability to send and receive data items via the wireless network 216 . In a preferred embodiment, the PIM data items are seamlessly integrated, synchronized and updated, via the wireless network 216 , with the mobile device user's corresponding data items stored or associated with a host computer system. Further applications may also be loaded onto the mobile device 200 through the network 216 , an auxiliary I/O subsystem 228 , serial port 230 , short-range communications subsystem 238 or any other suitable subsystem 240 , and installed by a user in the RAM 226 or preferably a non-volatile store for execution by the microprocessor 222 .
[0028] In a data communication mode, a received signal such as a text message or web page download is processed by the communication subsystem 202 and input to the microprocessor 222 , which may further processes the received signal for output to the display 100 or to an auxiliary I/O device 228 . A user of mobile device 202 may also compose data items, such as email messages, using the keyboard 232 , which is preferably a complete alphanumeric keyboard or telephone-type keypad, in conjunction with the display 422 and possibly an auxiliary I/O device 228 . Such composed items may be transmitted over a communication network through the communication subsystem 202 .
[0029] For voice communications, overall operation of the mobile device 200 is similar, except that received signals may be output to a speaker 234 and signals for transmission may be generated by a microphone 236 . Alternative voice or audio I/O subsystems, such as a voice message recording subsystem, may also be implemented on the mobile device 200 . Although voice or audio signal output is preferably accomplished primarily through the speaker 234 , the FS LCD 100 may also be used to provide an indication of the identity of a calling party, the duration of a voice call, or other voice call related information for example.
[0030] The serial port 230 may be implemented in a personal digital assistant (PDA)-type mobile device to synchronize with a user's desktop computer. A serial port 230 may enable a user to set preferences through an external device or software application and may provide a path for information or software downloads to the mobile device 200 other than through a wireless communication network. The serial port 230 may, for example, be used to load an encryption key onto the device through a direct and thus reliable and trusted connection to thereby enable secure device communication.
[0031] A short-range communications subsystem 238 may be included to provide communication between the mobile device 200 and different systems or devices. For example, the subsystem 238 may include an infrared device and associated circuits and components or a Bluetooth™ communication module to provide for communication with similarly-enabled systems and devices.
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A device and a method are provided for establishing a monochromatic background light source in an electronic device with a field sequential liquid crystal display. The device and method provide for the continuous illumination of one or more of a plurality of color backlights of a field sequential liquid crystal display to provide a monochromatic source of light behind the liquid crystal layer of the display. The intensities of the one or more of the plurality of color backlights may be selected to achieve a user selected color, or the intensities may be chosen to reduce power consumption. The monochromatic mode may be selected while in another mode of operation.
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BACKGROUND OF THE INVENTION
This invention relates to a novel method of screening and identification of anti-amebic drugs. More particularly, the invention relates to an assay that utilizes the ability to inhibit anaerobic growth of a novel bacterial mutant for identifying therapeutic agents effective against parasitic diseases and which thereby bypasses the conventional need for a parasitic culture.
(Note: Literature references on the following background information and on conventional test methods and laboratory procedures well known to the ordinary person skilled in the art, and other such state-of-the-art techniques as used herein, are indicated in parentheses, and appended at the end of the specification.)
The intestinal protozoan parasite Entamoeba histolytica (E. histolytica) causes amebic dysentery and amebic liver abscess, which are associated with significant morbidity and mortality worldwide. Amebiasis is currently treated with the drug metronidazole which remains an effective agent in most cases. However, side effects associated with metronidazole (1,2), and the growing problem of metronidazole resistance among other protozoan parasites such as Trichomonas vaginalis (3-5) and Giardia lamblia (6,7), has fueled interest in developing new anti-amebic agents.
E. histolytica is an anaerobic eukaryote which lacks mitochondria, and ferments glucose to acetaldehyde and alcohol with pyruvate and acetyl-CoA as intermediates (8,9). Recently, a potential target for anti-amebic chemotherapy was identified in the (E. histolytica) alcohol dehydrogenase/acetaldehyde dehydrogenase (EhADH2) molecule (10). EhADH2 is a bifunctional AND + -linked enzyme with both alcohol dehydrogenase (ADH) and acetaldehyde dehydrogenase (ALDH) activity, and is believed to be responsible for catalyzing two key steps in the E. histolytica fermentation pathway (9-11).
Because of the critical role of EhADH2 in the amebic fermentation pathway, and the lack of known eukaryotic homologues of the EhADH2 enzyme, EhADH2 represents a potential target for anti-amebic chemotherapy. However, screening of compounds for anti-amebic activity is hampered by the cost of large scale growth of E. histolytica and difficulties in quantitating drug efficacy in vitro by the cumbersome methods for measuring growth inhibition by counting viable trophozoites.
Accordingly, a method for the screening and identification of anti-amebic drugs which does not depend on the need for a parasitic culture would have substantial use in the pharmaceutical industry.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention, a rapid assay is provided for screening and identifying compounds with anti-EhADH2 activity. The assay utilizes the ability of the target compounds to inhibit anaerobic growth of a novel bacterial mutant that expresses the EhADH2 gene.
EhADH2 is a bifunctional gene that encodes an E. histolytica alcohol dehydrogenase (ADH) and acetaldehyde dehydrogenase (ALDH). The EhADH2 cDNA clone has an open reading frame of 2610 nucleotides encoding a 870-amino acid peptide with a predicted mol. wt. of 95,758 Daltons (10). It has about 48% amino acid homology with the multifunctional enzyme encoded by the E. coli adhE gene (10).
As used herein, the EhADH2 gene is expressed in a novel mutant strain of E. coli carrying a deletion of the adhE gene (ΔadhE). Said mutant strain is designated herein as E. coli/EhADH2. Expression of the functional EhADH2 protein in E. coli, restores the ability of the mutant E. coli strain to grow under anaerobic conditions. That is, by using a plasmid containing the EhADH2 cDNA to complement an E. coli strain with an engineered deletion of the adhE gene, a mutant E. coli is produced that requires the E. histolytica enzyme for anaerobic growth.
Suitable expression vectors for expression of EhADH2 in E. coli are illustratively constructed from the conventional T7 promoter based vector pET3a and recA promoter based vector pMON2670. The pET3 vectors contain a T7 promoter inserted into the BamHI site of the multicopy plasmid pBR322 in the orientation that transcription is directed counterclockwise, opposite to that from the tet promoter. In pET3a, the GGA triplet of the BamHI site is in the open reading frame (18). The pET3a vector also is commercially available from Novagen, Madison, Wis.
The recA promoter-based vector pMON2670 is described in U.S. Pat. No. 5,436,138 and is available without restriction from the American Type Culture Collection, Rockville, Md., under accession number ATCC 68218.
This plasmid is based on pMON5515 described by Olins et al., Gene 73, 227-235 (1988). It has an ampicillin resistance marker (AMP r ) and ColE1 replicon (ori-ColE1), the nalidixic acid-inducible E. coli recA promoter and the g10-L ribosome binding site.
In addition, pMON2670 carries a T7 transcription terminator (T7 ter).
This plasmid also contains an irrelevant coding region, namely a portion of the human proANF gene (atrial natriuretic factor, atriopeptigen) downstream of the g10-L ribosome binding site.
Unique NcoI, NdeI and HindIII restriction sites permit the simple removal of the irrelevant coding region.
The assay method of the invention thus comprises identifying anti-amebic compounds having anti-EhADH2 activity by screening the target compounds for the ability to inhibit the anaerobic growth of the E. coli/EhADH2 strain. That is, the E. coli/EhADH2 cell mutant is cultured under anaerobic cell culture conditions, a pre-determined or known quantity of the agent to be tested or target compound is combined with the cell culture, and the combination is then monitored to determine the inhibitory effect upon the anaerobic growth of the E. coli/EhADH2 cell mutant.
Conventional cell culture media for the maintenance and propagation of E. coli, e.g., M9 minimal medium agar, can be used for the anaerobic cell culture conditions.
In a preferred embodiment of the invention, the inhibition of anaerobic bacterial growth is monitored or quantitated by measuring the optical density (O.D.) of the cell culture at 600 nm following a predetermined period of time after inoculation with the target compound, e.g., at 24 and/or 48 hours after inoculation. The effect of the target compound on the resulting cell growth is measured as a change in the turbidity of the cell culture.
Since the EhADH2 is a AND + -dependent bifunctional enzyme with alcohol dehydrogenase (ADH) and acetaldehyde dehydrogenase (ALDH) activities which also uses Fe 2+ as a cofactor, the ADH and ALDH activities of the culture supernatant can also be readily determined spectrophotometrically by measuring the decrease in absorbance at 340 nm following oxidation of NADH to AND. This is based on the fact that reduced nicotinamide adenine dinucleotide (NADH) absorbs light with a peak at 340 nm, while the oxidized form (AND) shows no absorption between 300 and 400 nm.
Target compounds that are capable of inhibiting anaerobic growth, but not aerobic growth of the E. coli/EhADH2 strain in the method of assay defined herein, are useful inhibitors of EhADH2 activity and, therefore, potential therapeutic agents effective against parasitic diseases.
DETAILED DESCRIPTION OF THE INVENTION
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as forming the present invention, it is believed that the invention will be better understood from the following detailed description of preferred embodiments of the invention taken in conjunction with the appended drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show Expression of EhADH2 by E. coli. FIG. 1A shows Coomassie blue staining of SDS-PAGE separated lysates from:
Lane 1, BL21(DE3);
Lane 2, BL21(DE3)/pET3a;
Lane 3, BL21(DE3)/pET/EhADH2;
Lane 4, SHH31;
Lane 5, SHH31(DE3)/pET/EhADH2;
Lane 6, SHH31/pMON2670;
Lane 7, SHH31/pMON/EhADH2.
A band at 96 kDa (arrow) is seen in lysates from strains expressing EhADH2 (lanes 3,5,7) and not from control strains.
FIG. 1B shows immunoblotting of lysates with anti-EhADH2 serum. Lane assignments are identical to FIG. 1A; Lane 8 is lysates from E. histolytica HM1:IMSS. A species at 96 kDa is detected in E. coli lysates expressing EhADH2 (lanes 3,5,7) and in E. histolytica (lane 8). Molecular weight standards (in kDa) are indicated at the right of each of FIGS. 1A and 1B.
FIG. 2 shows purification of recombinant EhADH2. Coomassie blue staining is shown for SDS-PAGE separated samples of:
Lane 1, lysate of SHH31(DE3)/pET/EhADH2;
Lane 2, 35% ammonium sulfate precipitate fraction of lysates from lane 1;
Lane 3, fraction containing EhADH2 obtained from the gel filtration of ammonium sulfate precipitated lysates (lane 2) on a column of SEPHAROSE CL-6B Gel Filtration Media.
FIG. 3 shows complementation of E. coli ΔadhE strain SHH31 by expression of EhADH2.
Under aerobic conditions (culture A), all E. coli strains grow.
Under anaerobic conditions (culture B), SHH31 expressing EhADH2 (SHH31/pMON/EhADH2) can grow (colonies indicated by "X"), but SHH31 transformed with the pMON2670 vector alone (colonies marked by "Y"), or untransformed SHH31 (colonies marked "Z"), show no growth.
FIG. 4 is a graphical representation which shows inhibition on the anaerobic growth of ΔadhE mutant E. coli complemented with EhADH2 by pyrazole. SHH31/pMON/EhADH2 was inoculated on the M9 minimal liquid media containing pyrazole at the indicated concentrations (mM), and incubated aerobically (dotted lines) or anaerobically (solid lines) for two days. Optical densities (O.D.) at 600 nm were read at 1 and 2 days post-inoculation to assess the growth of the bacteria.
FIG. 5 is a graphical representation which shows pyrazole inhibits E. histolytica growth. Culture tubes containing E. histolytica HM1:IMSS trophozoites with an inoculation dose of 4×10 3 /tube were incubated for four days with pyrazole in concentrations ranging from 5 to 40 mM. The number of viable amebic trophozoites (E. histolytica trophozoites/ml) at 2 and 4 days post-inoculation is indicated.
The EhADH2 molecule is a bifunctional AND + /Fe 2+ -dependent enzyme with both ADH and ALDH activities (10,11).
It appears to be a critical enzyme in the amebic glucose to ethanol pathway, catalyzing two reactions (acetyl-CoA to acetaldehyde and acetaldehyde to ethanol) in fermentation (8,9).
The EhADH2 molecule is homologous to certain enzymes present in facultatively or obligate anaerobic bacteria (12-14).
The prototype of these enzymes is the E. coli AdhE molecule, an AND + -dependent enzyme which also uses Fe 2+ as a cofactor, and possesses ADH, ALDH, and pyruvate-formate-lyase deactivase activities (12-21).
The AdhE enzyme is required for anaerobic growth of E. coli, and expression of this gene is induced by anaerobic conditions (24).
In addition to its critical role in the amebic fermentation pathway, the EhADH2 molecule may serve other functions in E. histolytica as well.
The EhADH2 protein was originally isolated because of its ability to bind extracellular matrix proteins such as laminin and fibronectin (10), and it has been recently shown that the EhADH2 molecule, or an isoform, is shed or secreted by amebic trophozoites (25).
The assay method of the invention is based on the successful expression of a functional EhADH2 molecule in E. coli. The initial approach was to express EhADH2 as either a GST- or 6His-fusion protein. However, in both cases while a fusion protein was successfully expressed, it had no enzymatic activity.
This contrasts with the findings for the NADP + -dependent ADH of E. histolytica (EhADH1), which retained ADH activity as a GST-fusion protein (26).
This difference may reflect a requirement for multimer formation for EhADH2 activity which could not be achieved by fusion proteins.
Both the native EhADH2 enzyme and the homologous E. coli AdhE enzyme form multimers that array into helical structures of up to 100 nm (when viewed by electron microscopy) called spirosomes (11,21).
The functional recombinant EhADH2 enzyme that was produced in E. coli had a molecular mass of greater than 200 kDa by gel filtration, consistent with multimer formation. The purified recombinant enzyme was used to look at the substrate specificity of EhADH2.
The K m values for ethanol, AND + , NADH, and acetyl-Co-A were comparable to those obtained for the native enzyme (11), while values for acetaldehyde were somewhat higher than those seen with the native enzyme.
It was demonstrated that in addition to ethanol, the primary alcohols butanol and propanol are substrates for EhADH2, but methanol, retinol, isopropanol and sec-butanol are not.
The substrate specificity of the ADH portion of EhADH2 clearly differs from the NADP + -dependent EhADH1 which preferentially utilizes branch-chained alcohols (26).
No structural homologue to the full length EhADH2 has yet been found among eukaryotic ADH or ALDH enzymes, although there are eukaryotic ALDH enzymes with some homology to the N-terminal (ALDH) domains of EhADH2 and related prokaryotic molecules (13).
The unique structure of the EhADH2 molecule among eukaryotic ADH molecules and its critical role in the amebic fermentation pathway make it an ideal target for anti-amebic chemotherapy.
However, the cost of growing E. histolytica in culture, and the cumbersome methods for measuring growth inhibition (counting viable trophozoites), make large-scale screening of compounds for anti-amebic activity difficult.
To solve this problem, a screening system was developed for compounds with anti-EhADH2 activity which utilizes inhibition of anaerobic bacterial growth (easily quantitated by measuring the O.D. of liquid bacterial cultures) to identify effective compounds.
An E. coli strain was produced that requires EhADH2 activity to grow under anaerobic conditions by using the EhADH2 gene to complement a mutant strain of E. coli containing an engineered deletion in the adhE gene. Compounds capable of inhibiting anaerobic, but not aerobic growth of this strain, are potential specific inhibitors of EhADH2 activity.
The feasibility of this approach was tested using the compound pyrazole, which is known to inhibit AND + -dependent ADH enzymes. Pyrazole inhibited anaerobic but not aerobic growth of the E. coli SHH31/pMON/EhADH2 strain, and consistent with this finding, pyrazole was shown to inhibit both E. histolytica trophozoite growth and the purified recombinant EhADH2 enzyme at similar concentrations, indicating the effects of pyrazole on E. coli anaerobic growth and E. histolytica growth were based on inhibition of EhADH2.
In this regard, while the NADP + -dependent EhADH1 molecule is also inhibited by pyrazole (26), the K i for pyrazole and EhADH1 is 1.4 μM, a concentration range where pyrazole had no effect on E. histolytica growth. Thus, while pyrazole does not represent an ideal candidate for a specific EhADH2 inhibitor, its use in this screening assay demonstrates that this approach can identify compounds with anti-EhADH2 activity.
The growth requirements and complex life cycles of a number of parasites can make the identification of new anti-parasitic drugs and susceptibility testing of existing compounds difficult and costly endeavors. In addition, genetic systems which allow targeted mutations are poorly developed or non-existent for a number of protozoan and helminthic parasites.
The assay method of the invention for rapidly identifying specific inhibitors of the parasitic enzyme takes advantage of the presence of homologous genes in E. coli and the parasite E. histolytica which encode an enzyme required for a selectable function (the ability to grow anaerobically):
the ability to generate bacteria with mutations of that gene, and
the ability to complement that mutation with the parasitic gene.
The use of bacteria to bypass the need for parasite culture in the initial screening process for anti-parasitic agents can greatly simplify and reduce the cost of identifying new therapeutic agents effective against parasitic diseases.
In order to illustrate the invention in further detail, the following specific laboratory examples were carried out with the results indicated. Although specific examples are thus illustrated, it will be understood that the invention is not limited to these specific examples or the details therein.
EXAMPLES
Materials and Methods
E. coli and E. histolytica strains and culture conditions. Conventional E. coli strains, DH5α, BL21(DE3), and SHH31 (Δadh zch::Tn10 fadR met tyrT) (15) were used for transformation and the expression of recombinant EhADH2. Aerobic cultures were grown in LB medium with agitation at 37° C. For anaerobic growth, bacteria were incubated in anaerobic jars, BBL®GasPak® System under an H 2 -CO 2 atmosphere generated by BBL GAS PAK Anaerobic System Envelopes (Becton Dickinson, Cockeysville, Md.).
Anaerobic indicator strips were used to ensure anaerobic conditions. M9 minimal medium used for anaerobic growth was supplemented with glucose at 0.25%, thiamine (1 mM), CaCl 2 (0.1 mM), MgSO 4 (1.2 mM), and the following trace minerals: Fe(50 μM), Se(5 μM), Mo(5 μM), Mn(5 μM) (16).
Anaerobic liquid cultures were grown without agitation in tubes inside the anaerobic jars at 37° C. Solid media contained 1.5% Bacto Agar (Difco, Detroit, Mich.). Trophozoites of E. histolytica HM1:IMSS were cultured axenically in BYI-S-33 medium by conventional procedure as previously described (17).
Construction of the EhADH2 Expression Vectors
Two expression vectors were employed for prokaryotic expression of EhADH2, the T7 promoter-based vector pET3a (Novagen, Madison, Wis.) (18), and the recA promoter-based vector pMON2670 (19). As used herein, pET refers to pET3a, and pMON refers to pMON2670.
The sequences flanking the EhADH2 coding region were modified by the incorporation of a BamHI site next to the termination codon TAA at the 3' end of EhADH2, and a NcoI site at the initiating ATG codon using PCR with the EhADH2 cDNA as the template (10).
The EhADH2 sequence was then ligated in frame into NcoI and BamHI digested pET3a as two fragments, NcoI/PstI and PstI/BamHI to construct the expression vector pET/EhADH2. To construct pMON/EhADH2, the coding sequences were ligated in frame into NcoI/SacI digested pMON2670 as two fragments, NcoI/PstI and PstI/SacI.
Expression of Recombinant EhADH2 in E. Coli SHH31 (ΔadhE)
EhADH2 was first expressed in E. coli SHH31 using the pMON/EhADH2 vector. Subsequently, the SHH31 strain was lysogenized by λDE3 using a lysogenization kit (Novagen) according to the manufacturers product protocol. EhADH2 was then expressed in SHH31 (DE3) using the pET/EhADH2 vector. SDS-PAGE analysis of bacterial lysates for expression of recombinant EhADH2 was performed by conventional methods as previously described (20).
Western blotting was performed using a 1:500 dilution of rabbit antiserum raised to a recombinant 6His-EhADH2 fusion protein using previously described conventional methods (20). Complementation of the ΔadhE mutation by EhADH2 was tested by measuring the anaerobic growth of E. coli SHH31 transformed with pMON/EhADH2 on minimal glucose media compared with that of E. coli SHH31 transformed with pMON2670.
Assay of Alcohol Dehydrogenase (ADH) and Acetaldehyde Dehydrogenase (ALDH) Activity of Bacterial Lysates and Purified Recombinant EhADH2.
ADH activity of the supernatant fraction from bacterial lysates, or of the purified recombinant enzyme was assayed spectrophotometrically by measuring the decrease in absorbance at 340 nm following the oxidation of NADH to AND (21). The cuvette contained 6 mM DTT, 5 mM MgSO 4 , 0.1 mM Fe(NH 4 ) 2 (SO 4 ) 2 , 0.4 mM NADH, 10 mM acetaldehyde, and 0.1 M MOPS-KOH buffer (pH 7.5) to give a final volume of 1.0 ml. MOPS=3- N-Morpholino!propanesulfonic acid; DTT=dithiothreitol.
ALDH activity was assayed using the same method, with the substitution of 0.1 mM acetyl-CoA for acetaldehyde in the reaction buffer. A unit of enzyme activity is defined as the micromoles of product formed per min of incubation at room temperature.
To study the substrate specificity and kinetics of the purified recombinant EhADH2 molecule, the spectrophotometric assay of ADH activity was again utilized, with 5 μg of the purified enzyme in the presence of 50 mM glycine/NaOH buffer (pH 9.5) containing 6 mM DTT, 5 mM MgSO 4 , 0.1 mM Fe(NH 4 ) 2 (SO 4 ) 2 , 1 mM AND + , and varying concentrations of the substrate alcohol to be tested (11). The K m and K cat values expressed were determined using non-linear regression to fit the values for initial velocity and substrate concentration to the Michaelis-Menten equation.
Purification of recombinant EhADH2
A one-liter culture of E. coli SHH31(DE3) carrying pET/EhADH2 was grown overnight under aerobic conditions. The bacteria were collected by low speed centrifugation, resuspended in 20 mM MOPS-KOH buffer (pH 7.5), disrupted by sonication, and sedimented by centrifugation at 150,000 g for 1 h at 4° C.
The supernatant was brought to 35% saturation with solid ammonium sulfate and stirred for 1 hr at 4° C. The suspension was centrifuged at 15,000 g for 20 min at 4° C.
The supernatant was dialyzed extensively against 20 mM MOPS-KOH (pH 7.5), and chromatographed over a 1.6 cm×90 cm Sepharose® CL-6B (Sigma, St. Louis, Mo.) gel filtration column equilibrated with 20 mM MOPS-KOH buffer. Using a flow rate of 0.4 ml/min, fractions were collected and screened for AND + dependent ADH activity.
EhADH2 Inhibition Assay
E. coli SHH31 transformed with pMON/EhADH2 were inoculated into M9 minimal liquid medium and grown under anaerobic or aerobic conditions in the presence or absence of pyrazole (Sigma Chemical Co., St. Louis, Mo.) at concentrations of 5 to 20 mM. Growth was monitored by determining the optical density (O.D.) at 600 nm at 24 and 48 hrs post-inoculation. To study inhibition of E. histolytica growth, standard culture tubes containing an initial inoculation of 4×10 3 /tube E. histolytica HM1:IMSS trophozoites were incubated for four days in the presence or absence of pyrazole at concentrations of 5 to 40 mM. Viable trophozoites were counted using a hemacytometer at days 2 and 4, and the number of trophozoites/ml recorded.
RESULTS
Expression of Functional EhADH2 in E. Coli
Nucleotides 3 through 2,620, representing the entire coding region of the EhADH2 cDNA clone, were first expressed as glutathione-S-transferase (GST) and 6His-EhADH2 fusion proteins, using the pGEX-KG (22), and pQE (Qiagen, Chatsworth, Calif.) vectors, respectively. However, neither recombinant fusion protein possessed detectable ADH or ALDH activity.
The 6His-EhADH2 recombinant protein was purified and used to generate a specific anti-EhADH2 antiserum. The EhADH2 protein was expressed without a fusion partner using the pET/EhADH2 construct as described in "Materials and Methods". As shown in FIG. 1A, E. coli BL21(DE3) containing the pET/EhADH2 plasmid produced a protein at 96 kDa (the predicted size of the EhADH2 protein) (lane 3), while E. coli BL21(DE3) transformed with the pET3a vector alone did not show a species at 96 kDa (lane 1).
To confirm that the species at 96 kDa was EhADH2, Western blotting of the SDS-PAGE separated bacterial lysates with antiserum to the 6His-EhADH2 recombinant protein was performed. Anti-EhADH2 antiserum bound to the species at 96 kDa in lysates from BL21(DE3) expressing pET/EhADH2 (FIG. 1B, lane 3), but not in control lysates of BL21(DE3) transformed with the pET vector alone (FIG. 1B, lane 1).
The ADH and ALDH activity of the recombinant EhADH2 protein was first assessed by measuring the enzymatic activity of lysates obtained from aerobically grown E. coli expressing the pET/EhADH2 plasmid, and E. coli BL21(DE3) containing the pET vector alone. As shown in Table 1 below, lysates from pET/EhADH2-transformed bacteria expressing the 96 kDa EhADH2 enzyme, had high levels of ADH and ALDH activity when compared to lysates from control E. coli BL21(DE3) containing the pET vector alone.
EhADH2 Can Complement (ΔadhE) in E. coli SHH31
In order to determine whether the EhADH2 gene product would complement the E. coli adhE gene, EhADH2 was expressed in E. coli SHH31 (ΔadhE) (15). This strain produces no AdhE enzyme, and is unable to grow in M9/glucose minimal media under anaerobic conditions (15).
As shown in FIG. 3, E. coli SHH31 transformed with pMON/EhADH2 was able to grow on M9 minimal medium agar under both aerobic and anaerobic conditions, while E. coli SHH31 transformed with pMON alone could only grow under aerobic conditions. Thus, the product of the amebic EhADH2 gene can complement the E. coli (ΔadhE) mutation.
It was confirmed that SHH31 was producing the EhADH2 protein by examining bacterial lysates from both SHH31 transformed with pMON/EhADH2 and lysogenized SHH31(DE3) expressing the pET/EhADH2 vector. As shown in FIG. 1A, expression of EhADH2 was detected in SHH31/pMON/EhADH2 (lane 7), and SHH31(DE3)/pET/EhADH2 vector (lane 5).
The identity of the 96 kDa species as EhADH2 was confirmed by Western blotting using anti-EhADH2 antiserum (FIG. 1B, lanes 5 and 7). Lysates obtained from both SHH31(DE3) transformed with pET/EhADH2 and SHH31 transformed with pMON/EhADH2 contained detectable ADH and ALDH activity (Table 1) while lysates from the parent strains showed no detectable ADH or ALDH activity.
Purification and Determination of the Substrate Specificity of Recombinant EhADH2
By expressing EhADH2 in E. coli SHH31, a source of recombinant EhADH2 was obtained without any possible contamination by the bacterial AdhE enzyme. Because greater ADH and ALDH activity was detected in lysates from SHH31(DE3)/pET/EhADH2 (Table 1), this system was utilized for purification of recombinant EhADH2.
Purification of recombinant EhADH2 from lysates of pET/EhADH2 transformed E. coli SHH31(DE3) was accomplished using ammonium sulfate precipitation and gel filtration on Sepharose® CL-6B (FIG. 2). Purity was assessed using Coomassie staining of SDS-PAGE separated fractions (FIG. 2) and measuring ADH activity.
The purified recombinant EhADH2 retained both ADH and ALDH activity (Table 2). Based on gel filtration, the molecular mass for the recombinant EhADH2 enzyme was greater than 200 kDa; a similar pattern was seen with the purification of the native E. histolytica enzyme (11), and suggests the recombinant enzyme forms multimers similar to those seen with the E. coli AdhE protein and native EhADH2 (11).
The purified recombinant enzyme was used to study the substrate specificity of EhADH2. It was found that only the primary alcohols ethanol, 1-propanol, and butanol, were substrates for the enzyme (Table 2). No reactivity with isopropanol or sec-butanol was detected, and neither retinol nor methanol were substrates for the enzyme.
These results are similar to those seen with the E. coli AdhE enzyme which uses ethanol, 1-propanol, and 1-butanol as a substrate, but does not used methanol or secondary or branched chain alcohols. The K m value obtained for the recombinant EhADH2 enzyme for ethanol (85 mM) is essentially identical to that reported for the native EhADH2 enzyme (80 mM) (11), as were the K m values for AND + and NADH, while the K m value for acetaldehyde was somewhat higher than that reported for native enzyme (0.15 mM) (11).
The K m for the E. coli AdhE enzyme for ethanol is 30 mM. Measurements of ALDH activity confirmed the identity in substrate specificity between the recombinant and native EhADH2 enzymes, as K m values for acetyl-Co-A and NADH were essentially identical between the recombinant and native enzymes (11).
Screening For Compounds With Anti-EhADH2 Activity Using E. Coli SHH31 transformed with pMON/EhADH2
The successful complementation of the ΔadhE E. coli strain SHH31 by EhADH2, and the demonstration that the recombinant EhADH2 enzymes substrate specificity appears identical to the native EhADH2 enzyme, provided a useful system for the rapid screening of compounds to identify those capable of inhibiting EhADH2. In this protocol compounds can first be administered to E. coli SHH31 expressing EhADH2, and the effect of the compound on both aerobic and anaerobic growth of the bacteria measured. Compounds which specifically inhibit EhADH2 should inhibit anaerobic growth of SHH31/pMON/EhADH2, but should not significantly alter aerobic growth of this strain.
Compounds with inhibitory activity on anaerobic bacterial growth can then be screened for their effects on amebic growth, and for their ability to inhibit the recombinant EhADH2 enzyme.
To determine whether such a screening system was feasible, an illustrative study was performed by using the compound pyrazole, which is known to be a potent inhibitor of AND + -dependent alcohol dehydrogenases (23). As shown in FIG. 4, pyrazole in a dose-dependent manner significantly inhibited the anaerobic growth of SHH31/pMON/EhADH2, but had a much reduced effect on SHH31/pMON growing under aerobic conditions.
It was then examined whether pyrazole could inhibit the growth of E. histolytica trophozoites. As shown in FIG. 5, pyrazole, at a concentration of 20 to 40 mM significantly inhibited amebic growth. Finally, the K i of pyrazole for the recombinant EhADH2 molecule was measured and found to be 7.24 mM.
TABLE 1______________________________________Comparison of the NAD.sup.+ dependent ADH and ALDHactivities in the crude lysates of E. coli expressing EhADH2 andcontrol strains.E. coli strains ADH ALDH______________________________________BL21 (DE3) with pET/EhADH2 524 90SHH31 (DE3) with pET/EhADH2 417 72SHH31 with pMON/EhADH2 82 14BL21 (DE3) (control) ND NDSHH31 (control) ND ND______________________________________
Values are represented as milliunit (mU)/mg. A unit (U) of enzyme activity is defined as a micromole of product formed per minute of incubation.
TABLE 2______________________________________Enzyme activities and K.sub.m values of the purified recombinant EhADH2. K.sub.cat (mol substrate/Reactions mol of enzyme/min K.sub.m (mM)______________________________________acetaldehyde + NADH 854 acetaldehyde 2.9 NADH 0.28acetyl-CoA + NADH 154 acetyl-CoA 0.04 NADH 0.17ethanol + NAD.sup.+ 461 ethanol 85 NAD.sup.+ 0.551-propanol + NAD.sup.+ 326 1-propanol 40 NAD.sup.+ 0.25______________________________________
Various other examples will be apparent to the person skilled in the art after reading the present disclosure without departing from the spirit and scope of the invention. It is intended that all such other examples be included within the scope of the claims appended hereto.
References
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There is disclosed an assay method of screening and identification of anti-amebic drugs which utilizes the ability to inhibit anaerobic growth of a novel bacterial mutant that expresses the EhADH2 gene and which bypasses the conventional need for a parasitic culture. The novel mutant, designated E. coli/EhADH2, is cultured under anaerobic conditions, a predetermined or known quantity of the agent to be tested or target compound is combined with the cell culture, and the combination is then monitored to determine the inhibitory effect upon the anaerobic growth of the E. coli/EhADH2 cell mutant.
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention relates to improved thermally insulated window sash constructions and a uniquely configurated framing element for use therein.
2. Description Of The Prior Art
Numerous types of window constructions have been used previously in an effort to resist undesired heat loss from a building or undesired heat gain into a building. It has been known to place "storm windows" on the exterior of regular windows to minimize air leakage, conduction of heat and undesired condensation on the window interior during cold weather.
It has also been known to employ windows having two or more panes of glass with a dead air space therebetween. In connection with such windows which have been evacuated and sealed, problems have been encountered with air leakage and undesired condensation of moisture between the two panes of glass. Also, it has been known to employ metal frames such as aluminum frames for such windows. As aluminum is a good conductor of heat, condensation on the frames has resulted. Also, the aluminum surface could oxidize, scratch, pit or dent. It has also been known to provide thermal breaks in such frames to minimize thermal conduction through the sash frame.
It has also been known to employ vinyl sash frames in an effort to minimize heat conduction through insulated replacement window sash frames.
While a number of the above-described advances in the art have served to improve the efficiency through reductions in undesired heat transfer through conduction or leakage as well as condensation, there remains a very real and substanial need for further improvements in thermally insulated windows.
SUMMARY OF THE INVENTION
The present invention has met the above-described need. A window sash frame may have horizontal rails and vertical members or stiles employing a framing element of the identical cross-section. Rails may have a hollow chamber for insertion of reinforcing means. The sash frame may be established by thermally welded jointure, as by a miter joint of the rails to the stiles. The glazing strip may be secured to each framing element so as to permit replacement of glass without requiring full disassembly or destruction of the sash frame. The lower extremity of the framing element for the sash may be so configurated as to be adapted to be used in combination with a wide variety of types of windows such as a double hung, sliding, single hung and pivoting ventilator type windows, for example.
The rail assembly may be such as to permit effective mechanical securement of handle elements and latch and keeper elements with anchorage being effected in metal reinforcing members.
It is an object of the present invention to provide a window sash member which is adapted to permit integral reinforcing means to be incorporated within rail members.
It is another object of the present invention to provide such a window sash member wherein a uniquely configurated sash framing element may be employed in both rails and vertical members.
It is a further object of the present invention to minimize tolerance problems and leakage through joints between vertical members and rails by providing a thermally effected welded joint for such connections.
It is a further object of the present invention to provide such a window construction which is adapted to be made of a material having a low thermal conductivity.
It is a further object of the present invention to provide such a sash construction wherein glass replacement may be effected readily by removing the glazing strips.
It is a further object of the present invention to provide such a sash framing element which is adapted to cooperate with a wide variety of types of window frames.
It is a further object of the present invention to provide such a window sash construction wherein effective means for resisting undesired conduction of heat through the window and seepage of air and moisture condensation through the window are all accomplished in an economical and aesthetically pleasing fashion.
These and other objects of the invention will be more fully understood from the following description of the invention on reference to the illustrations appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a form of double hung window employing sash members of the present invention.
FIG. 2 is a partially exploded, fragmentary perspective view showing a portion of a joint between a sash rail member and sash vertical member of the present invention.
FIG. 3 is a front elevational view of a portion of a sash framing element of the present invention.
FIG. 4 is an end elevational view of the framing element of FIG. 3.
FIG. 5 is a top plan view of the framing element of FIG. 3.
FIG. 6 is a front elevational view of a portion of a glazing strip of the present invention.
FIG. 7 is a left-hand elevational view of the glazing strip of FIG. 6.
FIG. 8 is a top plan view of the glazing strip of FIG. 6.
FIG. 9 is a front elevational view of a cap member employable in the present invention.
FIG. 10 is an end elevational view of the cap member of FIG. 9.
FIG. 11 is a top plan view of the cap member of FIG. 9.
FIG. 12 is a cross-sectional view of a portion of the sash member of the present invention.
FIG. 13 is a fragmentary perspective view of a portion of the window sash and a portion of the window sill.
FIG. 14 is an exploded view of a portion of the window sash showing the handle.
FIG. 15 is a fragmentary perspective view showing a portion of a sash framing element with the handle attached.
FIG. 16 is a fragmentary perspective view of a sash framing member showing a latch keeper.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more specifically to FIG. 1, there is shown a window 2 which, in the form shown, is a double hung window having an upper sash 4 and a lower sash 6. As the window sill 8 jambs 10, 12 and head 14 do not form part of the invention per se, they may take any form which is structurally compatible with the unique window sash member of the present invention.
The upper sash 4 has a bottom rail 20, a top rail 22 and vertical members or stiles 24, 26. A glass pane 28 is retained in place by glazing strips 30, 32, 34, 36. Similarly, bottom sash 6 has a bottom rail 40, a top rail 42 and vertical members or stiles 44, 46. Glass pane 50 is retained in position by glazing strips 56, 58, 60, 62. Handles 70, 72 are secured to the upper rail 22 of upper sash 4 and handles 74 76 are secured to lower rail 40 of the bottom sash 6. Rotating latch members 80, 82 are secured to upper rail 42 and cooperate with associated keepers (not shown) in lower rail 20 of upper sash 4 to provide a locked position wherein relative movement between the sash members 4, 6 is prohibited.
One of the principal elements of the present invention is the uniquely configurated sash framing element and the associated components which combine to create the rail or vertical member construction. These features will be discussed in detail with reference to FIG. 2 and other associated figures.
Before getting into the structural details, a standard of orientational reference will be defined in order to facilitate clarity of disclosure. It will be appreciated that the sash framing element 100, as shown in FIGS. 2 and 4, will be in various positions with respect to the sash frame depending upon whether it is in the position of lower rail, upper rail or either vertical member. For convenience of description, with reference to the structure shown in FIGS. 2 and 4, a direction moving vertically through the structure toward the upper end of the drawing page will be considered upwardly, the reverse direction will be considered downwardly and a direction perpendicular to the upward and downward directions will be referred to as transverse. A direction moving from either outer extremity transversely toward the interior of the shape will be considered transversely inwardly.
Referring in greater detail to FIGS. 2-5, details of the sash framing element 100 will be considered. The sash framing element 100 is shown in the position of the lower rail. It has a first sidewall 102 and a second sidewall 104 which is disposed generally parallel with respect to the first sidewall 102. The first sidewall 102 has a greater vertical extent than the second sidewall 104. A first transverse wall 108 connects the sidewalls 102, 104 as does a second transverse wall 110. The first and second transverse walls 108, 110 cooperate with portions of the first sidewall 102 and second sidewall 104 to define a first elongated hollow chamber 112 which, in the form shown, is substantially rectangular.
First sidewall 102 terminates in a transversely inwardly directed flange 116 and second sidewall 104 terminates in a transversely inwardly directed flange 114. These portions of the sidewalls cooperate with first transverse wall 108 to define a generally downwardly open recess 118.
Interior wall 120 has its lower end connected to second transverse wall 110 and its upper end connected to third transverse wall 122, thus defining a second hollow chamber 125. Third transverse wall 122 projects from first sidewall 102 and beyond transverse wall 122 in the form of extension 124. Generally transversely inwardly directed flange 126 on second sidewall 104 cooperates with portions of second transverse wall 110, third transverse wall 122 and extension 124 thereof to define a generally upwardly open recess 128.
The portion of first sidewall 102 which projects upwardly beyond third transverse wall 122 has been designated 132 and has a pair of inwardly projecting ribs 134, 136 which serve to define a gasket retaining recess 138.
As is shown in FIG. 2, vertical framing member 140 has substantially the identical cross-sectional configuration as rail framing element 100. These elements are shown as being joined at a miter joint 142 which in the preferred practice of the present invention is effected by welding. One of the shortcomings of prior systems involved difficulty in achieving the desired joint due to components which might be slightly out of tolerance in respect of dimension or shape and the further problem that miter joints have been known to leave gaps through which undesired air infiltration can occur. In the present system, the rail member 100 and vertical member 140 are subjected to local elevation of temperature at their free ends and under the influence of pressure, while subjected to the elevated temperature, are caused to self bond through welding action thereby creating the precise desired leak-free joint. As a result of the manner in which the glass panes are retained in the sash of the present invention, it is possible and preferred to effect all four joints between the rails and vertical members through this welding action.
It will be appreciated that the rail framing element 100, except for the joint area, preferably has a substantially uniform cross-sectional configuration throughout its longitudinal extent. If desired, weep holes may be provided in portions of first transverse wall 108 and second transverse wall 110 in order to permit any moisture entering recess 128 to drain downwardly and out of the structure through recess 118. Such local weep hole discontinuities shall not be deemed for purposes of the present disclosure to depart from the cross-sectional configuration being "substantially" uniform throughout the longitudinal extent of the rail member. Similarly, the stile member 140 has a framing element which preferably has a substantially uniform cross-sectional configuration throughout its longitudinal extent. In the preferred embodiment of the invention, the cross-sectional configuration of the rail members and vertical or stile members are substantially identical. This serves to facilitate use of a single extrustion die in manufacturing the component and permits a single profile to be used for both purposes.
Referring still to FIG. 2, there is shown a preferred form of reinforcing member 150. In a preferred practice of the invention, the rail and vertical framing members will be formed by extrusion and be composed of a resinous plastic material such as vinyl, for example. While these resinous plastic materials are preferably substantially rigid, in order to further strengthen the structure, it is preferred that reinforcing member such as that identified by the reference number 150 be provided substantially coextensively with the rail members, but not within the vertical members, although they could be employed in both types of elements should such usage be desired. In the form illustrated, the reinforcing member is a hollow, generally rectangularly configurated element having its major axis in a transverse direction. Generally parallel walls 152, 154 are separated by walls 156, 158. The reinforcing member may preferably be metal such as an aluminum extrusion, for example. A preferred feature of this form of reinforcing member is that it substantially completely fill the peripheral portions of recess 112. It will be noted that fin elements 162, 164, 166, 168 project transversely from the reinforcing member. This serves to reduce the amount of metal which comes into contact with sidewalls 102, 104 within recess 112 thereby minimizing the likelihood of the reinforcing member permitting meaningful conductive heat transfer through the sash framing member.
Referring to FIGS. 1, 2 and 6 through 8, a preferred form of glazing strip will be considered. It is this glazing strip in combination with the uniquely configurated sash framing member which permits glass to be replaced in the sash without requiring destruction of the miter joint created frame. The glazing strip 170 is generally L-shaped and has a first leg 172 and a second leg 174. Leg 174 terminates in an enlargement 175 which is intended to be engaged under third transverse wall extension 124. A pair of transversely inwardly directed ribs 176, 178 project from leg 172 and are adapted to be in engagement with one surface of one of the glass panes. Another feature of this "drop in" glazing which is best shown in FIGS. 1 and 6 is the biased edge 180 which mates with a similar edge of the adjacent glazing strip. This creates a mitered appearance. It is preferred that this miter line be generally aligned with miter joint 142 of the frame (FIG. 2).
Referring to FIGS. 2 and 9 through 11, the form of cap member which is adapted to be used with the sash rails is shown The cap member 190 has a main web 192 and a pair of transversely outwardly projecting flanges 194, 198 which respectively define recesses 196 and 200 which in turn receive flanges 116, 114. This permits the cap to be inserted through relative longitudinal sliding movement between the sash frame member and the cap thereby closing recess 118. If desired, weep holes (not shown) may be provided in web 192.
In the event the sash frame is employed with other types of windows, different attachments may be secured to this portion of the sash framing members. Roller inserts, for example, could be secured within recess 118.
It will be appreciated that the sash framing assembly is preferably composed substantially completely of a synthetic resinous material with the exception of the reinforcing member 150. This serves to provide the desired thermal insulation while establishing other desired performance characteristics. This material serves to eliminate the need for undesired painting, resists chipping, scratching and other aesthetically unpleasing changes in the article.
Referring to FIG. 12, there is shown a cross-sectional illustration of a sash frame of the present invention. The sash in this embodiment has three panes of glass 202, 204, 206 which are disposed in generally parallel spaced relationship. Pane 202 is supported adjacent its periphery on one surface by gasket 210 which is secured in the recess defined within sidewall 102. In the preferred form as shown, the gasket 210 has a generally T-shaped configuration with shoulders 211, 212 interposed between glass pane 202 and ribs 134, 136 of leg 102 to resist contact therebetween. Among the preferred materials for gasket 210 is ethylene propylene diene methane which is offered under the trade designation EPDM by Lauren Manufacturing Company, of New Shiloh, Ohio. Pane 206 has contact along its periphery with transversely inwardly projecting ribs 176, 178 of glazing strip 170. It is noted that the glazing strip as a result of the undercut in the lower leg 174 (FIG. 7), is received on flange 126 (FIG. 4) of sidewall 104 and has its enlarged portion 175 underlying projection 124 of third transverse wall 122.
Interposed between glass panes 202 and 204 are gasket member 214 and overlying spacer 220 which may take the form of a tubular aluminum extrusion. Similarly, panes 204, 206 are provided with a gasket 216 and an overlying spacer 224. In the form shown, the spacer 224 has been filled with a suitable dessicant in order to absorb any moisture which might be contained within the air trapped between the panes 204, 206.
Referring to FIGS. 2 and 12, should it be desired to replace the glass in the window, all that is required is that the glazing strips 170 be removed. This permits free withdrawal of the glass pane assembly in a direction toward the left as shown in FIG. 12. The replacement glass may then be inserted and the glazing strips 170 replaced. In general, it will be preferred that the three panes of glass be pre-assembled and that their edges be sealed throughout thereby creating a unitary assembly.
Referring to FIG. 13, there is shown sash framing member 100 positioned in overlying supported relationship with respect to a window frame member 240. In this embodiment the modified cap member 190' has a generally downwardly projecting seal 230 which has an upper portion 234 and depending resilient tapered portions 236. Window frame portion 240 has inwardly open channel 244 which supports a gasket 246 which is in contact with leg 104 to effect a seal. Seal 230 has a rearwardly open channel 242 which is adapted to receive a gasket (not shown) for sealing engagement with stepped surface 248 of window frame portion 240. In the form illustrated the window frame portion 240 has a stepped upper member 250 which is in interlocked supported relationship with respect to extrusion 252. In this manner the window sash when in closed position is in sealing contact with respect to the window frame. It will be appreciated that window frames of various slopes may be employed with the sash of the present invention.
As is shown in FIGS. 14 and 15 the invention is adapted to provide firm securement of the window handles to the sash frame. The rail 260 is secured to vertical sash member 262 and has a notch 264. Fastener receiving holes 266, 268 are formed in transverse wall 269. Handle 270 has a gripping portion 272 and an anchoring portion 274. Anchoring portion 276, 278 are adapted to receive fasteners such as screws 286, 287 which will be anchored in reinforcing member 280. In this manner the handle will be effectively anchored with the axis of the fasteners being oriented generally in the direction of window sash movement.
In FIG. 16, there is shown a sash framing member 300 which is notched to receive a latch keeper 302 which is anchored by suitable fasteners such as screws 304, 305 to reinforcing member 306. A rotatable latch member secured to another sash in a similar manner (not shown) will be rotated into and out of recess 310.
While for purposes of convenience of illustration herein the preferred system employing three panes of glass has been shown, it will be appreciated that the present invention may also be employed with two panes of glass. For example, with reference to FIG. 12, if pane 204 were to be eliminated, a gasket bridging the gap between panes 202 and 206 and a spacer similarly bridging the gap could be provided.
It will be appreciated, therefore, that the present invention has solved a number of previously unsolved problems in respect of providing a functionally effective, aesthetically pleasing, thermally insulated sash member employing multiple panes of glass. In a preferred form, a resinous plastic material provides a framing element which may be employed for both rails and vertical members or stiles and is adapted to cooperate with reinforcing members and suitable glazing strips to thereby provide sufficient strength and structural integrity while facilitating ease of glass replacement and through the use of the welded miter joints, elimination of undesired tolerance and leakage problems. All of this is accomplished in a simple and efficient manner.
Whereas particular embodiments of the invention have been described above for purposes of illustration, it will evident to those skilled in the art that numerous variations of the details may be made without departing from the invention as defined in the appended claims.
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A window sash member is composed of a pair of rail members and a pair of vertical sash members or stiles which may each include a framing element having a unique cross-sectional configuration. The sash member is so constructed as to permit replacement of glass panes without destroying the integrity of the frame. This is accomplished by removing a series of glazing strips. A hollow defined within the framing element provides the rails with a reinforcing member which has fins to minimize undesired thermal conduction across the frame. A downwardly open recess is defined within the framing element so as to permit it to be employed with a wide variety of window frame elements and adapting it for use in a wide variety of types of windows. The rails are preferably joined to the stiles by welding. The sash framing element is particularly adapted to be used with insulated windows having two or three panes of glass which define a thermally insulating dead air space therebetween. The sash framing elements are preferably composed of a synthetic resinous material.
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FIELD OF INVENTION
This invention relates to network systems and more particularly to a system for the fast reliable transfer of data relating to objects from one node of a network to another where respective processes are running.
BACKGROUND OF INVENTION
In the case where a number of users on a network wish to share data such as graphical objects in a virtual reality scene and to be able to communicate changes in those objects to processes running at each of the nodes, there is a need for a fast and reliable updating system so that each user may quickly and reliably know what changes one user wishes to transmit. For instance, assuming there is a group of asynchronous processes interacting via the shared data-object model of distributed shared memory or some similar sharing model where the processes share objects; and further assuming that this group is possibly communicating over a network, possibly geographically separated and possibly participating in a distributed virtual environment, then the goal is to simultaneously achieve: first, rapid interaction to maximize the speed of communication of object changes in order to achieve near real-time interaction; second, low bandwidth to minimize the communication bandwidth used; third, reliability to guarantee that object changes are eventually, if perhaps sometimes slowly, successfully communicated between the processes; and fourth rapid joining to allow a new user to join a communication group and rapidly become up to date on what all the other processes know.
In the following description, assume that the data to be interactively worked on resides in a world model which is used to describe the set of all objects being shared at any given moment.
When considering how to achieve the above goal, it is important to consider the following spectrum of ways that objects can change. A communications solution must work acceptably at all points of this spectrum and should work particularly well at whatever points are most likely in a particular application.
At one extreme, some objects change very frequently, e.g., tens of times a second or more. For many applications, it matters very little to recover a particular lost message describing a change, because it is not liable to be possible to do so before the change is rendered obsolete. Rather, the focus should be on always being able to utilize the latest information as soon as it arrives. In addition, one should use as few resources as possible on useless repair attempts. Using application specific knowledge to determine that some lost messages are not worth repairing, because they have been obsoleted by subsequent changes, is central to the strategy referred to as object-based repair.
At the other extreme, some objects change very infrequently, e.g., only once every few minutes or hours. In this situation, the exact moment a change occurs may or may not matter, but the fact of the change certainly matters. It is very important that each individual change be communicated. It is also important that if information is lost about a particular change, this is detected long before the next change occurs. In this situation, some sort of positive acknowledgment scheme is needed to detect lost messages.
In the middle are objects that change at moderate speed, e.g., once every few seconds or so. Here repair is important and must be relatively timely. This is a particularly difficult part of the spectrum to support well. Fortunately, it is plausible that many applications make use of the two ends of the spectrum more than the middle.
It should be realized that a single object may be changed rapidly for a while and then change slowly or not at all for a while. Therefore, a general purpose approach cannot rely on knowing in advance which objects will exhibit which kind of behavior. Rather it must adjust dynamically to whatever is happening.
As to Distributed Database and Shared Memory Technology, one way to approach the goal above is to use standard distributed database or shared memory technology. In these approaches the paramount goal held up above all others is insuring that at any moment when two processes access a given shared object, the two processes will always obtain the same values. To satisfy this goal, locks must be used to prevent processes from accessing objects at the wrong time.
For example, suppose that process Pi wants to modify object A. To do this P1 must:
1. check that no other process has locked A, waiting if necessary until the lock is free,
2. lock A so that other processes are prevented from accessing A,
3. send messages to all the other processes in the group notifying them that the lock is set,
4. wait until it receives return messages from all other processes acknowledging the lock. Note, this may result in discovering that some other process took the lock first, in which case P1 must return to step 1 above.
5. make the desired change in A,
6. send messages to all other processes specifying the change,
7. wait until it receives return messages from all other processes acknowledging receipt of the change messages,
8. remove the lock on A,
9. send messages to all other processes saying that the lock is removed.
This handshaking wastes bandwidth and dramatically slows interaction. Setting and freeing the lock on A requires multiple messages to be sent between P1 and the other processes in the group. The back and forth communication greatly increases the latency interval between the time P1 decides to change A and the earliest time at which any other process can access the change. Each message must be sent completely reliably which further increases bandwidth usage and latency.
Finally, the latency rises rapidly as the number of processes in a group rises. As a result, standard distributed database or shared memory approaches cannot be used for the near real-time interaction of more than a handful of processes.
To achieve near real-time interaction between even a moderate number of processes, one must abandon the otherwise desirable requirement that when two processes access a given shared object, the two processes will always obtain the same values. Rather, one must dispense with inter-process locking and allow temporary disagreements between processes about the values associated with an object. In particular, when a process P1 modifies an object A, there will be a short period of time before another process P2 finds out about this change and during that time the values obtained by P1 and P2 when they access A will differ.
It is convenient to also assume that each object has an owning process and only that process can modify the object. This avoids writers/writers problems and means that there does not have to be any means of arbitrating between simultaneous changes. If an application wants to have several processes that can alter a given object, then the ownership of the object can be transferred from one process to another. Alternatively, a single process can be appointed as arbiter of change requests for the object and be the process that actually makes the changes based on these requests. This essentially mimics exactly what would have to be happening if multiple processes were to directly modify the object, because there would in that case have to be some arbitration method. For purposes of discussion, what follows assumes that at any given moment each object has only one process that can alter it.
Given a relaxed equality constraint, several approaches have been used to attempt to meet the goal above: central server systems, Distributed Interactive Simulation, DIS, and reliable multicast.
Central server approaches have each process in a group communicate the changes it makes to a central server, which then notifies the other processes. This approach does a good job of keeping the information known by the processes as close to the same as possible.
It also does a good job of allowing rapid joining, because a new process can receive a rapid download from the central server of everything it is supposed to know. In addition, by sending the messages to and from the server using a reliable protocol such as TCP, the central server approach can easily guarantee reliable delivery of information.
However, the central server approach has two problems. First, interaction speed is significantly limited, because all messages have to go first to the central server and then to the other processes in the group. In comparison to sending messages directly from one process to another, this adds an additional message flight time and adds the time required for the server to interpret the incoming message, decide what to do with it, and generate an outgoing message.
Second, bandwidth needs are increased somewhat due to the need to send messages to the central server as well as to the other processes in the group.
Systems conforming to the Distributed Interactive Simulation standard, DIS, Standard for Information Technology, Protocols for Distributed Interactive Simulation, DIS ANSI/IEEE standard 1278-1993, American National Standards Institute, 1993, send messages about object changes directly from one process to another using what is effectively multicast messages using the UDP protocol. Actually, early DIS systems use broadcast in dedicated subnetworks with special bridging hardware/software to forward messages from one subnetwork to another, but this is essentially what multicast capable network routers do.
The key virtue of the DIS approach is that it communicates information between processes at the maximum possible speed. In addition, multicast uses significantly less system bandwidth than multiple point to point connections. However, there is no guarantee of delivery of UDP messages. Therefore, DIS does not guarantee that a change made by one process will ever be known by a given other process.
To counteract the reliability problem, DIS takes two actions. First, each message sent contains full information about an object so that it can always be understood even if previous messages about the object have been lost. Second, DIS systems send out frequent `keep-alive` messages specifying the current state of each object, typically once every 5 seconds. This means that lost information is typically repaired within 5-10 seconds. It also means that a new process will be informed of everything it needs to know in 5-10 seconds.
The above notwithstanding, DIS is still left with four significant problems. First, the fact that differential messages cannot be used, and therefore each message describes an object fully, wastes a lot of bandwidth, because even when only a small part of an object is changing, a description of the whole object is continually being sent.
Second, the keep-alive messages waste a lot of bandwidth, because when an object is not changing at all, repeated messages are still sent describing the whole object.
Third, while keep-alive messages cause eventual repair, they do not cause fast repair. Therefore, the processes in the group can get significantly out of synchronization in what they believe about the data they share and near real-time interaction is impaired.
Fourth, joining is not rapid, because it takes 5-10 seconds for a new process to learn what the other processes know.
A clever part of DIS is that there is no central server process at all, and no need for any process to figure out what information other processes have received. Rather, all processes just forge ahead in ignorance of the others. When few messages are lost, things work extremely well, albeit at the cost of significant additional bandwidth. When a significant number of messages are lost, things continue to work out with no increase in bandwidth usage, albeit with a reduction in real-time interaction.
A final piece of related prior work is research on reliable multicast protocols. In that work, the primary goal is to achieve low bandwidth operation using multicast messages, but to incorporate handshaking that ensures reliability. There are two basic ways to do this: with acknowledgment messages, ACKs, or negative acknowledgment messages, NAKs.
In ACK-based approaches, each recipient sends explicit ACKs of the receipt of the messages sent to it. As in protocols such as TCP, this allows the sender to know exactly what has to be resent and to whom. However, the problem with this is what is referred to as an "ACK explosion".
Suppose that a process P is sending messages to N other processes. Each time P sends a message, N ACKs are generated. This uses significant bandwidth and causes P to receive N messages that it has to deal with for each message it sends out. Note that in the group as a whole, there are N times as many ACK messages as data carrying messages. As a result, the ACK messages soon come to dominate all communication as the group grows large. If the ACKs are themselves sent by multicast, then all the processes have to deal with all the ACKs. If the ACKs are send directly from the various processes back to the sending processes, then this means that on the order of N-squared 1-to-1 channels are open and the bandwidth needed for communicating ACKs is increased.
In NAK-based approaches, control messages are sent only when messages are lost. Specifically, when a process P2 notices that it has failed to receive a message M from another process P, it sends a NAK requesting that the message be resent. The advantage of this approach is that when messages are received, bandwidth is not wasted sending ACKs. However, there are still significant problems.
First, the primary way for P2 to tell that it has missed M is for it to receive a different message sent by P after M. In comparison to using ACKs, this delays the time at which the loss of M can be detected and therefore repaired. This problem is particularly severe if P does not send any message after M. In that case, P2 might never notice that M was lost. To counteract this problem, some kind of message must be sent that specifies what processes should have received. A pure NAK-based approach is only possible when each process sends a steady stream of messages.
Secondly, as with ACKs, if NAKs are themselves sent by multicast, then all the processes have to receive all the NAKs. If the NAKs are send directly from the various processes back to the sending processes, then this means that on the order of N-squared 1-to-1 channels are open and the bandwidth needed for communicating NAKs is increased. In either case, the N NAKs that converge on the sender when a message is entirely lost is referred to as a "NAK implosion". The existence of this traffic causes difficulty at the sender that can further impede communication beyond whatever problem caused the communication to fail in the first place.
From this perspective, reliable multicast protocols have several key problems. First, most of them do not even attempt to support near real-time interaction or rapid joining, focusing instead on reliability, and low bandwidth.
Second, many of them expend significant resources ensuring reliability features such as order of arrival that are not useful for solving the problem posed above.
Third, if ACKs are used, this uses a significant amount of bandwidth, even when few messages are being lost. If a significant number of messages are being lost, then bandwidth usage goes up further due to the need to resend messages that are lost. If NAKs are used, then bandwidth usage is much lower when things go well, but ramps up much more steeply as messages are lost, due to the need to begin sending many NAKs in addition to resending messages.
In both cases, the basic behavior of requiring more bandwidth when messages are being lost is unfortunate since bandwidth limitations are a prime reason why messages get lost. Particularly in NAK-based approaches, this can cause a negative spiral where the initial onset of problems causes more problems.
Fourth, and perhaps worst, pushing directly for reliability at the low level of multicast messages themselves does not strike at the heart of the problem posed above. For example, suppose that process P1 changes object A at time T1 and sends a message M describing this change. Suppose in a NAK-based approach that at some later time T2, a process P2 discovers that it has not received M. P2 then sends a NAK requesting the retransmission of M. This is all well and good, but what P2 really wants to get is not M, but what the state of A is at T2. That is to say, the reliability that is desired is not necessarily the receipt of every message, but rather getting at all times the most up-to-date information about A possible.
SUMMARY OF THE INVENTION
The basic solution to the problem above is to use a central server to support reliability and rapid joining, while using UDP multicast messaging to achieve rapid interaction and low bandwidth. Differential messages are used to achieve still lower bandwidth, and object-based repair is used to avoid unnecessary repairs.
Specifically, a system for fast, efficient and reliable communication of object state information among a group of processes combine the use of a fast, but lossy and thus unreliable multicast link to a group of processes and a server coupled to the processes for providing data which has been lost in the multicasting. In one embodiment, a central server supports reliability and rapid joining while using UDP multicast messaging to achieve rapid interaction and low bandwidth. Differential messages are used to enable detection of changes and lost data in which differential descriptions are created that describe how to compute the new state of an object from any of several previous states so that a description can be interpreted even if some prior descriptions were not received, thus achieving still lower bandwidth. In one embodiment, messages sent out by the central server to reliably know when information has been lost prevent the need for keep-alive messages.
In one embodiment of the subject system, to reliably know when information has been lost, the server sends messages specifying what should have been received by each process.
Keep-alive messages are avoided because they waste bandwidth without allowing timely repair or truly rapid joining. Because the expected situation features objects that are changed many times with only a small change each time, bandwidth can be greatly reduced by using differential object descriptions that describe only the changes themselves, rather than the full state of objects.
The simplest differential object description specifies how to compute the new state of an object from the previous state. If this kind of description is used, then a process cannot interpret a differential description D unless it has received the prior description. However, one can create differential descriptions that will compute the new state of an object from any of several previous states. If this is the case, then a description D can be interpreted even if the prior description was not received.
Bandwidth can be reduced most if reliability is introduced at a high level where one can take maximum advantage of the constraints of the particular domain, rather than by using brute force at a low level.
In particular, reliability is added to insure that processes end up with the latest state values for each object, not to insure that they actually receive every low-level message. For instance, object state messages that are lost, but soon rendered obsolete by subsequent object state messages do not have to be, and therefore should not be, resent.
To reliably interact in a global shared environment, objects are identified by Globally Unique IDs or GUIDs. To be truly unique in space and time, GUIDs must have many bits, e.g., a hundred or more.
Unfortunately, if nothing is done to counteract it, the use of such GUIDs can use up a lot of bandwidth in messages. In the subject invention, GUIDs are allocated so that there will be many bits in common between the GUIDs used in a given message. Therefore, the GUIDs can be represented in a compact compressed form.
In one embodiment, a compact differential message describes the current state of an object as an update from any of several previous states. This reduces the latency in a system where messages can be lost or arrive out of order. This allows the messages to be interpreted and applied to as soon as they arrive, rather than having to wait for out of order messages to arrive, or for lost messages to be repaired or resent. This also allows robust behavior when messages are lost, without even having to repair the lost messages because one can do repair on an object basis, rather than at the message level.
Note that there is no point in using this technique over a reliable communication channel where the messages are delivered in order. In such a situation, ordinary deltas are sufficient. On the other, the subject system introduces some redundancy that is valuable when messages may be lost or delivered out of order.
In the subject system a technique is used for efficiently computing what changed, by OR-ing together bitmasks or the words that changed in each cycle. If one or more fields are being changed repeatedly, a common case, our encoding incurs no extra cost for reaching back over many previous states, compared to the cost of describing the delta to the immediately previous state.
In these uses of differential messages in ISTP, they are arranged for a lot of redundancy among the GUIDs in the same message in order to increase compressibility.
The following describes the overall approach to region-based communication which is the basis for the subject system. In a networked computer system with one or more nodes updating information about objects they control, and one or more nodes needing to receive those updates, the subject system reliably communicates those updates in a way that delivers them more quickly and with less bandwidth than previous techniques.
As to keypoints, multicast, group-based, communication between peers, with a server listening to that communication. This central server is the focus of reliability, with multicast being used for low-latency, low-bandwidth interaction.
Object-based reliability, as opposed to message-level repair, avoids useless repairs. When repair is needed, if more up-to-date information than that which was lost is now available, we are able to provide that instead.
In the subject system the amount of information that participants must remember about objects that have been removed is bounded by automatically rejecting all overly late messages and using object-based repair to recover any lost information.
Entry into a session is made as rapid as possible by combining an immediate download of all current session state with having the new client join the multicast group where the ongoing updates are being sent. This download includes information about all recently-removed objects, so the new client would not be deceived by later-arriving multicast updates about those objects.
The server is responsible for selecting the multicast address or addresses used by the group, and can use channel hopping to avoid interference or to evict badly behaved participants. This is an extension of the mechanism by which cordless phones select channels to avoid interference.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the subject invention will be better understood taken in conjunction with the Detailed Description, in conjunction with the Drawings, of which:
FIG. 1 is a diagrammatic representation of a new object being added to a shared virtual world by one of the participating nodes;
FIG. 2 is a diagrammatic representation of the central server approach to implementing a shared world model;
FIG. 3 is a diagrammatic representation of using peer-to-peer messaging, or multicast, to implement a fully distributed world model, in the style of DIS;
FIG. 4 is a diagrammatic representation of the subject invention, showing the use of multicast to share object update information among a group of peers, with a server listening in;
FIG. 5 is a diagrammatic representation of the subject invention, showing how the server interoperates with each client node to ensure overall system reliability at the object level;
FIG. 6 is a diagrammatic representation illustrating a sequence of differential messages in which a message depends on the immediately preceding message to form a conventional encoding of the change in object state;
FIG. 7 is a diagrammatic representation of the subject system in which differential messages are based on more than one proceeding message to permit reconstruction of data in the event of lost or late prior messages;
FIG. 8 is a table showing a sequence of changes in an object over time in which fields of the object change at each time step;
FIG. 9 is a listing of the full state description of the object of FIG. 8 at T4, illustrating the fields existent at time T4;
FIG. 10 is a listing indicating the state of the object of FIG. 8 at time T4 with respect to the immediately previous state, at time T3, indicating the change; and,
FIG. 11 is a listing indicating the state of the object of FIG. 8 at time T4 with respect to either of the three previous states, at times T1, T2 and T3, indicating changes in the field F3 and the field F5.
DETAILED DESCRIPTION
Referring now to FIG. 1, a networked series of processes are running on a series of computers 10, 12, and 14 coupled to network 16, in which in one embodiment, the process includes virtual reality scene 18, displayed on monitors 20, 22 and 24. Users A, B and C at respective computers 10, 12 and 14 are participating in creating the virtual reality scene in which each user, and thus each computer, has an associated world model 26, 28 and 30, each divided up into portions for which each user is responsible.
As can be seen, each world model is thus divided up into sections A, B and C, with user A seeking to modify the virtual reality scene through the addition of a graphical element, in this case dog 32. The change, 34, is to be transmitted to the world model of each of the users as indicated at 28' and 30'.
While it will be appreciated that this embodiment will be described in terms of a multi-user creation of a virtual reality scene, any transmission amongst a number of users of data which is to be modified or changed desirably requires reliable, low-latency, low-bandwidth transmission.
In the past, attempts have been made for such transmission by either transmitting the data and/or the changes to a server for re-transmission to all users. This is referred to as a central server system, and will be described in connection with FIG. 2.
The second common method of transmission of this data and/or its changes is through the utilization of broadcast or multicast networking in which the data or changes are directly communicated to each user. The aforementioned Distributed Interactive Simulation Standard, DIS, is a protocol that uses this approach, which is described in connection with FIG. 3.
Referring now to FIG. 2, the change to the world model 40 specified by a user is transmitted to a server 42, which simply transmits the changed data or change to the various users on the network. As mentioned, hereinbefore, the major problems with such an approach are the increased time needed to send the change through the server on its way to each user, and the bottleneck the server places on scaling such a system to a large number of users.
Referring now to FIG. 3, the change to the world model 40 is communicated directly to each of the computers 10, 12 and 14 in a peer-to-peer approach in which all processes subscribing to the appropriate address receive the new data. Note heretofore multicast systems of the type described in FIG. 3 have relied on transmitting whole objects, rather than differential messages indicating changes to the data.
Referring now to FIG. 4, in the subject system, assuming user A wishes to change his world model 26, this change is transmitted simultaneously to server 50 and directly to computers 12 and 14. This transmission may take the form of any conventional broadcast or multicast protocol. What is transmitted is the changed data which user A wishes users B and C to have. As mentioned above, multicasting in general can result in lost or out-of-order data, although the transmission is relatively timely.
A missing data detector 52 is coupled to each of the computers 10, 12 and 14 to perform two functions. The first function is to detect the cases when data from a user has not been received by the server. The second function is to detect when the data stored at a given computer does not contain a change specified by another user.
Referring now to FIG. 5, two functions of the missing data detector 52 are now described. Object state summary messages 58 are sent from the server 50 to each computer that describe the set of object state updates the server has processed since it last sent such an object state summary. In this case, user A has specified a change in the data A'. Once it receives the change, the server will include this change in its next object state summary message. If this expected portion of the object state summary is absent, the missing data detector 52' can determine the update was lost. In one embodiment, this is then repaired by sending a differential message directly to the server, as indicated at 56.
As to users B and C, if the direct message sent to them from user A is lost, then the summary 58 from the server 50 will inform them of the existence of the lost data. Having determined that the version of the data described in the lost message is not resident at computer 12 or 14, a request 60 is made to server 50 to supply the latest data pertaining to the object whose update was lost.
As a result, the subject system provides reliable and timely data change transmission to a number of networked users by first broadcasting the changes directly to each user, and then permitting repair of lost messages through the utilization of a central server which has been provided with the change.
It will be appreciated that, in general, objects have a number of fields which comprise their state, and in a typical case only one or a small number of fields will change at a given time. However, due to the difficulties just mentioned, the DIS protocol referred to in conjunction with FIG. 3 always sends complete object state, regardless of the nature of the change. This has the virtue of simplicity, but for many applications it is clearly desirable to be able to encode object changes in a manner that both conserves bandwidth and speeds up processing of changes by being able to process out-of-order messages as they arrive. FIGS. 4 and 5 summarizes how one utilizes a central server to ensure that the subject system operates reliably; FIGS. 6 through 11 will illustrate the details of the scheme for encoding object updates.
Further benefits are derived from coupling this network architecture shown in FIG. 5 with differential messages and object based repair. It will be appreciated that changes to data may be transmitted in terms of a message describing which fields of the object have been changed. However, an improvement to standard object deltas can be achieved through the utilization of a multi-based differential messaging technique in which sufficient redundant information is included in each message as to permit reconstruction of complete object state even when some number of intervening updates have been lost.
Referring now to FIG. 6, in the prior art, assuming an object had one or more fields of an object change at each stage and that each message describes only the change in state from the previous stage, then the loss of a single message M2 makes it impossible to reconstruct the entire object's state. This simplest case of differential messaging is referred to as single-based differential messages. Note that when single-based differential messages arrive out of order, the opportunity to process early arrivals as they arrive is lost because each message can not be processed until all prior messages have been processed. Single-based differential messages are only useful in the context of a reliable network protocol, such as TCP.
Referring now to FIG. 7, dual-based differential messages are illustrated in which the loss of a single message does not cause any trouble. For example, if M2 is lost or late, M3 can still be processed because it describes the object's state at that stage in relation to both the state at Ml and the state at M2.
Referring now to FIG. 8, one can see an object with six fields, F1 through F6, that is going through a sequence of changes at times T1 through T5. In this table, one can see the complete state of the object at each time step.
Referring now to FIG. 9, this is a complete description of the object of FIG. 8, at time T4. The value of each field is specified.
Referring now to FIG. 10, the single-based differential description of the object of FIG. 8 at time T4 relative to time T3 is shown. In this case, the new state is the previous state with the field F3 set to the value C.
Referring now to FIG. 11, a differential state description of the object of FIG. 8 is shown that describes the state at time T4 relative to any of the previous times T1, T2, or T3. Any computer that received messages describing any of those previous three states can properly decode this description. Such recipients of this description are thereby instructed that starting from whatever previous states is present locally, the new state is reached by setting field F3 to C and setting field F5 to H. It will be appreciated that this differential state description is much more compact that the full state description of FIG. 9 and much more useful for transmission over unreliable networks than the single-based differential description of FIG. 10.
In one embodiment and more particularly the participants are a server S and n communicating processes P1 . . . Pn. Note, the messaging protocol used by the subject system is referred to herein as the Interactive Sharing Transfer Protocol, ISTP. Each process Pj owns a number of objects and sends out descriptions of the objects whenever Pj makes changes in them.
Each process receives messages from the other processes about the objects those processes own.
Each process Pj has a 1-to-1 TCP connection to the server S. This is used for the reliable communication of control information. In addition, the processes Pj in a multicast communication group participate in a multicast communication using an address chosen by S.
There are several key parts of the solution: How information about object state is communicated; How multicast messages are sent out and received; How processes are informed of what they should know; How message loss repairs are made; How processes join a communicating group; How processes leave a communicating group.
Each of these parts is described separately below. As part of this three kinds of messages are used.
1. Object State--describes the state of objects
2. Object State Summary--specifies what processes should know
3. Locale Entry--sets things up when a new process joins a group.
a. How Information About Object State Is Communicated
The state of one or more objects is communicated in an object State message, which has the following format.
Object State message fields:
MessageTypeID: 16 bits--value 1 indicates this is an Object State message.
SenderID: 32 bits--compressed GUID identifying sender's spCom.
SendTime: 32 bits--time message sent in milliseconds modulo one week.
NumberOfGUIDPrefixes: 16 bits--number of prefixes G in GUIDTable.
NumberOfDescriptions: 16 bits--number of descriptions D in body of message.
GUIDTable: G GUID prefix entries-96 bits each
TableEntryIndex: 16-bits--used in compressed GUIDs.
GUIDPrefix: 80-bits--prefix potentially shared by many GUIDs in message.
Descriptions: D object descriptions-varying length
Every ISTP message begins with a 16 bit message type that specifies which kind of ISTP message a given message is. Ample bits are provided so that additional types can be used to support extended versions of the ISTP protocol.
The SenderID is the GUID, see below, of the spCom object, see below, identifying the sender of the message. Note that all ISTP messages have the property that they can be fully interpreted without having to know what communication connection they were received on.
The SendTime is the local time in milliseconds modulo one week, 604,800,000 msecs that the message was sent. The NumberOfGUIDPrefixes specifies the number of entries in the GUIDTable.
The NumberOfDescriptions specifies the number of objects described.
The GUIDTable contains entries that allow for the compact representation of GUIDs, including the SenderID, in the rest of the message.
The Descriptions describe the current state of objects using either absolute or relative descriptions, see below.
To understand object descriptions, one must first understand the following facts about objects in ISTP. It is expected that applications will use many kinds of objects. In particular, they are allowed to define new kinds of objects. However, only a very few types of objects matter to ISTP. Two of the most important are sp objects and spClass objects.
b. GUIDs
Every object in ISTP is identified by a Globally Unique Identifier or GUID. ISTP uses 96-bit, or 12-byte, 3-word GUIDs that are unique in time and space. These will expand to 192 bits under IPv6. The GUIDs are composed of two parts:
PROCESS ID: 80 bits corresponding to an ISTP process. This will expand to 176 bits under IPv6. This value is assigned whenever a new process starts and is guaranteed to be unique in space and time, e.g. for a century. This value is opaque. No way is specified for obtaining any information about a process if one only has a process identifier.
The process identifier 0, zero, is reserved for indicating built in objects--i.e., built-in classes.
OBJECT ID: 16 bits. As an ISTP process creates new objects, it generates names for them by changing the object ID part of the name, holding the process identifier constant. Names are never reused. Once 2 16 names have been generated, the process ID is changed.
ISTP does not specify how the Process ID part of a GUID should be generated. However, one plausible way is to compose 80 bit process Ids using internet addresses as follows. This will expand to 176 bits under IPv6.
INTERNET ADDRESS--of the machine a ISTP process is running on. Currently this is 32 bits. It will expand to 128 bits under IPv6.
PORT NUMBER--16 bits. Whenever an ISTP process starts up, it attaches itself to a port. This port is used to differentiate between multiple processes on a machine.
GENERATION COUNTER--32 bits guaranteed to be different every time an ISTP process starts on a given machine. As an initial approximation, one might use time in seconds for this. However, down the road, something that also involves file system interaction and/or communication with a trusted server should be used, because clocks can stop and be set backward.
Note that because the generation counter is a time in seconds, it can be incremented once per second without risking accidental name collision when a process restarts. This allows a processes to use 2 16 object names per second.
To promote memory and communication efficiency, GUIDs are represented at all times in the following compressed form.
PROCESS ID TABLE POINTER: 16 bits that indicates an entry in a table of process ids. The process id table pointer 0, zero, is reserved for indicating built-in objects.
OBJECT ID: The 16-bit object ID for the object.
A table of process ids is used to interpret the process-id-table-pointers in compressed object names. In a world model copy, the process-id-table-pointers are indexes into this table. In a message, the part of the whole table that is needed in order to understand the compressed object names in the message is sparsely represented as a vector of process-id-table-pointer/process-id pairs.
Note that in an Object State message containing several object messages, there is only one unified vector of process-id-table-pointer/process-id pairs.
The GUIDs above are designed so that it is possible to use one indefinitely without having to worry about name collisions. However, it is pragmatically important not to do so. A key benefit of the way GUIDs are used in ISTP is that even though they are in principal very large, the actual communication bandwidth needed is not large. The benefit depends critically on the assumption that almost all the names owned by a given process have the same process id.
If, in the extreme, every object had a different process id, then bandwidth usage would be much larger than it need be. If names were used permanently, then as the days wore on, the ratio of process ids to names in use would relentlessly rise toward 1.0 with unfortunate consequences. Rather than let this happen, one should take the opportunity to remove old objects and create new ones with new names from currently active name spaces whenever possible.
c. Fields of Shared Objects
Every shared object is an instance of a subclass of the class sp. The class sp specifies that every shared object includes the following fields, which are the foundation of object descriptions. All shared objects have the following fields that are shared between processes:
Counter: 16 bits--Incremented whenever the object changes.
DescriptionLength: 16 bits--The total size of the shared data in bytes.
Name: 32 bits--The compressed GUID for the object.
Class: 32 bits--The compressed GUID for the object's class.
Owner: 32 bits--The compressed GUID identifying the owning process.
SharedBits: 16 bits--representing logical values.
IsRemoved: the low-order bit, bit zero--if 1, this indicates that the object has been removed.
The counter value is used as an identifier for the state of an object A. Every time any shared part of A is modified A's counter is incremented.
The DescriptionLength specifies how long a full description of the data in the object has to be. As will become clear below, this is limited to a 13 bit unsigned integer. A 13 bit description length allows objects 4 k bytes long. Since full descriptions are limited to fitting into single UDP packets the length is plenty long enough.
The name of an object is a GUID that is used to uniquely refer to it from fields of other objects and in various ISTP messages.
Each object has many fields in addition to the ones above. The Class is the GUID of a machine manipulable spClass object, see below, that describes what all of the fields of the object are. ISTP can manipulate arbitrary application specific objects with reference to their spClass descriptions.
The owner of an object is a GUID that is used to uniquely refer to the process that owns the object. From the perspective of the discussion here, the only important aspect of this is that it allows every process to determine which objects it does and does not own.
The SharedBits are used to compactly represent various logical values. The only one of these values that is relevant here is the low-order bit, which specifies whether or not an object has been removed.
Counter incrementing and comparison is done using arithmetic modulo 2 16 so that the largest positive counter value rolls over to the smallest. To accommodate this, all comparisons are done using modular arithmetic. That is to say the counter C is less than D, i.e., C<D, if 0<D-C<2 15 or D-C<-2 15. The counter value zero is reserved to mean a state in which nothing is known about the object A. The counter for an object starts at 1 and skips the value zero as it wraps around when counting up.
A 16 bit state counter allows us to correctly order 2 15=32 k object states. At a rate of 30 state changes per second for an object, this is 16 minutes worth of changes. This is plenty of time considering that ISTP's time horizon for object communication is on the order of seconds.
d. spClass Objects
Object classes are described using spClass objects. Without going into detail here, suffice it to say that an spClass object specifies the position and type of every field in an object. Some classes are built in but most are defined by applications. Two types of fields are worthy of special note.
Fields that refer to other objects contain compressed GUIDs for those objects as discussed above. Fields that contain times represent these times using 32 bit integers whose units are milliseconds modulo one week.
Each receiving process Pk, maintains an estimate DTj of the total time that typically elapses between the time at which a process Pj sends a message M and the time at which Pk processes the message.
This is computed by observing the difference between the SendTime on each received message and the local time on Pk at which the message is processed and computing a moving average, with outlying values ignored. Note that this estimate DTj intentionally conflates estimates of firstly, the time of flight of messages from Pj to Pk; secondly, the average delay at Pk before a message is processed; and thirdly, the absolute difference in the clock settings of Pj and Pk. Because of the last factor, DTj can be negative.
The time estimates DTj are used to adjust times specified in object descriptions from the time frame of Pj to that of Pk as discussed in R. C. Waters, Time Synchronization In Spline, MERL TR 96-09, MERL Cambridge Mass., April 1996.
e. Full Object Descriptions
Full object descriptions can be understood in isolation without reference to any other information about the object. They have the following form: Note that every description starts with 3 bits that specify what kind of description it is.
A full description contains:
DescriptionFormatCode: 3 bits--which for full descriptions is equal to 0.
DescriptionLength: 13 bits--Bytes in description and therefore shared data.
Counter: 15 bits--counter value for object.
Name: 32 bits--compressed GUID that is the name of the object.
Class: 32 bits--compressed GUID for spClass of object.
Data: byte [ ]--Other data fields in object.
Full descriptions are trivial to construct by merely copying all the shared data from the object in question. They are equally trivial to interpret by copying in the reverse direction. The only complexity is dealing with references to other objects via GUIDs and times as discussed above.
f. Differential Object Descriptions
Differential descriptions describe changes in objects from one state to another.
A differential description contains:
DescriptionFormatCode: 3 bits--which for differential descriptions is 1.
BaseCounterDelta: 5 bits--Delta from reference object state.
FirstCode: 8 bits--First byte describing where changes have occurred.
Counter: 16 bits--counter value for object.
Name: 32 bits--compressed GUID that is the name of the object.
OtherCodes: byte [ ]--Remaining bytes indicating positions of changes.
In groups of 4 to preserve alignment.
Data: long [ ]--new word data representing changes.
The BaseCounterDelta specifies what prior states the differential description can be decoded with respect to.
If BaseCounterDelta=0, the description can be interpreted by itself.
If BaseCounterDelta=1, the description cannot be understood unless the prior object state is available.
If BasecounterDelta=N, the description can be interpreted based on any of the last N object states. The penalty for using this approach is that it is harder to encode and that data might have to be included that did not change on the last cycle but rather only on an earlier cycle. However, the gain is that latency is reduced and the message stream is robust against the loss of some descriptions. One place you might use this is when rapidly moving an object around. If the only changes were in X-Y-Z position, then BaseCounterDelta could be quite large without increasing the length of descriptions.
The byte change Codes have the following form. Positive bytes indicate offsets from beginning for the first and after the last change for the rest. Negative bytes, by their absolute values, indicate run lengths. A zero byte signals the end of the change bytes. If there are two non-negative bytes in a row, the length associated with the first offset is one. As a special case, if the very first byte is negative, it is still treated as an offset, the length is one and the set of change codes consists of just this one byte. This special case allows a one-word change to be specified in just 3 words. Each change is specified as an offset relative to the word after the last change. The words of data are aligned in the description and copied into the object as specified by the byte Codes.
For example, <3, -30, 1203> <88088> <A> specifies that state 1203 of object 88088 can be computed from state 1200, 1201, or 1202 by writing the word A at offset 30*4=120. This 12 byte message is an example of the minimal differential description and specifies a 4-byte change.
As a more complex example,
<1, 80; 1203> <88088><-3, 10, 0, 0> <A> <B> <C> <D> specifies that state 1203 of object 880088 can be computed from state 1202 by writing the word A at offset 80*4=320, writing the word B at offset 81*4=324, writing the word C at offset 82*4=328, and writing the word D at offset 93*4=372.
This 28 byte message specifies a 16 byte change. If the first change is more than 127 words into an object, a dummy change has to be used on the way to the real change. Similarly, a change after a one word change can only move 127 words farther down the object. However, given that objects are required to be short enough so that a full description, which we still often have to send, can fit into a single UDP packet, there should be little problem here.
Constructing differential descriptions is harder than computing full descriptions, because one needs to know exactly which words in the object have changed. To compute descriptions where the BaseCounterDelta is 1, one needs to either directly know what words have changed, e.g., recorded in a bit map, where ones indicate changed words, or have a record of the prior state so that comparison can reveal which words have changed. Given either of the above constructing the differential description is straightforward.
To compute descriptions where the BaseCounterDelta is 2, one needs to know which words were altered due to either of the last two state changes. Note that if a word was changed and then changed back to its old value, it still must be included in the description, in case the recipient has the last state rather than the state before last.
A straightforward way to support BaseCounterDeltas of N and less is to save bit maps summarizing the N previous state changes. These can then be OR'ed together to yield a specification of what words to send for any BaseCounterDelta less than or equal to N. If a larger BaseCounterDelta is needed at a given moment, then one can fall back on using a full description. Each time an object is changed a new bit map is computed and saved in a per-object queue, while the oldest bit map, if there are more than N, is discarded.
Having differential messages complicates the handling of GUIDs and times in descriptions, because it is harder to figure out where they are in descriptions. However, the bandwidth savings are well worth the extra complexity.
An important case of differential messages is ones that specify that an object has been removed. In that situation, the only thing that matters is that the IsRemoved bit is set. The values in other fields are irrelevant. As a result, a short differential message can be constructed with a BaseCounterDelta of 0.
It should be noted that we already have a special kind of full description that is differential in nature. Since messages about removed objects call for the destruction of an object, they need not contain the full state. They only need to indicate the bit that specifies that the object is removed. One can therefore send a differential message containing just this information.
g. How Multicast Messages Are Sent Out and Received
On a frequent basis, e.g., once every 30-100, milliseconds, a process Pj sends out one or more Object State messages describing all the objects it has changed since the last time it sent messages. At a similar rate, it processes Object State messages sent by others.
Messages are sent out using UDP multicast packets. Each message is sent in a single packet and each packet contains just one message. The address to use is specified by the server S as discussed below.
An important requirement is that each Object State message must fit in a single UDP packet. That is to say, it must be less than the Maximum Transmission Unit or MTU. What the MTU is depends on the transmission medium. Currently MTU's vary widely from only a couple hundred bytes for modems to 1,500 bytes for Ethernet and beyond. Under IPV6, there will be a minimum MTU of 600 bytes.
At a given moment, if no object has been modified, no message is sent. If several objects have changed, then as many descriptions as possible are packed into each message. Note, Grouping descriptions significantly increases bandwidth usage and improves processing performance at the receivers.
To minimize bandwidth, differential descriptions are used whenever possible. Full descriptions must be used whenever an object is first communicated to the group, i.e., when it is first created. After that differential descriptions are possible. Whenever practical, differential messages are constructed so that they are not relative just to the last state of the object, but all the way back to the initial full message, or failing that, back at least several states.
Having differential descriptions interpretable based on the state before last is clearly a huge advance in being able to tolerate lost messages over going back just one state, which requires the receipt of every message. Going back more than two states has advantages, but clear diminishing returns. Nevertheless, if one small part of an object is being changed rapidly, then one may be able to have differential descriptions interpretable across many states with no added costs.
Since UDP is not a reliable protocol, a given message M sent by Pj may arrive at Pk: never, multiple times, and/or out of order with respect to other messages sent by Pj. Pk must be able to deal with all these situations. This is done primarily on a per-object description basis, rather than on a per-message basis, but one key thing is done with messages as a whole.
A receiving process Pk keeps track of the send and receipt times of the messages it receives from each other process Pj. If Pk receives a message M from Pj that has an earlier SendTime than some other message it has already received from Pj, then M has been received out of order. If two messages have the same SendTime, they have been sent at the same time and their order does not matter to ISTP.
A parameter of ISTP is a maximum delay MaxDelay, typically on the order of several seconds. If a late-arriving message M arrives more than MaxDelay seconds after any previously received message from the same source with a later SendTime, then M is discarded without processing. This imposed limit on the lateness of messages is important for a number of reasons that are discussed below.
As an example, consider the following table:
TABLE I______________________________________message SendTime at Pj message arrival time at Pk______________________________________ 1 11 2 17 3 13 4 17 5 15 6 16______________________________________
The messages sent at 2 and 4 arrive out of order. If MaxDelay=3 then the message sent at 4 can still be used when it arrives. However, the message sent at 2 is discarded because it arrives 4 seconds after the message sent at 3. If MaxDelay=5, both messages could be used.
If MaxDelay=1 both messages would have to be rejected. Since times in messages are represented modulo one week, being able to detect the above rests on the assumption that no message will ever arrive more than 3.5 days late. This is a very safe assumption given that lateness is typically measured in only seconds.
Note that the lateness limit MaxDelay, limits the size of the table needed to record historic information about incoming messages. In particular, there never needs to be more than one message in this table that was received more than MaxDelay seconds ago.
If a message N was received more than MaxDelay seconds ago, then it will force any message sent before N to be discarded on arrival. If there is some other message N' sent later than N that was also received more than MaxDelay seconds ago, then N can be dropped from the table, because any message discarding that is forced by N is also forced by N'. For example, if MaxDelay=3 in the example above, the only information that needs to be retained at time 16 is information about the messages sent at 3, 5, and 6.
If a message is not discarded as being too late, then the object descriptions in it are processed individually as follows.
If a given description D has a counter value less than or equal to the current counter value for the object in Pk, D is ignored. Typically this occurs when D is in a message that has arrived out of order or more than once.
If the counter value in D is greater than the current counter value for the object in Pk, or there is no such object, then the information in D is used as follows. If D is a full description, than it can always be immediately processed to update, or create or remove, the object in question. If a description is differential, then it can be immediately processed as long as it is interpretable relative to the current known state of the object. If not, then there must be some intervening description that has not yet arrived. Descriptions that are not immediately interpretable are saved on per-object queues for later use when missing intervening descriptions arrive.
Once a description has been used, the relevant object description queue is examined to see whether there are any other descriptions that can now be used. One could choose to simply discard differential descriptions that could not be immediately used. This would be simpler, but would reduce the ability of the system to make use of out-of-order messages. If differential descriptions span several states, this might not be a problem.
Because of the differential descriptions that span several states, it is of often possible to act immediately using a description even if the previous description is in a message that was lost or delayed. This limits the damage due to lost and delayed messages without having to detect they are missing or resend them.
One issue that needs special discussion is what happens when a shared object is removed. When an object is being removed, one can use a differential description that can always be interpreted, because the only fact relevant about the object is that it is removed. Once an object has been removed, a potential problem could arise.
Suppose that all trace of a removed object A were removed from process Pk. If so, then a subsequent out-of-order full description of A would appear to be a message specifying the creation of A, and would cause A to erroneously reappear in Pk's memory. To avoid this, a record is maintained about the removal of A for MaxDelay seconds so that such late arriving descriptions can be successfully ignored. If there were no lateness limit MaxDelay, then every object removed would have to be remembered forever by Pk, in order for out-of-order description rejection to be supported.
Note that the multicast Object State messages above are received not only by the other processes in the group, but also by the server S.
Just like the various processes, S uses the messages to maintain a record of the current state of every object.
h. How Processes Are Informed Of What They Should Know
To inform the process Pk of what they should know, the server sends out periodic Object State Summary messages once each MaxDelay seconds.
Object State Summary message fields:
MessageTypeID: 16 bits--value 2 indicates this is an Object State Summary.
SenderID: 32 bits--compressed GUID identifying spCom of receiver.
SendTime: 32 bits--time message sent in milliseconds modulo one week.
NumberOfGUIDPrefixes: 16 bits--number of prefixes G in GUIDTable.
NumberOfNewEntries: 16 bits--number of new object entries N in body.
NumberOfObjectChanges: 16 bits--Number C of object changes.
GUIDTable: G GUID prefix entries-96 bits each
GUIDTableEntryIndex: 16-bits--used in compressed GUIDs.
GUIDPrefix: 80-bits--prefix potentially shared by many GUIDs in message.
NewEntries: N new object summaries-64 bits each
ObjectsTableIndex: 16-bits--specifies table position for object.
CounterValue: 16-bits--CounterValue for object.
CompressedGUID: 32-bits--identifies new object.
ObjectChanges: short [ ]--C object change summaries.
The message type, SenderID, SendTime, NumberOfGUIDPrefixes, and GUIDTable are exactly the same as in an Object State message except that the message type has a different value and the SenderID is the spCom that was used by the process Pk receiving the Object State Summary message when Pk initially contacted the server S. Thus the SenderID only indirectly identifies the sender.
The NumberOfNewEntries specifies how many new table entries are described in the NewEntries part of the message.
The NumberOfObjectChanges specifies how many object changes are described in the ObjectChanges part of the message.
The NewObjects field describes what new objects have appeared since the last Object State Summary message from S. This is discussed in detail below.
The ObjectChanges describe what objects have changed since the last Object State Summary message from S. This is discussed in detail below. Before discussing the payload of an Object State Summary message it is necessary to discuss the objects table maintained in each process Pk. This table lists the compressed GUIDs of each object that exists and its associated current counter value. The table compactly summarizes exactly which objects exist and the counter in the last Object State Summary message sent out about them.
Identical tables are maintained in the server S and each process Pk in a communication group. As discussed in a later section, the objects table for a process Pk is initially constructed as part of finding out what objects exist when Pk joins a communication group. S constructs its master copy of the objects table incrementally by updating it every time it finds out new information about an object.
An Object State Summary message is a differential type of message that specifies changes in the objects table. The summary messages are used to keep the objects tables in each Pk synchronized with the table in S and therefore to tell each Pk whether they have up to date information about all of the objects.
The NewEntries field contains triples of objects table indices, CounterValues and CompressedGUIDs. It specifies that a new entry be created with the indicated data. Entries that have previously been is carded, are reused as much as possible. Dynamic table expansion might be necessary.
It is expected that new objects appearing is a much less frequent event than objects changing. It is possible that an object could appear and the disappear in a single time interval, but this is very rare. In that situation, there would be a new object entry specifying a counter value corresponding to the object having been removed.
If for some reason, a new entry specifies collides with an existing entry, then the new entry information supersedes the existing entry. This can be used by a server to make arbitrary changes in the objects table in a process--e.g., during a reinitialization.
The ObjectChanges field is designed for maximum compactness. It uses a series of byte codes to specify changes in CounterValues for objects. The bytes are decoded as follows.
There are two basic kinds of codes: compact codes and full codes.
Case A: If the high order bit of a code is 0, then the first byte is used to increment the counter associated with the indexed object. The index to use is computed by adding the second unsigned byte to the last table index used. Note, the table index starts at zero.
Case B: If the high order bit of an index code is 1, then the first two bytes are interpreted as a decrement to subtract from the last table index used; and the next two bytes are used as an absolute counter value for the indexed object entry. In order to skip more than 2 15 entries down the table, one has to string together two full entries, the first of which leaves the relevant CounterValue unchanged. In either case A or B above, if the counter part of the code is zero, this indicates that the indexed entry in the objects table should be discarded.
Note that for case B to be useful, we are relying on the fact that typically at least several percent of the objects in a table are changing, so that the entries that have to be changed are reasonably near together. In addition, we are relying on the fact that it is unlikely for a counter to increase by more than 127 between two Object State Summary messages. For 30 changes per second, more than 8 seconds are required to go through 255 changes.
When case B is applicable and there are no new object entries that have to be made, Object State Summary messages have a header of 28 bytes-one GUIDPrefix is required for the SenderID--and can therefore describe N changed objects using just 28+2N bytes.
If 100 objects were changing continually, and Object State Summary messages were sent out once every second, this would cause 1.8 kbps of traffic from S to each process Pj.
As an example of the object changes encoding consider the following <2 8, 0 5, 20 100, -1000 44555>.
This specifies that the 8th table entry should have its counter incremented by 2, the 13th table entry should be discarded, the 113th table entry should have its counter incremented by 20, and the 1113th table entry should have its counter set to 4555. Object Summary messages are processed as follows. Pk processes the new object entries, if any. These entries specify the creation of new objects table entries. S picks the positions of these entries so that they reuse free slots when possible, but do not collide with preexisting entries that are still in use. A new entry is created with the specified index, counter, and GUID.
Each object change entry is then processed as follows. If the entry specifies that an object A has changed, then the CounterValue in the local objects table is updated.
Alternatively, if the object change indicates that the entry should be discarded, then it is discarded.
Note, discarded entries are tagged by giving them zero GUID and CounterValues. Note also that discarding a table entry is very different from removing an object. If an object A is removed, this is specified by an object description that specifies that A is removed. Subsequent to this removal, the server will eventually discard the relevant objects table entry, but it should wait a considerable time before doing so. In particular, it should wait long enough that the process Pk has found out that A has been removed.
In particular, it is suggested that S wait a time like 10* MaxDelay after an object is removed before reusing its table entry. This should with high probability ensure that each process Pk knows that the object has been removed, before the table entry is reused. However, if some processes does not get this information, the object will in any event eventually get removed due to the mechanism discussed below for removing objects that have no objects table entry.
Each time a CounterValue in the local objects table is changed, the following checking is performed. If Pk does not own the object A whose CounterValue C has changed, then Pk checks to see whether it has up-to-date information about A. If Pk does not know about A at all, or has a smaller counter value for A, then Pk sends a request to S for updated information as described, in the next section. Note Pk might have a larger value for the counter, because it might have received information from the owner of A that is not yet included in the summary from S.
For Pk to receive an Object State Summary message M with state C for A, the process Pj that owns A must have sent out a message N with state C of A that S received and processed. Pk should have received N and been able to process it before receiving M under the assumption that sending a message from Pj to S and then from S to Pk should always take longer than sending a message directly from Pj to Pk.
If Pk does own the object A whose CounterValue C has changed, then the Object acknowledgment of as a positive acknowledgment of the receipt of information sent by Pk to S. Pk must know a CounterValue greater than or equal to C even if A has been removed.
If Pk has a larger CounterValue, then it might be the case that the latest message sent out about A got lost and therefore did not reach S. Alternatively, it might be the case that the message is proceeding on its way, but just did not get to S before the Object State Summary message was created. Pk has to decide which of these two situations is most likely. It can do this based on its estimate of the flight time of messages between itself and S. Note that on the current internet, this flight time can be quite long. If Pk concludes that a message was lost, then it resends the message as described in the next section. Note that Pk also has to consider whether a message has been lost if it has information about an object it owns that never gets into the objects table at all.
Note that when Pk removes an object A, it must remember this fact however long is necessary to receive an acknowledgment that S knows that A has been removed. This will typically require Pk to remember that A has been removed much longer than it would need if all it were doing was rejecting out of order descriptions. If Pk forgot about A before getting an acknowledge and the message specifying removal somehow failed to get to S, then a subsequent Object State Summary message could force A to erroneously reappear.
A final way the objects table is used concerns objects that are in Pk's world model, but not in the table. Suppose object A exists, but has no table entry. This is a normal occurrence, if A was just created, by Pk or another process, and the existence of A has not yet made it into an Object State Summary message. However, this situation should not last long.
If Pk owns A, then Pk will eventually send information about A to S via TCP and the problem will be resolved.
If Pk does not own A and yet A remains absent from the objects table for a significant period of time, say 10*MaxDelay, then A somehow arose in an erroneous way. Scenarios which can lead to such are situation are complex and include such things as processes crashing during moments when various processes have inconsistent information about what process owns what object. In any event, Pk rectifies the situation by removing A from its world model. If by some reason, A really should be in the world model, then it will eventually get into an Object State Summary and reappear.
The above mechanism is included in ISTP as a last resort way to make sure that all processes eventually agree on what objects exist.
A critical parameter of the above is how often Object State Summary messages are sent. There is a trade-off between quickness of repairs and the bandwidth used.
If the summary interval is made very small, e.g., fractions of a second, then repairs will be made very quickly, but a significant amount of bandwidth will be used sending the summaries and perhaps worse, resources will be expended making repairs that are better off never being made, because they will soon be obsolete.
The bandwidth used for Object State Summaries themselves could be reduced by not sending any summary at all when the server thinks that no objects have changed or been newly added. However, if this is done, then processes have to be prepared to reason from the absence of Object State Summary messages that information they are sending is not reaching S.
If the summary interval is made very large, e.g., many seconds, then repairs will not be timely, but the bandwidth used for both summary messages and repairs is minimized.
The parameter MaxDelay is used to control the summary interval, because it makes sense for both intervals to be the same. From the perspective of remembering information about out of order messages, making MaxDelay larger has very little cost. On the other hand, handling out-of-order messages with lateness greater than the time explicit repairs are made has little if any value. Only experimentation in a particular network and application environment can yield the best value for MaxDelay. However, we expect that all things being equal a value of one to a few seconds is best. Because Object State Summary messages are incremental, they ensure reliability only if they are themselves 100% reliably communicated.
The code doing the TCP transport must take great care to ensure this. If any interruption in TCP communication occurs, this must reported as a break in communication so that a complete restart and reinitialization can ensue.
i. How Message Loss Repairs Are Made
UDP messages sent by a process Pj can either be lost on their way to S or on their way to other process Pk. Losses are repaired in different ways in these two cases.
As noted above, a process Pj determines that one or more descriptions it has sent out about an object A it owns have not been received by S if too much time elapses without these descriptions being reflected in an Object State Summary message from S. Specifically, one of two cases obtains.
One, the highest counter value for A in the objects table is C while Pj knows that A is in state D, D>C. Note this case includes the case that state D specifies that A has been removed. In that case, Pj sends a description of A to S that can be understood given state C. This is sent in an Object State message over the TCP connection from Pj to S to guarantee that it will be received.
Two, A is not in the objects table while Pj knows that A is in state D. Note this case could also conceivably include a situation where A was removed already. In that case, Pj sends a full description of A to S that can be understood given no prior information. Again, This is sent in an Object State message over the TCP connection from Pj to S to guarantee that it will be received.
Also as noted above, a process Pk determines that it has failed to receive one or more descriptions about an object A it does not own via Object State Summary messages. It if discovers in the summary that the object has been deleted, it can take care of this based solely on the information in the summary. Otherwise, Pk sends, via TCP, an Object State Summary message to S stating what Pk already knows. S replies via TCP with an Object State message containing appropriate differential messages. A single pair of messages suffices to update all lost information.
The Object State Summary message sent by Pk is syntactically identical to the ones sent by S. It is also semantically identical in the sense that it is accurately summarizing what Pk knows about objects it does not own. However, it is used in a different way, because it is not used to update the objects table in S. Rather, S sends a message to Pk, to update the world model copy in Pk. Note also that the SenderID in the Object State Summary Pk sends is Pk's spCom object and that there are never any new object entries and never any reference to an object Pk owns.
Suppose that the most recent state information known to S for an object A corresponds to counter E. Suppose further that S receives an Object State Summary message from Pk specifying that Pk knows only about state C of A (C<E). In that case, S sends a description of state E of A to Pk that can be understood relative to C. Pk can use the state C=0 to indicate that it knows nothing about A. This forces S to send a full description of S.
As messages travel between S and Pk, both S and Pk may be learning more about A from arriving UDP messages. That is all to the good. At any moment S and Pk respond based on the best information they have.
It is important to realize that while the above is the method of explicit message repair in ISTP, it is not the only method of repair and in many situations not even the most important method of repair. In particular, information about rapidly changing objects is often rendered obsolete by descriptions that can be understood without reference to lost messages. This allows many repairs to effectively be made without taking any extra action other than creating differential messages that can be understood based on several prior states.
j. How Processes Join A Communicating Group
A process Pj joins a communication group by opening a TCP connection to the server for the group if one does not already exist and sending an Object State message contain an spCom object that expresses the process's desire for a connection. Note that unlike other world model objects, spCom objects are never communicated by multicast, but rather only via TCP connections between processes and servers. spCom objects have the following fields that are shared between process:
. . all the fields in any shared object including SharedBits: 16 bits--representing logical values.
Initialize: the next to low-order bit, bit 1--if 1, forces initialization.
Disconnect: bit 2--if 1, indicates that process is disconnecting.
ProcAddress: 32+16 bits--Internet address and port number for process.
MaxDelay: 32 bits--requested MaxDelay time in milliseconds modulo one week.
As described below, the Initialize bit requests that the server send all the information, see below, that is needed to initiate or reinitiate communication in the group.
As will be discussed, the disconnect bit indicates that the process is disconnecting.
The ProcAddress specifies the communication address for the server to use when sending information to the process. It serves to identify the TCP communication link to use.
The MaxDelay field can be used to request a particular MaxDelay value for a process. Alternatively, it can be set to zero, leaving the choice entirely up to the server. Note that in ISTP all processes are capable of being both clients and servers. A process discovers that it is being requested to be a server because it is sent an spCom object that it does not own. When this happens it can decide to refuse the request in which case no further action is necessary. Otherwise, it initiates a connection to the group as discussed below. Note that a process can also refuse or forward the initial request for a TCP connection.
To grant a request for communication in a group, the server first sends a LocaleEntry message to the process. Locale Entry message fields:
MessageTypeID: 16 bits--value 3 indicates this is a Locale Entry message.
SenderID: 32 bits--compressed GUID of spCom requesting connection.
SendTime: 32 bits--time message sent in milliseconds modulo one week.
Bits: 16 bits--representing logical values.
Initialize: the next to low-order bit, bit 1--if 1, forces initialization.
Disconnect: bit 2--if 1, forces disconnection.
NumberOfGUIDPrefixes: 16 bits--number of prefixes G in GUIDTable.
GUIDTable: G GUIDPrefix entries-96 bits each
GUIDTableEntryIndex: 16-bits--used in compressed GUIDs.
GUIDPrefix: 80-bits--prefix potentially shared by many GUIDs in message.
MulticastAddress: 32+16 bits--Internet address and port number.
MaxDelay: 32 bits--MaxDelay time in milliseconds modulo one week.
The MessageTypeID, SenderID, SendTime, NumberOfGUIDPrefixes, and GUIDTable are the same as in the other message types. The spCom object that initiated the request is used to identify the Locale Entry message granting the request.
The Initialize bit specifies that the process Pj should send or resend all the information, see below, that is needed to initiate or reinitiate communication in the group.
The disconnect bit indicates that the process should disconnect as fast as possible. If it does not do so, the server may forcibly evict the process.
The key field in this message is the MulticastAddress, which specifies the address to use when sending and receiving information about changes in objects.
The MaxDelay field specifies the MaxDelay value that Pj should use for messages communicated on the MulticastAddress.
The server picks the multicast address the group should use. If it detects interference from other traffic on this address, then it can pick a new address and send new Locale Entry messages specifying that the members of the group should change the address they are using.
This channel hopping approach can also be used to evict a rogue process from the group.
The server also picks the MaxDelay to use. A simple server can pick one fixed value for the entire group. Alternatively, the server can assess the needs of individual processes and pick per-process delays. In either case, it is important for the server to make these decisions so that there will be proper synchronization between the MaxDelay for a process and the corresponding Object State Summary message rate.
Immediately after the Locale Entry message, the server sends a Object State message containing a full description of each object being shared by the group. This potentially quite large message initializes the world model in Pj to the current state. Once this is done, Pj can proceed as if it had always been in the group.
Following the Object State Message, the server sends an Object State Summary message that appropriately initializes the objects table in Pj. This message is moderately large because all the objects are new in the table.
As soon as a Locale Entry message is received, a process can begin sending out information about the objects it owns and listening for information about other objects. However, it cannot understand incoming differential messages until it has gotten the current state downloaded from the server.
If the Locale Entry message has the initialize bit on, then Pj must send out full messages about every object it owns on the specified address.
Several things are worthy of particular note about the group connection method above. First, the joining is as fast as practically possible. In particular, the download happens by the fastest possible reliable means. The complete time to join also includes connecting to the specified multicast address, depending how the relevant routers work, this can take a fair amount of time, but this is out of the control of ISTP.
Second, the initial download of information must contain descriptions of all the objects removed less than MaxDelay seconds in the past, so that delayed messages about these objects will not cause them to erroneously appear in Pj.
k. How Processes Leave A Communicating Group
To leave a communication group, a process Pj must first cease changing any objects it owns and therefore cease sending messages to the group address. It must then wait to see that the server S has obtained information about the final state of these objects, sending this information to S by TCP if necessary. Once S has the requisite information, Pj should send an Object State message to S containing the appropriate spCom object with the disconnect bit on and then can simply break its connection to S.
Typically, it is expected that Pj will remove all its objects or transfer there ownership to other processes before leaving the group. If objects are left with no running owner, ISTP does not specify what should happen to them. The server could choose to maintain the existence of the objects, or to remove them.
If a process Pj crashes or otherwise becomes disconnected from S, this can be detected relatively quickly by the server S, because the server will no longer be able to send Object State Summaries to Pj. Again ISTP does not specify exactly what should happen in this situation. As above, the server could choose to maintain the existence of Pj's objects in the hope that Pj will soon reconnect to S, or to remove them.
l. Reliability Control In order to provide detailed application level control of the level of reliability vs speed in ISTP, every shared object is given the following two additional shared control bits.
All shared objects have the following fields that are shared between process:
______________________________________. . .SharedBits: 16 bits - representing logical values.. . .ForceReliable: the next low-order bit, bit 1 - if 1, forceschanges to be communicated by TCP via the server.InhibitReliability: bit 2 - if 1, inhibits the server fromensuring that changes are reliably communicated.______________________________________
If the ForceReliable bit, which by default is not set, is set in an object when a change is going to be communicated, then the change is communicated by TCP to the server, which in turn uses TCP to communicate the change to the other processes in the group. This is the same kind of communication that is used when multicast has to be simulated, see below. Note that the ForceReliable bit must be shared, because the server needs to know when it is on. This is slower than using multicast to communicate the information and requires greater bandwidth, but minimizes the time until every process in the group will know that the change has occurred. Several non-obvious aspects of this communication are important:
First, in general it is intended that this feature will be used sparingly. In some sense the whole purpose of ISTP is to make this kind of communication unnecessary.
Second, beacons which are the subject of U.S. patent application Ser. No. 08/556,227 filed Nov. 9, 1995 by Richard C. Waters and incorporated herein by reference are always communicated in this style via beacon servers. In many situations, beacons provide a more selective way to get highly reliable communication between processes.
Third, whenever TCP is used to communicate object changes by a client or the server all the objects that need to be communicated are communicated together at the same time by placing them in a single Object State message. This guarantees that all the changes will be received at the same time. As a result, the ForceReliable bit can be used for synchronization.
If several objects are changed together, and the ForceReliable bit is set on in each object, then all the changes will be communicated together and every other process will see the changes as a group, rather than piecemeal. Note that if UDP were being used, it would be difficult to guarantee this, because some changes could be received before others and a message with some of the changes in it could get lost.
Fourth, when TCP is forced by the ForceReliable bit, differential messages are used in the interest of minimizing bandwidth. However, in order to guarantee that the messages can always be decoded by the receiver, they have to be differential with respect to the last ForceReliable message if any, not just the last message. The reason for this is that if the last message was not reliable, then some receiver may not have gotten the last message.
As a result, if the ForceReliable bit is set on after having been off for a while, it is very likely that a full object message will have to be sent. This can make the cost of setting the ForceReliable bit quite high. Objects have to have an associated field that specifies what the most recent reliably sent counter value was, or the system core must just use a full message whenever the prior message was not sent reliably.
Fifth, when the ForceReliable bit is set on, it stays on rather than automatically being turned off. If you want it turned off again, you have to do that explicitly.
If the InhibitReliable bit, which by default is not set, is set in an object, then information about changes in the object are communicated by multicast, and the system minimizes the effort spent to ensure that the message will be received. In particular, when the server finds out about a change that has the InhibitReliable bit set, it does not include the new counter value in Object State Summary messages. Note that the InhibitReliable bit must be shared, because the server needs to know when it is on. This means that while processes will get multicast change messages, processes that happen to miss messages about changes with the InhibitReliable bit on will never know that they have missed anything and therefore will not expend resources trying to get this information. Several non-obvious aspects of this communication are important:
First, in general it is intended that this feature will be used sparingly. In some sense the key purpose of ISTP is to make reliable communication so cheap that there is no need to have unreliable communication. Nevertheless, setting the InhibitReliable bit is appropriate when sending something like very rapid position updates, where the information is so rapidly out of date that there is no point in making it reliable.
Second, there is complexity here in that if the server gets several changes only the last of which has InhibitReliable set, then it must include the counter for the next to last change in its next Object State Summary message. It can achieve this by not updating its objects table when it receives changes with InhibitReliable set.
Third, another complexity here is that when using InhibitReliable one certainly also wants to use differential messages. However, these messages should reliably be differential all the way back to the last reliable message so that they can always be decoded. Alternatively, processes have to be able to ask for updates from the server when they are getting differential messages they cannot decode even when they are not getting Object State Summary messages that say that changes are occurring. The latter is certainly permitted by ISTP, but it would be easy to make a mistake and fail to support it.
Fourth, even if InhibitReliable is set all the time for an object, some changes nevertheless have to be sent reliably. In particular, the initial creation of an object and its eventual removal are always communicated reliably. If these changes were not reliably sent, then processes could get completely mixed up.
Fifth, when the InhibitReliable bit is set on, it stays on rather than automatically being turned off. If you want it turned off again, you have to do that explicitly.
Sixth, merely not changing the counter value would have a similar effect to the InhibitReliable bit, but would neither allow differential messages to work right nor allow processes to treat descriptions with duplicate counter values as coming from duplicate messages.
If the ForceReliable and InhibitReliable bits are both set in an object then changes are sent both by TCP and multicast UDP. This is costly of bandwidth, but guarantees minimum latency of communication and full reliability in minimum time.
m. Ownership Transfer
From the perspective of ISTP, a relatively small detail is that the ownership of objects can change. This is done by having the current owning process Pj send out a message in which the owner field has been changed to some other process Pk. However, several things need to be kept in mind.
First, after changing ownership, Pj cannot send out any other messages about the object, except that Pj must remember the state of the object in which the ownership changed as long as necessary to ensure that the server S finds out about the change or later states.
Once that has happened, all responsibility of Pj for the object ceases. While this is going on, and after, Pk can send out messages about the object.
Second, in the discussion above whenever it talks about a process Pj owning an object, what this means is when a process Pj `thinks` it owns an object. That is to say, when the world model in a process specifies that the process owns the object. This is distinct from some global concept of ownership.
Note that when a process Pj gives up ownership to Pk, Pj knows it is no longer the owner before Pk or any other process can find out that Pk is the owner. Therefore, there are brief periods when no process thinks that it is the owner of a given object. However, it can never happen that two processes think they are the owner of an object.
Note that if out-of-order messages later than MaxDelay were processed, then multiple simultaneous owners is one of the weird things that could result.
n. Simulated Multicast
For simplicity, the above assumed that all the processes in a group can be in multicast communication with each other. However, given the current state of the Internet, this may not be possible for many reasons including the fact that many routers are not multicast capable and many firewalls will not allow multicast traffic to pass through. Therefore, ISTP includes the capability to do communication via simulated multicast using TCP rather than actual UDP multicast.
In the simulated multicast mode, a process Pj does all of its communication with the server S rather than directly with other processes Pk. In particular, all the Object State messages it would have sent by UDP multicast, it instead sends directly to the server over the TCP connection. Similarly, all the messages Pj would have received by multicast it receives over the TCP connection instead. To facilitate this, everything is arranged in ISTP so that messages can be correctly interpreted no matter what communication channel they arrive on.
In simulated multicast mode, ISTP essentially operates in a central server mode and has no communication speed advantage over other central server designs. This mode is included in ISTP purely to allow graceful degradation when a given process is not capable of multicast communication with other processes in the group.
Note that given a group of processes, the situation involving multicast capabilities might be very complex featuring: multiple disconnected subgroups that are multicast capable within subgroups, processes that can send multicast but not receive it, and vice versa, and dynamic changes where processes are capable of multicast communication at some moments but not others. ISTP does not attempt to optimally use multicast in all this situations, rather it attempts to work well in a few common situations while working correctly in all situations.
In particular, the communication group is divided into two parts: one part which must include the server is the part where every process can multicast send and receive to and from every other, and the remainder where TCP is used for all communication. Therefore, each process Pj is tagged as either using multicast communication or not. Automatic switching from multicast capable to not is supported, but there is no automatic support for the reverse.
The following discusses in detail exactly how multicast is simulated, how the use of simulated multicast is triggered, and how a process could resume multicast operation after having switched to simulated multicast.
Locale Entry objects have an additional bit field not discussed above.
______________________________________Locale Entry message fields:. . .Bits: 16 bits - representing logical values.. . .UseTCP: bit 3 - if 1, forces all communication via TCP.. . .______________________________________
If a process Pj receives a Locale Entry message with the UseTCP bit on, it stops sending its relevant output via multicast and instead sends all of it directly to the server via TCP. If the UseTCP bit is on, then the value of the MulticastAddress field is irrelevant. Pj does not try to open a connection to the address and neither sends or receives on it. If a multicast connection was open, Pj closes it.
Note that a Locale Entry message with UseTCP on might arrive to initiate communication, or on the middle of communication. If Pj subsequently receives a Locale Entry message with UseTCP off, then Pj will attempt to resume the use of multicast.
If the server S has told a process Pj not to use multicast, then S forwards all the information originating from other process Pk to Pj via TCP and takes the information from Pj and multicasts it to the processes in the group that are multicast capable.
The decision of whether a process Pj uses multicast is a joint one between Pj and the server S. It can be done unilaterally by either party by direct request. Specifically, S can tell Pj not to use multicast as described above. Similarly, Pj can request that multicast not be used. For this purpose there is an additional bit in spCom objects not described above.
spCom objects have the following fields that are shared between process:
______________________________________. . .SharedBits: 16 bits - representing logical values.. . .UseTCP: bit 3 - if 1, forces all communication via TCP.. . .______________________________________
If the server receives an spCom object with the UseTCP bit on, then it should take this as a very strong request to reply with a Locale Entry message that also has the UseTCP bit on. A process Pj should turn this bit on initially if it has good reason to know that it is not multicast capable. Otherwise, as discussed below, there will be a period of low quality communication before ISTP automatically switches Pj to TCP mode.
Note that such an spCom could be sent to initiate communication or in the middle of communication to trigger a change. It is possible for an spCom requesting TCP to be followed later by one that requests that multicast communication be resumed. Using the bits above, either Pj or S can specify the use of TCP from the moment that Pj joins the group. However, it is expected that one might often want to be more optimistic, initially trying multicast and only switching to TCP if the multicast fails. To do this, Pj and S start out with multicast and observe the error rate in communication.
If Pj observes, based on Object State Summary messages from S, that a low percentage of its multicast output is getting to S, then Pj should send a new spCom requesting a switch to TCP.
If S observes, based on requests from Pj for object updates, that a low percentage of the data sent to it from other processes is reaching Pj, then S should send a new Locale Entry message switching Pj into TCP mode. For optimum performance, S should individually monitor how communication is going between each pair of processes in the group, but this is probably not necessary in most situations.
Using the above, it is easy to dynamically switch from multicast to TCP mode. However, once a process Pj is in TCP mode, there are no more attempts at multicast communication with Pj and therefore no basis on which to decide that one could switch successfully back to multicast mode. However, there are various approaches that could be used to make such a decision.
First, the server could occasionally switch Pj back into multicast mode and see if it worked. The price for this would be periods of reduced communication effectiveness. Therefore, if S takes this approach, it should reduce the frequency of its attempts if it meets with consistent failure.
Second, one could have Pj keep its multicast port open during TCP operation and create some experimental traffic specifically to assess whether multicast communication starts working. This is more complex, but allows the multicast connection to be assessed without forcing the application to suffer periods of poor communication.
Using one of the above approaches might be a good idea if multicast was working and unexpectedly stopped working. However, they are probably not worth the trouble if multicast never worked.
o. Locales
For simplicity, the discussion above has assumed that each process Pj participates in only a single communication group. However, the size of this group is limited by the number of processes a server can serve. This is a fundamental limit on scalability. A key aspect of ISTP is that it achieves scalability by breaking a virtual world into many chunks called `locales` as discussed in U.S. patent application Ser. No. 08/520,099 by Barrus J. W. and Waters R. C., A System For Designing a Virtual Environment Utilizing Locales, filed Aug. 28, 1995 and incorporated herein by reference. Each locale is associated with a separate multicast communication group and a given process is expected to belong to several of these groups.
The key aspect of locales is that everything described above operates per-locale, rather than just once. For example, a given process does not just have one connection to one server, but rather several connections to several servers.
Similarly, a process does not have just one spCom, but several. Each object in the world model is identified by an explicit field as being `in` at most one locale. All communication regarding an object occurs in the communication group associated with the locale the object is in. The information, including the multicast address, governing a communication group is cached in the associated locale object.
spCom objects are in locales just like any other. They trigger communication in the communication group associated with this locale.
Each locale is associated with a server. A given server may serve several locales. Locale objects specify, among other things, what server process serves the locale.
In general, having multiple simultaneous locale communication groups does not present any fundamental complications. However, there is one key thing that must be addressed--what happens when an object moves from one locale to another.
First, whenever an object changes locales, a full message describing the object has to be sent in the new locale and a possibly differential message has to be sent in the old locale specifying that the object has left the locale.
Second, just as the removal of an object has to be remembered for MaxDelay time, the leaving of an object from a locale has to be remembered for MaxDelay time, so that out-of-order messages will not erroneously cause an object to reappear in the locale.
Third, just as the initial download of information about objects in a locale must include information about recently removed objects, it must contain information about objects that have recently left the locale.
Fourth, a suggested MaxDelay interval can be specified as part of a locale object.
Having now described a few embodiments of the invention, and some modifications and variations thereto, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by the way of example only. Numerous modifications and other embodiments are within the scope of one of ordinary skill in the art and contemplated as falling within the scope of the invention as limited only by the appended claims and equivalents thereto.
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A system for fast, efficient and reliable communication of object state irmation among a group of processes combines the use of a fast, but lossy and thus unreliable communications channel to the group of processes and a server coupled to the group for providing data which has been lost in the multicasting. In one embodiment, a central server supports reliability and rapid joining while using UDP multicast messaging to achieve rapid interaction and low bandwidth. Differential messages are sent over the lossy channel to compactly describe how to compute the new state of an object from any of several previous states. Such a description can be interpreted even if some number of prior descriptions were not received, greatly reducing the need for explicit, round-trip message repairs while also conserving bandwidth. In one embodiment, the central server communicates with each member of the group over a reliable channel to robustly detect and repair objects affected by lost messages.
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CROSS-REFERENCE
[0001] This application claims priority to U.S. application Ser. No. 14/273,522, filed May 8, 2014 entitled “METHOD AND APPARATUS FOR RAPID SCALABLE UNIFIED INFRASTRUCTURE SYSTEM MANAGEMENT PLATFORM”, which claims the benefit of Provisional Patent Application Nos. 61/820,703 filed May 8, 2013 entitled “METHOD AND APPARATUS TO REMOTELY MONITOR INFORMATION TECHNOLOGY INFRASTRUCTURE”; 61/820,704 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ORCHESTRATE ANY-VENDOR IT INFRASTRUCTURE (COMPUTE) CONFIGURATION”; 61/820,705 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ORCHESTRATE ANY-VENDOR IT INFRASTRUCTURE (NETWORK) CONFIGURATION”; 61/820,706 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ORCHESTRATE ANY-VENDOR IT INFRASTRUCTURE (STORAGE) CONFIGURATION”; 61/820,707 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ENABLE LIQUID APPLICATIONS”; 61/820,708 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ENABLE LIQUID APPLICATIONS”; 61/820,709 filed May 8, 2013 entitled “METHOD AND APPARATUS TO ENABLE CONVERGED INFRASTRUCTURE TRUE ELASTIC FUNCTION”; 61/820,712 filed May 8, 2013 entitled “METHOD AND APPARATUS FOR OPERATIONS BIG DATA ANALYSIS AND REAL TIME REPORTING”; and 61/820,713 filed May 8, 2013 entitled “METHOD AND APPARATUS FOR RAPID SCALABLE UNIFIED INFRASTRUCTURE SYSTEM MANAGEMENT PLATFORM”; 61/827,635 filed May 26, 2013 entitled “METHOD AND APPARATUS FOR REMOTELY MANAGEABLE, DECLARATIVELY CONFIGURABLE DATA STREAM AGGREGATOR WITH GUARANTEED DELIVERY FOR PRIVATE CLOUD COMPUTE INFRASTRUCTURE”, 61/827,636 filed May 26, 2013 entitled “METHOD AND APPARATUS FOR REMOTELY MANAGEABLE, DECLARATIVELY CONFIGURABLE DATA STREAM AGGREGATOR WITH GUARANTEED DELIVERY FOR PRIVATE CLOUD COMPUTE INFRASTRUCTURE” and this application also claims the benefit of U.S. Provisional Patent Application No. 61/827,637 filed May 26, 2013 entitled “METHOD AND APPARATUS FOR REMOTELY MANAGEABLE, DECLARATIVELY CONFIGURABLE DATA STREAM AGGREGATOR WITH GUARANTEED DELIVERY FOR PRIVATE CLOUD COMPUTE INFRASTRUCTURE”, the contents of which are all herein incorporated by reference in its entirety.
FIELD
[0002] The disclosure generally relates to enterprise cloud computing and more specifically to a seamless cloud across multiple clouds providing enterprises with quickly scalable, secure, multi-tenant automation.
BACKGROUND
[0003] Cloud computing is a model for enabling on-demand network access to a shared pool of configurable computing resources/service groups (e.g., networks, servers, storage, applications, and services) that can ideally be provisioned and released with minimal management effort or service provider interaction.
[0004] Software as a Service (SaaS) provides the user with the capability to use a service provider's applications running on a cloud infrastructure. The applications are accessible from various client devices through either a thin client interface, such as a web browser or a program interface. The user does not manage or control the underlying cloud infrastructure including network, servers, operating systems, storage, or even individual application capabilities.
[0005] Infrastructure as a Service (IaaS) provides the user with the capability to provision processing, storage, networks, and other fundamental computing resources where the user is able to deploy and run arbitrary software, which can include operating systems and applications. The user does not manage or control the underlying cloud infrastructure but has control over operating systems, storage, and deployed applications; and possibly limited control of select networking components (e.g., host firewalls).
[0006] Platform as a Service (PaaS) provides the user with the capability to deploy onto the cloud infrastructure user-created or acquired applications created using programming languages, libraries, services, and tools supported by the provider. The user does not manage or control the underlying cloud infrastructure including network, servers, operating systems, or storage, but has control over the deployed applications and possibly configuration settings for the application-hosting environment.
[0007] Cloud deployment may be Public, Private or Hybrid. A Public Cloud infrastructure is provisioned for open use by the general public. It may be owned, managed, and operated by a business, academic, or government organization. It exists on the premises of the cloud provider. A Private Cloud infrastructure is provisioned for exclusive use by a single organization comprising multiple users (e.g., business units). It may be owned, managed, and operated by the organization, a third party, or some combination of them, and it may exist on or off premises. A Hybrid Cloud infrastructure is provisioned for exclusive use by a single organization comprising multiple users (e.g., business units). It may be owned, managed, and operated by the organization, a third party, or some combination of them, and it may exist on or off premises.
[0008] The promise of enterprise cloud computing was supposed to lower capital and operating costs and increase flexibility for the Information Technology (IT) department. However lengthy delays, cost overruns, security concerns, and loss of budget control have plagued the IT department. Enterprise users must juggle multiple cloud setups and configurations, along with aligning public and private clouds to work together seamlessly. Turning up of cloud capacity (cloud stacks) can take months and many engineering hours to construct and maintain. High-dollar professional services are driving up the total cost of ownership dramatically. The current marketplace includes different ways of private cloud build-outs. Some build internally hosted private clouds while others emphasize Software-Defined Networking (SDN) controllers that relegate switches and routers to mere plumbing.
[0009] The cloud automation market breaks down into several types of vendors, ranging from IT operations management (ITOM) providers, limited by their complexity, to so-called fabric-based infrastructure vendors that lack breadth and depth in IT operations and service. To date, true value in enterprise cloud has remained elusive, just out of reach for most organizations. No vendor provides a complete Cloud Management Platform (CMP) solution.
[0010] Therefore there is a need for systems and methods that create a unified fabric on top of multiple clouds reducing costs and providing limitless agility.
SUMMARY OF THE INVENTION
[0011] Additional features and advantages of the disclosure will be set forth in the description which follows, and will become apparent from the description, or can be learned by practice of the herein disclosed principles by those skilled in the art. The features and advantages of the disclosure can be realized and obtained by means of the disclosed instrumentalities and combinations as set forth in detail herein. These and other features of the disclosure will become more fully apparent from the following description, or can be learned by the practice of the principles set forth herein.
[0012] A Cloud Management Platform is described for fully unified compute and virtualized software-based networking components empowering enterprises with quickly scalable, secure, multi-tenant automation across clouds of any type, for clients from any segment, across geographically dispersed data centers.
[0013] In one embodiment, systems and methods are described for sampling of data center devices alerts; selecting an appropriate response for the event; monitoring the end node for repeat activity; and monitoring remotely.
[0014] In another embodiment, systems and methods are described for discovery of compute nodes; assessment of type, capability, VLAN, security, virtualization configuration of the discovered compute nodes; configuration of nodes covering add, delete, modify, scale; and rapid roll out of nodes across data centers.
[0015] In another embodiment, systems and methods are described for discovery of network components including routers, switches, server load balancers, firewalls; assessment of type, capability, VLAN, security, access lists, policies, virtualization configuration of the discovered network components; configuration of components covering add, delete, modify, scale; and rapid roll out of network atomic units and components across data centers.
[0016] In another embodiment, systems and methods are described for discovery of storage components including storage arrays, disks, SAN switches, NAS devices; assessment of type, capability, VLAN, VSAN, security, access lists, policies, virtualization configuration of the discovered storage components; configuration of components covering add, delete, modify, scale; and rapid roll out of storage atomic units and components across data centers.
[0017] In another embodiment, systems and methods are described for discovery of workload and application components within data centers; assessment of type, capability, IP, TCP, bandwidth usage, threads, security, access lists, policies, virtualization configuration of the discovered application components; real time monitoring of the application components across data centers public or private; and capacity analysis and intelligence to adjust underlying infrastructure thus enabling liquid applications.
[0018] In another embodiment, systems and methods are described for analysis of capacity of workload and application components across public and private data centers and clouds; assessment of available infrastructure components across the data centers and clouds; real time roll out and orchestration of application components across data centers public or private; and rapid configurations of all needed infrastructure components.
[0019] In another embodiment, systems and methods are described for analysis of capacity of workload and application components across public and private data centers and clouds; assessment of available infrastructure components across the data centers and clouds; comparison of capacity with availability; real time roll out and orchestration of application components across data centers public or private within allowed threshold bringing about true elastic behavior; and rapid configurations of all needed infrastructure components.
[0020] In another embodiment, systems and methods are described for analysis of all remote monitored data from diverse public and private data centers associated with a particular user; assessment of the analysis and linking it to the user applications; alerting user with one line message for high priority events; and additional business metrics and return on investment addition in the user configured parameters of the analytics.
[0021] In another embodiment, systems and methods are described for discovery of compute nodes, network components across data centers, both public and private for a user; assessment of type, capability, VLAN, security, virtualization configuration of the discovered unified infrastructure nodes and components; configuration of nodes and components covering add, delete, modify, scale; and rapid roll out of nodes and components across data centers both public and private.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the principles briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0023] FIG. 1 is a block diagram of an exemplary hardware configuration in accordance with the principles of the present invention;
[0024] FIG. 2 is a block diagram describing a tenancy configuration wherein the Enterprise hosts systems and methods within its own data center in accordance with the principles of the present invention;
[0025] FIG. 3 is a block diagram describing a super tenancy configuration wherein the Enterprise uses systems and methods hosted in a cloud computing service in accordance with the principles of the present invention;
[0026] FIG. 4 is a logical diagram of the Enterprise depicted in FIG. 1 in accordance with the principles of the present invention;
[0027] FIG. 5 illustrates a logical view that an Enterprise administrator and Enterprise user have of the uCloud Platform depicted in FIG. 1 in accordance with the principles of the present invention;
[0028] FIG. 6 illustrates a flow diagram of a service catalog classifying data center resources into service groups; selecting a service group and assigning it to end users;
[0029] FIG. 7 illustrates a flow diagram of mapping service group categories to user groups that have been given access to a given service group, in accordance with the principles of the present invention;
[0030] FIG. 8 illustrates the Cloud administration process utilizing the tenant cloud instance manager as well as the manager of manager and the ability of uCloud platform to logically restrict and widen scope of Cloud Administration, as well as monitoring;
[0031] FIG. 9 illustrates a hierarchy diagram of the Cloud administration process utilizing the tenant cloud instance manager as well as the manager of manager and the ability of uCloud platform to logically restrict and widen scope of Cloud Administration in accordance with the principles of the present invention;
[0032] FIG. 10 illustrates the logical flow of information from the uCloud Platform depicted in FIG. 1 to a Controller Node in a given Enterprise for compute nodes;
[0033] FIG. 11 illustrates the logical flow of information from the uCloud Platform depicted in FIG. 1 to the Controller Node in a given Enterprise for network components;
[0034] FIG. 12 illustrates the logical flow of information from the uCloud Platform to the Controller Node in a given Enterprise for storage devices;
[0035] FIG. 13 illustrates the application-monitoring component of the uCloud Platform in accordance with the principles of the present invention;
[0036] FIG. 14 illustrates the application-orchestration component of the uCloud Platform in accordance with the principles of the present invention;
[0037] FIG. 15 illustrates the integration of the application-orchestration and application-monitoring components of the uCloud Platform in accordance with the principles of the present invention;
[0038] FIG. 16 illustrates the big data component of the uCloud Platform depicted in FIG. 1 and the relationship to the monitoring component of the platform
[0039] FIG. 17 illustrates the process of deploying uCloud within an Enterprise environment;
[0040] FIG. 18 illustrates a flow diagram in accordance with the principles of the present invention;
[0041] FIG. 19 illustrates a flow diagram in accordance with the principles of the present invention;
[0042] FIG. 20 illustrates a flow diagram in accordance with the principles of the present invention;
[0043] FIG. 21 illustrates a flow diagram in accordance with the principles of the present invention;
[0044] FIG. 22 illustrates a block diagram in accordance with the principles of the present invention;
[0045] FIG. 23 illustrates a block diagram in accordance with the principles of the present invention; and
[0046] FIG. 24 illustrates a block diagram in accordance with the principles of the present invention;
[0047] FIG. 25 illustrates a block diagram in accordance with the principles of the present invention;
[0048] FIG. 26 illustrates a block diagram in accordance with the principles of the present invention; and
[0049] FIG. 27 illustrates a block diagram in accordance with the principles of the present invention.
DETAILED DESCRIPTION
[0050] The FIGURES and text below, and the various embodiments used to describe the principles of the present invention are by way of illustration only and are not to be construed in any way to limit the scope of the invention. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims. A Person Having Ordinary Skill in the Art (PHOSITA) will readily recognize that the principles of the present invention may be implemented in any type of suitably arranged device or system. Specifically, while the present invention is described with respect to use in cloud computing services and Enterprise hosting, a PHOSITA will readily recognize other types of networks and other applications without departing from the scope of the present invention.
[0051] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by a PHOSITA to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein.
[0052] All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates, which may need to be independently confirmed.
[0053] Reference is now made to FIG. 1 that depicts a block diagram of an exemplary hardware configuration in accordance with the principles of the present invention. A uCloud Platform 100 combining self-service cloud orchestration with a Layer 2- and Layer 3-capable encrypted virtual network may be hosted by a cloud computing service such as but not limited to, Amazon Web Services or directly by an enterprise such as but not limited to, a service provider (e.g. Verizon or AT&T), provides a web interface 104 with a Virtual IP (VIP) address, a Rest API interface 106 with a Virtual IP (VIP), a RPM Repository Download Server and, a message bus 110 , and a vAppliance Download Manager 112 . Connections to and from web interface 104 , Rest API interface 106 , RPM Repository Download Server, message bus 110 , and vAppliance Download Manager 112 are preferably SSL secured. Interfaces 104 , 106 , 107 and 109 are preferably VeriSign certificate based with Extra Validation (EV), allowing for 128-bit encryption and third party validation for all communication on the interfaces. In addition to SSL encryption on Message BUS 110 , each message sent across on interface 107 to a Tenant environment is preferably encrypted with a Public/Private key pair thus allowing for extra security per Enterprise/Service Provider communication. The Public/Private key pair security per Tenant prevents accidental information leakage to be shared across other Tenants. Interfaces 108 and 110 are preferably SSL based (with self-signed) certificates with 128-bit encryption. In addition to communication interfaces, all Tenant passwords and Credit Card information stored are preferably encrypted.
[0054] Controller node 121 performs dispatched control, monitoring control and Xen Control. Dispatched control entails executing, or terminating, instructions received from the uCLoud Platform 100 . Xen control is the process of translating instructions received from uCLoud Platform 100 into a Xen Hypervisor API. Monitoring is performed by the monitor controller by periodically gathering management plane information data in an extended platform for memory, CPU, network, and storage utilizations. This information is gathered and then sent to the management plane. The extended platform comprises vAppliance instances that allow instantiation of Software Defined clouds. The management, control, and data planes in the tenant environment are contained within the extended platform. RPM Repository Download Server 108 downloads RPMs (packages of files that contain a programmatic installation guide for the resources contained) when initiated by Control node 121 . The message bus VIP 110 couples between the Enterprise 101 and the uCloud Platform 100 . A Software Defined Cloud (SDC) may comprise a plurality of Virtual Machines (vAppliances) such as, but not limited to a Bridge Router (BR-RTR, Router, Firewall, and DHCP-DNS (DDNS) across multiple virtual local area networks (VLANs) and potentially across data centers for scale, coupled through Compute node (C-N) nodes (aka servers) 120 a - 120 n . The SDC represents a logical linking of select compute nodes (aka servers) within the enterprise cloud. Virtual Networks running on Software Defined Routers 122 and Demilitarized Zone (DMZ) Firewalls are referred to as vAppliances. All Software defined networking components are dynamic and automated, provisioned as needed by the business policies defined in the Service Catalogue by the Tenant Administrator.
[0055] The uCloud Platform 100 supports policy-based placement of vAppliances and compute nodes ( 120 a - 120 n ). The policies permit the Tenant Administrator to do auto or static placement thus facilitating creation of dedicated hardware environment Nodes for Tenant's Virtual Machine networking deployment base.
[0056] The uCloud Platform 100 created SDC environment enables the Tenant Administrator to create lines of businesses or in other words, department groups with segregated networked space and service offerings. This facilitates Tenant departments like IT, Finance and development to all share the same SDC space but at the same time be isolated by networking and service offerings.
[0057] The uCloud Platform 100 supports deploying SDC vAppliances in redundant pair topologies. This allows for key virtual networking building block host nodes to be swapped out and new functional host nodes be inserted managed through uCloud Platform 100 . SDCs can be dedicated to data centers, thus two unique SDCs in different data centers can provide the Enterprise a disaster recovery scenario.
[0058] SDC vAppliances are used for the logical configuration of SDC's within a tenants private cloud. A Router Node is a physical server, or node, in an tenant's private cloud that may be used to host certain vAppliances relating SDC networking. Such vAppliances may include the Router, DDNS, and BR-RTR (Bridge Router) vApplications that may be used to route internet traffic to and from an SDC, as well as establish logical boundaries for SDC accessibility. Two Router Nodes exist, an active Node (-A) and a standby Node (-S), used in the event that the active node experiences failure. The Firewall Nodes, also present in an active and standby pair, are used to filter internet traffic coming into an SDC. There is a singular vAppliance that uses the Firewall Node, that being the Firewall vAppliance. The vAppliances are configured through use of vAppliance templates, which are downloaded and stored by the tenant in the appliance store/Template store.
[0059] Reference is now made to FIG. 2 depicting a block diagram describing a tenancy configuration wherein the Enterprise hosts systems and methods within its own data center in accordance with the principles of the present invention. The uCloud platform 100 is hosted directly on an enterprise 200 which may be a Service Provider such as, but not limited to, Verizon FIOS or AT&T uVerse, which serves tenants A-n 202 , 204 and 206 , respectively. Alternatively, enterprise 200 may be an enterprise having subsidiaries or departments 202 , 204 and 206 that it chooses to keep segregated.
[0060] Reference is now made to FIG. 3 depicting a block diagram of a super tenancy configuration wherein the Enterprise uses systems and methods hosted in a cloud computing service 300 in accordance with the principles of the present invention. In this configuration, the uCloud platform is hosted by a cloud computing service 300 that services Enterprises 302 , 304 and 306 . It should be understood that more or less Enterprises could be serviced without departing from the scope of the invention. In the present example, Enterprise C 306 has sub tenants. Enterprise C 306 may be a service provider (e.g. Verizon FIOS or AT&T u-Verse) or an Enterprise having subsidiaries or departments that it chooses to keep segregated.
[0061] Reference is now made to FIG. 4 depicting a block diagram describing permutations of a Software Defined Cloud (SDC) in accordance with the principles of the present invention. The SDC can be of three types namely Routed 400 , Public Routed 402 and Public 404 . Routed and Routed Public SDC types 400 and 402 respectively are designed to be reachable through the Enterprise IP address space, with the caveat that the Enterprise IP address space cannot be in the same collision domain as these types of SDC IP network space. Furthermore, Routed and Public Routed SDC 400 and 402 respectively can re-use same IP network space without colliding with each other. The Public SDC 404 is Internet 406 facing only, it can have overlapping collision IP space with the Enterprise network. Public SDC 404 further provides Internet facing access only. SDC IP schema is automatically managed by the uCloud platform 100 and does not require Tenant Administrator intervention.
[0062] SDC Software Defined Firewalls 408 are of two/one type, Internet gateway (for DMZ use). The SDC vAppliances (e.g. Firewall 408 , Router 410 ) and compute nodes ( 120 a - 120 n ) provide a scalable Cloud deployment environment for the Enterprise. The scalability is achieved through round robin and dedicated hypervisor host nodes. The host pool provisioning management is performed through uCloud Platform 100 . The uCloud Platform 100 manages dedicated nodes for the compute nodes ( 120 a - 120 n ), it allows for fault isolation across the Tenant's Virtual Machine workload deployment base.
[0063] Referring back to FIG. 1 , an uCloud Platform administrator 102 A, an Enterprise administrator 102 B, and an Enterprise User 102 C without administrator privileges are depicted. To deploy uCloud platform 100 , Enterprise administrator 102 B grants uCloud Platform administrator 102 A information regarding the enterprise environment 101 and the hardware residing within it (e.g. compute nodes 120 a - n ). After this information is supplied, platform 100 creates a customized package that contains a Controller Node 121 designed for the Enterprise 101 . Enterprise administrator 102 B downloads and install Controller Node 121 into the Enterprise environment 101 . The uCloud Platform 100 then generates a series of tasks, and communicates these tasks indirectly with Controller Node 121 , via the internet 111 . The communication is preferably done indirectly so as to eliminate any potential for unauthorized access to the Enterprise's information. The process preferably requires uCloud platform 100 to leave the tasks in an online location, and the tasks are only accessible to the unique Controller Node 121 present in an Enterprise Environment 101 . Controller Node 121 then fulfills the tasks generated by uCloud platform 100 , and thus configures the compute 122 , network 123 , and storage 120 a - n capability of the Enterprise environment 101 .
[0064] Upon completion of the hardware configuration, uCloud platform 100 is deployed in the Enterprise environment 101 . The uCloud platform 100 monitors the Enterprise environment 101 and preferably communicates with Controller Node 121 indirectly. Enterprise administrator 102 B and Enterprise User 102 C use the online portal to access uCloud platform 100 and to operate their private cloud.
[0065] Software defined clouds (SDCs) are created within the uCloud platform 100 configured Enterprise 101 . Each SDC contains compute nodes that are logically linked to each other, as well as certain network and storage components (logical and physical) that create logical isolation for those compute nodes within the SDC. As discussed above, an enterprise 101 may create three types of SDC's: Routed 400 , Public Routed 402 , and Public 404 as depicted in FIG. 4 . The difference, as illustrated by FIG. 4 , is how each SDC is accessible to an Enterprise user 102 C.
[0066] Reference is now made to FIG. 5 that depicts a logical view of the uCloud Platform 100 that the Enterprise administrator 102 B and Enterprise user 102 C have in accordance with the principles of the present invention. Resources compute 502 , network 504 and storage 506 residing in a data center 507 are coupled to the service catalog 508 that classifies the resources into service groups 510 a - 510 n . A monitor 512 is coupled to the service catalog 508 and to a user 514 . User 514 is also coupled to service catalog 508 . Service catalog 508 is configured to designate various data center items (compute 502 , network 504 , and storage 506 ) as belonging to certain service groups 510 a - 510 n . The Service catalog 508 also maps the service groups to the appropriate User. Additionally, monitor 512 monitors and controls the service groups belonging to a specific User.
[0067] The service catalog 508 allows for a) the creation of User defined services: a service is a virtual application, or a category/group of virtual applications to be consumed by the Users or their environment, b) the creation of categories, c) the association of virtual appliances to categories, d) the entitlement of services to tenant administrator-defined User groups, and e) the Launch of services by Users through an app orchestrator. The service catalog 508 may then create service groups 510 a - 510 n . A service group is a classification of certain data center components e.g. compute Nodes, network Nodes, and storage Nodes.
[0068] Monitoring in FIG. 5 is done by periodically gathering management plane information data in the extended platform for memory, CPU, network, storage utilizations. This information is gathered and then sent to the management plane.
[0069] FIG. 6 illustrates a flow diagram of a service catalog classifying data center resources into service groups; selecting a service group and assigning it to end users. FIG. 7 illustrates a flow diagram of mapping service group categories to user groups that have been given access to a given service group, in accordance with the principles of the present invention.
[0070] Reference is now made to FIGS. 8 and 9 that illustrate the Cloud administration process its hierarchy respectively, utilizing the tenant cloud instance manager as well as the manager of manager and the ability of uCloud platform to logically restrict and widen scope of Cloud Administration as well as monitoring;
[0071] It should be noted that reference throughout the specification to “tenants” includes both enterprises and service providers as “super-tenants”. Each Software Defined Cloud (SDC) has a management plane, as well as a Data Plane and Control Plane. The Management plane provisions, configures, and operates the cloud instances. The Control plane creates and manages the static topology configuration across network and security domains. The Data plane is part of the network that carries user networking traffic. Together, these three planes govern the SDC's abilities and define the logical boundaries of a given SDC. The Manager of Manager 604 in uCLoud Platform 100 which is accessible only to the uCloud Platform administrator 102 A, manages the tenant cloud instance manager 706 ( FIG. 10 ) in every tenant private cloud. The hierarchy of this management is shown in FIG. 9 .
[0072] Referring now to FIGS. 10 , 11 and 12 , the tenant cloud instance manager 706 is responsible for overseeing the management planes of various SDC's as well as any other virtual Applications that the tenant is running in its compute Nodes, network components and storage devices, respectively. The uCloud Platform 100 generates commands related to the management of Compute Nodes 120 a - n based on tenant cloud instance manager 706 and extended platform orchestrator. The extended platform orchestrator is responsible for intelligently dispersing commands to create, manage, delete, or modify components of a tenant's uCloud platform 100 , or the extended platform based on predetermined logic. These commands are communicated indirectly to the Controller Node 121 of a specific Enterprise environment. The controller node 121 then accesses the compute Nodes 120 a - n and executes the commands. The launched cloud instance (SDC) management planes are depicted as 708 a - n in FIG. 10 . The ability of the tenant cloud instance manager 706 to modify and delete SDC management plane characteristics (compute, network, storage, Users, and business processes is provided over the internet 111 . Tenants (depicted in FIGS. 3 as 302 , 304 and 306 ) each have a Tenant cloud instance manager 706 viewable to through the web interface 104 depicted in FIG. 1 .
[0073] Again with reference to FIG. 8 , the monitoring platform 602 is not limited to one controller but rather, its scope is all controllers within the platform. The monitoring done by the controller 512 ( FIG. 5 ) is performed in a limited capacity, periodically gathering management plane information data in the extended platform for memory, CPU, network, storage utilizations. This information is gathered and then sent to the tenant cloud instance manager 706 .
[0074] Centralized management view of all management planes across the tenants is provided to uCloud Platform administrator 102 A through the uCloud web interface 104 depicted in FIG. 1 .
[0075] Reference is now made to FIG. 11 illustrating the logical flow of information from the uCloud Platform 100 to the Controller Node in a given Enterprise. The uCloud Platform 100 generates commands related to the management of Network components 122 and 123 based on tenant cloud instance manager and extended platform orchestrator element. The extended platform orchestrator is responsible for intelligently dispersing commands to create, manage, delete, or modify components of 100 , or the extended platform based on predetermined logic. These commands are communicated indirectly to the Controller Node ( 121 in FIG. 1 ) of a specific Enterprise environment 101 . The controller node then accesses the pertinent router nodes, and within them, the pertinent vAppliances, and executes the commands.
[0076] Reference is now made to FIG. 12 illustrating the logical flow of information from the uCloud Platform to the Controller Node in a given Enterprise. The uCloud Platform 100 generates commands related to the management of Storage components tenant cloud instance manager and extended platform orchestrator. The extended platform orchestrator is responsible for intelligently dispersing commands to create, manage, delete, or modify components of 100 , or the extended platform based on predetermined logic. These commands are communicated indirectly to the Controller Node 121 of a specific Enterprise environment. The controller node then accesses the pertinent storage devices and executes the commands.
[0077] Reference is now made to FIG. 13 illustrating the application-monitoring component of the uCloud Platform 100 in accordance with the principles of the present invention. The platform indirectly communicates with the Controller Node which monitors the application health. This entails passively monitoring a) the state of Enterprise SDC's ( 400 , 402 , 404 in FIG. 4 ), and b) the capacity of the Enterprise infrastructure. The Controller Node also actively monitors the state of the processes initiated by the uCloud Platform and executed by the Controller Node. The Controller Node relays the status of the above components to the uCloud Platform monitoring component 1000 .
[0078] Reference is now made to FIG. 14 illustrating the application-orchestration component of the uCloud Platform in accordance with the principles of the present invention. The app orchestrator performs the process of tracking service offerings that are logically connected to SDC's. It takes the requests from the service catalog and deterministically retrieves information on what compute Nodes and vAppliances are part of a given SDC. It launches service catalog applications within the compute nodes that are connected to a targeted SDC.
[0079] The process is as follows:
1. receive request for launch of a virtual application from service catalog 508 . 2. retrieve information on destination of the request (which SDC in which tenant environment) 3. Retrieve information of what devices compute Nodes and vAppliances are involved in the SDC 4. once it determines the above, the app orchestrator sends a configuration to launch these virtual applications to the controller Node.
Additionally, the app orchestrator will be used in conjunction with the app monitor in the uCloud platform 100 as well as the monitoring controller present in the controller node in the extended platform to a) receive requests from controller node and b) access the relevant tenant extended platform, determines the impacted SDC, and c) perform appropriate corrective action.
[0084] Reference is now made to FIG. 15 illustrating the integration of the application-orchestration and application-monitoring components of the uCloud Platform in accordance with the principles of the present invention. FIG. 15 illustrates part of the Monitoring functionality of the uCLoud platform 100 . Through use of the monitoring controller, the app monitor collects health information of the extended platform (as detailed herein above). In addition, a tenant can define a “disruptive event”. In the event of a disruptive event the monitoring controller will alert the app orchestrator to perform corrective action. The monitoring controller performs corrective action by rebuilding relevant portions of extended platform control plane.
[0085] Reference is now made to FIG. 16 illustrating the big data component of the uCloud Platform 100 and the relationship to the monitoring component of the platform. Based on the data collected by the Controller Node 121 that is relayed to the Platform and stored in a Database, an analysis can be made of, a) SDC and compute nodes usage, and b) disruptive events reported. Heuristics of cloud usage is tracked by the Controller Node. Heuristic algorithmic analysis is used in 100 to understand aspects of tenant cloud usage.
[0000] SDC instance information is collected from the SDC management plane by the tenant cloud instance manager. (achieved by a) tenant cloud instance manager sending a command to the controller node via the message bus, b) controller node uses the command to retrieve collected information from the correct SDC management plane, c) information is relayed to tenant cloud instance manager, d) information is stored in a database)
SDC instance Information refers to Data about services usage, services types, SDC networking, compute, storage consumption data. This Data is collected continuously (via process outlined above) and archived to an external Big Data database ( 1303 , contained in 100 ).
Big data analytics engine processes the gathered information and performs heuristic big data analysis to determine cloud tenant services usage, services types, SDC networking, compute, storage consumption data, and then suggests optimal cloud deployment for tenant (through web interface in 100 ).
[0086] This analysis can contain a determination of high priority events, and report it to the relevant administrators 102 A, and 102 B. Additional analysis can be made using business metrics and return on investment computations.
[0087] Reference is now made to FIG. 17 illustrates the process of deploying uCloud within an Enterprise environment. Using gathered information on compute nodes 120 a - n , uCloud Platform 100 creates a customized package that contains a Controller Node 121 , designed for the Enterprise 101 . Administrator 102 B then downloads and installs Controller Node 121 into the Enterprise environment 101 . The uCloud Platform then orchestrates the infrastructure within the Enterprise environment, via the Controller Node. This includes configuration of router nodes 122 , firewall node 123 , compute Nodes 120 a - n , as well as any storage infrastructure.
[0088] FIG. 17 represents a holistic view of the cloud management platform capabilities of uCloud Platform. The platform is separated into the hosted platform 100 and the management platform.
[0089] The uCloud Platform 100 can support many tenants recalling that a tenant is defined as an enterprise or a service provider. The multi tenant concept can be seen in FIG. 2 , as well as in FIG. 3 . The tenant environment prior to deployment of uCloud is a collection of Compute Nodes. Post uCloud deployment, the environment, now called a private cloud, comprises an extended platform and compute nodes. The extended platform comprises of a limited number of Nodes dedicated for the logical creation of clouds (SDC's). The compute Nodes are used as Enterprise resources, and can be part of a single or multiple SDC's, or software defined clouds. The SDC concept is seen in FIG. 4 . This is referred to as the “logical view” of the private cloud. The division of the extended platform and the compute nodes is seen in FIG. 1 . This will be referred to as the “hardware view” of the private cloud. The combination of the logical and hardware views is seen in ( FIG. 18 ). As mentioned, the extended platform consists of several Nodes (servers). Each Node will run specific types of virtual Appliances, or vAppliances, that regulate and create logical boundaries for an SDC. Every SDC will contain a specific set of vAppliances. The shaded regions of (FLOW 1 ) represent exclusive use of a set of vAppliances by a specific SDC. The Compute Nodes of a private cloud, seen in FIG. 1 and in FLOW as C-N, are a resource that can be shared between multiple SDC's. This sharing concept is seen in FIG. 18 .
[0090] The uCLoud Platform manages SDC's by providing several features that will assist a tenant in operating the private cloud. These features include, but are not restricted to, a) service catalog of virtual applications to be run on a given SDC, b) monitoring of SDC's, c) Big Data analytics of SDC usage and functionality, and d) hierarchical logic dictating access to SDC's/virtual applications/health information/or other sensitive information. The process of performing each feature has been shown in FIGS. 5-14 .
[0091] The uCloud Platform configuration process is summarized as follows: Using gathered information on compute nodes 120 a - n , uCloud Platform 100 creates a customized package that contains a Controller Node 121 , designed for the Enterprise 101 . 102 B then downloads and installs 121 into the Enterprise environment 101 . The uCloud Platform then orchestrates the infrastructure within the Enterprise environment, via the Controller Node. This includes configuration of router nodes 122 , firewall node 123 , compute Nodes 120 a - n , as well as any storage infrastructure. The combination of all uCLoud Platform components in the hosted and extended platforms allows for the operation of a multi-tenant, multi-User, scalable Private cloud.
[0092] FIGS. 22-24 illustrate embodiments of systems and methods for secure transmission of data to and from a tenant environment to the uCloud Platform to the tenant environment. FIG. 22 is a block diagram of an overview of an embodiment of a system according to the current invention. FIGS. 23 and 24 are block diagram of embodiment of a system according to the current invention.
[0093] Due to the nature of secure networking, it is not ideal to allow direct external access to a secure tenant environment. In order to allow the transmission of data from the uCloud Platform to a tenants environment, a system is created in the following manner. A tenant is onboarded initially, reserving certain nodes for the uCloud extended platform. This extended platform includes router nodes, firewall nodes, as well as a controller node 121 . This controller node 121 will contain several components. One such component is the tElastic Controller 2310 . The tElastic Controller 2310 is a vAppliance, similar to the router, firewall, DDNS, and bridge router vAppliances shown in FIG. 18 . The tElastic Controller 2310 serves as a Data stream aggregator, and will receive information from the uCloud Platform via a secure datastream.
[0094] Appropriate templates are downloaded in the nodes 120 reserved for the extended platform, an element corresponding to the tElastic Controller 2310 is created in the uCloud Platform. This element is called the Q. Together, both components will create a secure channel through which the tElastic Controller 2310 can receive messages, and execute commands.
[0095] In order to initial configuration of the tElastic Controller 2310 , the tenant is onboarded, tenant specifies nodes for Extended Platform, templates are downloaded for vAppliances, and a connection is established with Q in the uCloud Platform. In the initial connection, authentication of the tElastic Controller is performed by the uCloud Platform. The data stream is created through which the Q will communicate messages and commands to the tElastic Controller 2310 .
[0096] In operation, in the exemplary process, the application orchestrator utilizes the secure data stream to execute a certain result pertaining to the compute nodes 120 of a tenant's private cloud. The application orchestrator receives a compute node related request from a manager within uCloud Platform. The application orchestrator is in cooperation with the Q to create a simple data packet containing instructions for the tElastic Controller, as well as a return address. The tElastic Controller 2310 receives the data packet and executes the commands in the appropriate compute nodes 120 . The tElastic Controller 2310 sends a message confirming the completion of the task to the uCloud Platform via a protocol such as RestAPI call (show in FIG. 1 in 100 ).
[0097] The Q receives data packets via a redundant system of messaging servers. In order to guarantee delivery of the messages, the following process is implemented to the system. Messaging servers of Q receive data packet with instructions for/requests for information from compute nodes 120 of the tenant private cloud. These instructions are sent to the tElastic Controller. Messaging servers save a copy of the message in memory as well as in a file system. The Q sends messages to controller node 121 . If the tElastic Controller 2310 is overcapacity due to requests or the controller node 121 is non-responsive, the Extended Platform Monitor notifies the tenant administrator of the event. After the controller node 121 becomes available, the queued messages are delivered.
[0098] FIGS. 25 and 26 illustrate alternate embodiments of the invention which facilitate use of the secure data stream to execute network related instructions within the configured capabilities of a tenant's private cloud. The application orchestrator receives a network related request (for example router nodes, firewall nodes, vAppliances) from a manager within the uCloud Platform. The application orchestrator coordinates with the Q to create a simple data packet containing instructions for the tElastic Controller 2310 , as well as a return address. The tElastic Controller 2310 receives the data packet and executes the commands in the appropriate network related device, or through the extended platform monitor. The tElastic Controller 2310 sends a message confirming the completion of the task to the uCloud Platform via protocol such as a RestAPI call (seen in FIG. 1 in 100 ).
[0099] The Q receives data packets via a redundant system of messaging servers. In order to guarantee delivery of the messages, the following process is implemented to the system. Messaging servers of Q receive data packet with instructions for/requests for information from compute nodes 120 of the tenant private cloud. These instructions are sent to the tElastic Controller. Messaging servers save a copy of the message in memory as well as in a file system. The Q sends messages to controller node 121 . If the tElastic Controller 2310 is overcapacity due to requests or the controller node 121 is non-responsive, the Extended Platform Monitor notifies the tenant administrator of the event. After the controller node 121 becomes available, the queued messages are delivered.
[0100] FIG. 27 illustrates an alternate embodiment of the invention which facilitates use of the secure data stream to execute network related instructions within the configured capabilities of a tenant's private cloud. The application orchestrator receives a storage related request (for example disk storage or other I/O device) from a manager within the uCloud Platform. The application orchestrator coordinates with the Q to create a simple data packet containing instructions for the tElastic Controller 2310 , as well as a return address. The tElastic Controller 2310 receives the data packet and executes the commands in the appropriate network related device, or through the extended platform monitor. The tElastic Controller 2310 sends a message confirming the completion of the task to the uCloud Platform via protocol such as a RestAPI call (seen in FIG. 1 in 100 ).
[0101] The Q receives data packets via a redundant system of messaging servers. In order to guarantee delivery of the messages, the following process is implemented to the system. Messaging servers of Q receive data packet with instructions for/requests for information from compute nodes 120 of the tenant private cloud. These instructions are sent to the tElastic Controller. Messaging servers save a copy of the message in memory as well as in a file system. The Q sends messages to controller node 121 . If the tElastic Controller 2310 is overcapacity due to requests or the controller node 121 is non-responsive, the Extended Platform Monitor notifies the tenant administrator of the event. After the controller node 121 becomes available, the queued messages are delivered.
[0102] While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.
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Method and Apparatus for rapid scalable unified infrastructure system management platform are disclosed by discovery of compute nodes, network components across data centers, both public and private for a user; assessment of type, capability, VLAN, security, virtualization configuration of the discovered unified infrastructure nodes and components; configuration of nodes and components covering add, delete, modify, scale; and rapid roll out of nodes and components across data centers both public and private.
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] Exemplary embodiments of the invention relate to a method for operating an internal combustion engine, and an internal combustion engine which is designed for carrying out the method.
[0002] In automotive technology it is customary to filter soot particles from the exhaust gas, in particular from diesel engines, by means of a particle filter. The aim is to avoid an excessive accumulation of filtered particles in the particle filter. Accumulated soot particles in the particle filter may be continuously removed by oxidation, using NO 2 and H 2 O as oxidizing agents, at temperatures above approximately 250° C. This effect is also known as the continuous regeneration trap (CRT) effect, referring to a filter having continuous regeneration. Since the nitrogen oxides contained in the exhaust gas usually consist almost exclusively of NO, it is customary to increase the NO 2 portion by oxidizing this NO in an oxidation catalytic converter upstream from the particle filter. A corresponding system made up of a diesel oxidation catalytic converter (DOC) and a diesel particle filter (DPF) is known as a CRT System™.
[0003] The formation of NO 2 at the oxidation catalytic converter is improved by high proportions of noble metals, for example platinum and platinum group metals, which entails corresponding costs and is therefore disadvantageous. If the soot removal rate achieved by the CRT effect is not adequate, the particle filter is actively regenerated by thermally burning off the soot, specifically, by means of the oxygen contained in the exhaust gas. However, this thermal regeneration requires much higher temperatures of typically greater than 550° C. Such high temperatures seldom occur during normal driving operation, in particular in diesel engines, and must therefore often be provided by measures internal and/or external to the engine. This may take place, for example, by enrichment of exhaust gas with fuel, in particular in the form of uncombusted or partially combusted fuel, by means of fuel post-injection in the engine and subsequent exothermic oxidation of this fuel in an oxidation catalytic converter situated upstream from the particle filter and/or in the particle filter itself. The heating of the particle filter may be influenced by suitably adjusting the post-injection parameters, such as the time and quantity of the post-injection. Numerous variation options are described, for example, in PCT Publication WO 2005/003537 A1.
[0004] Exemplary embodiments of the invention are directed to an operating method for an internal combustion engine that effectively assists in particle filter regeneration, even under unfavorable operating conditions. Moreover, exemplary embodiments of the invention are directed to an internal combustion engine in which particle filter regeneration is made possible in the widest possible operating range, in particular even under partial load or low load.
[0005] In the method according to the invention, for assisting a regeneration of a particle filter situated in an exhaust gas tract of the internal combustion engine and downstream from an oxidation catalytic converter, post-injections of fuel by means of an injector take place in at least one cylinder of the internal combustion engine. According to the invention, it is additionally provided to advance a closing time of an exhaust valve of a cylinder of the internal combustion engine. The advance of the closing time is carried out in a first temperature range for a temperature of the oxidation catalytic converter, and the post-injections take place in a second temperature range for the temperature of the oxidation catalytic converter, an upper range limit of the first temperature range having a lower value than an upper range limit of the second temperature range.
[0006] The invention is based on the finding that, for carrying out intermittently performed particle filter regeneration by thermal soot burn-off, as well as for carrying out continuously performed particle filter regeneration by soot oxidation by means of NO 2 , in particular at low loads of the internal combustion engine it may be necessary to raise the exhaust gas temperature to a correspondingly required level. However, fuel post-injection has been found to be disadvantageous in two respects. First, oxidation of fuel introduced into the exhaust gas by post-injection cannot take place when the temperature of the oxidation catalytic converter is below its light-off temperature, i.e., the oxidation catalytic converter is not yet able to oxidize the fuel, which is present in the form of uncombusted or partially combusted fuel, to an appreciable extent. Second, it has been shown that uncombusted or partially combusted fuel portions in the exhaust gas may inhibit the ability of the oxidation catalytic converter to oxidize NO to NO 2 , in particular at comparatively low temperatures. These disadvantages may be avoided by carrying out advancement of the exhaust valve closing time, which increases the temperature, in an essentially lower temperature range that is the same as for the post-injection. Starting from low temperatures, heating of the exhaust gas initially takes place by advancing the exhaust valve control times. After the oxidation catalytic converter has reached a suitable temperature level, further heating takes place by oxidation of fuel that is introduced into the exhaust gas via the post-injection.
[0007] The post-injection preferably takes place in a range of approximately 60° crank angle to approximately 170° crank angle, particularly preferably in a range of 90° crank angle to 150° crank angle after top dead center, in the power stroke in at least one cylinder. At best, this results in a negligible influence of the post-injection on the torque provided by the internal combustion engine. Essentially uncombusted, possibly cracked, fuel is then discharged from the cylinder in question. This fuel is composed predominantly of short- to medium-chain hydrocarbons, carbon monoxide, and hydrogen. When post-injection takes place, at least one such post-injection is usually carried out after each torque-effective main injection.
[0008] Up to five individual post-injections per power stroke of the internal combustion engine operating according to the four-stroke process may take place in a time window having a duration of approximately 20 ms. In particular, one or more injections may be performed over a period of 0.2 ms to 3 ms in the power stroke. This period of 0.2 ms to 3 ms, for example, thus represents the speed-dependent time window per power stroke or working cycle of a particular cylinder operated with post-injection.
[0009] The second temperature range, i.e., the temperature range in which the post-injections are provided, preferably extends approximately from a lower range limit up to the upper range limit in the range of the light-off temperature of the oxidation catalytic converter, which may be regarded as the optimal temperature for formation of the CRT effect, and which is approximately 450° C. for the oxidation catalytic converter. The light-off temperature of a catalytic converter is usually understood to mean the temperature above which a noticeable quantity, typically approximately 50%, of the exhaust gas constituents to be treated is converted. A typical value of the light-off temperature is approximately 230° C. to 250° C.
[0010] At higher temperatures in the vicinity of the upper range limit of the second temperature range, the downstream particle filter is also advantageously heated by heat transfer. However, heating of the oxidation catalytic converter due to the exhaust gas enrichment with fuel by means of post-injection within the engine, resulting in an exhaust gas temperature downstream from the oxidation catalytic converter of greater than 330° C., and thus, a particle filter temperature of likewise greater than 330° C., may be quite adequate. The upper range limit of the second temperature range is typically not above 480° C. for the oxidation catalytic converter or for exhaust gas temperatures present on the outlet side of the oxidation catalytic converter, in order to minimize the complexity to the greatest extent possible.
[0011] Particularly effective oxidation of nitrogen oxide (NO) contained in the exhaust gas to nitrogen dioxide (NO 2 ), and particularly effective soot oxidation by the NO 2 that is generated, are made possible due to the setting of the temperature of the oxidation catalytic converter brought about by the post-injection. This in turn allows use of an oxidation catalytic converter having reduced loading of the noble metals platinum and/or palladium. In addition, particle filter regeneration by thermal soot burn-off may be largely avoided. The thermal load on the oxidation catalytic converter and disadvantageous aging effects are thus minimized. Therefore, little or no noble metal has to be kept on hand for compensating for an aging-related drop in activity.
[0012] Therefore, in the present case an oxidation catalytic converter is preferably used whose noble metal content, based on a volume of the oxidation catalytic converter, is in the range of 170 g/m 3 to 700 g/m 3 , in particular approximately 350 g/m 3 . Noble metal loadings of catalytic converters are also expressed in g/ft 3 ; with these units, the above-mentioned quantities correspond to values of 5 g/ft 3 to 20 g/ft 3 , preferably 10 g/ft 3 . Such noble metal loadings are relatively low compared to typical values, which are in the range of approximately 40 g/ft 3 to 70 g/ft 3 . The noble metals may comprise platinum and/or palladium. Even with such a low noble metal loading of the oxidation catalytic converter compared to customary values, significant activity for oxidation from NO to NO 2 may be achieved in the present case. By use of an oxidation catalytic converter having the above-described comparatively low noble metal content, a significant soot conversion rate, based on the CRT reaction, may already be achieved at a temperature above approximately 230° C.
[0013] With regard to the advancing of a closing time of an exhaust valve of a cylinder, this causes the exhaust valve to close before an exhaust stroke of the particular cylinder has ended, resulting in intermediate compression of the exhaust gas in the cylinder. During this intermediate compression, compression work is performed that results in an increase in the temperature of the exhaust gas. The oxidation catalytic converter may thus be heated and in particular brought to its light-off temperature in a particularly easy manner. It is particularly preferred to advance the closing time of at least one exhaust valve in all cylinders of the internal combustion engine.
[0014] Advancing the exhaust valve closing time may take place by means of a so-called phase shifter, i.e., a variable camshaft adjustment. The phase shifter thus ensures that the exhaust valve of the corresponding cylinder of the internal combustion engine closes earlier, and in customary designs of the phase shifter, thus also opens earlier.
[0015] Advancing the exhaust valve closing time represents a very effective method for exhaust gas heating, even when a post-injection is ineffective in this regard because the oxidation catalytic converter is still below its light-off temperature. The first temperature range, in which the advancement takes place, therefore preferably extends from very low temperatures of approximately 0° C. or even lower, to an upper range limit in the range of the light-off temperature of the oxidation catalytic converter.
[0016] In one embodiment of the invention, the lower range limit of the second temperature range is selected in such a way that it at least approximately corresponds to the light-off temperature of the oxidation catalytic converter. Thus, enrichment of the exhaust gas with fuel as a result of the post-injection does not occur until the oxidation catalytic converter has been brought to its light-off temperature. It is thus ensured that the oxidation catalytic converter is able to largely react the fuel introduced into the exhaust gas, and thus be brought to a temperature that is suitable for providing NO 2 . In particular, it may be provided that exhaust gas enrichment or fuel post-injection is not activated until a certain threshold value or trigger value of the temperature of the oxidation catalytic converter of approximately 230° C., for example, as the lower range limit for the second temperature range, has been reached. It is generally preferred for fuel enrichment of the exhaust gas to take place in a temperature range of the oxidation catalytic converter of 250° C. to 450° C. This ensures that, although the oxidation catalytic converter has reached its light-off temperature, the temperature remains in a range in which thermal damage to the oxidation catalytic converter may be largely avoided.
[0017] In another embodiment of the invention, the upper range limit of the first temperature range falls within the second temperature range, or at least approximately coincides with the lower range limit of the second temperature range.
[0018] In the first case, a gradual transition occurs between the operation of the internal combustion engine with advanced control time of the exhaust valve and the operation in which post-injection is carried out. Thus, for example, in the range of the light-off temperature of the oxidation catalytic converter, a post-injection quantity of fuel introduced into a particular cylinder of the internal combustion engine is increased with increasing temperature, while at the same time, an advance of the closing time of the exhaust valve or the exhaust valves is decreased, in particular in comparison to the operation of the oxidation catalytic converter strictly in heating mode. Thus, at the beginning, when the exhaust valve is still opening comparatively early, it is possible for only a small quantity of fuel to be introduced into the second cylinder via the post-injection. The farther the exhaust valve is advanced toward an early closing or opening time, the larger the quantity of fuel that can then be introduced into the cylinder in each post-injection. Wetting of the cylinder wall with post-injected fuel is thus largely avoided.
[0019] Undesirable wetting of the cylinder wall may result when, for early closing of the exhaust valve, the exhaust valve is also opened comparatively early. In this case, the pressure in the combustion chamber drops during the power stroke of the particular cylinder. If a post-injection takes place at this point in time, there is a risk of wetting the cylinder wall with fuel. This is due to the fact that, with reduced pressure in the combustion chamber, the fuel jet has a particularly large range during the post-injection. Wetting of the cylinder wall may in turn result in undesirable dilution of the engine lubricating oil. To prevent this, it may be provided that when post-injections are carried out, the control times of the exhaust valve are not advanced, and conversely, the closing or opening time of the exhaust valve is advanced only when post-injection is (still) not being carried out. Thus, post-injections are not begun until the control times of the exhaust valve once again correspond to those of normal operation without intermediate compression. In this case, the upper range limit of the first temperature range coincides with the lower range limit of the second temperature range.
[0020] In another embodiment of the invention, within the first temperature range, essentially a reduction in the advance of the closing time of the exhaust valve takes place with increasing temperature of the oxidation catalytic converter. Preferably the advance is progressively reduced with increasing temperature, in particular to quickly reset it to zero in the range of the light-off temperature or just before reaching same, and thus to produce the normal operating state. Further heating of the oxidation catalytic converter then occurs by oxidation of post-injected fuel.
[0021] In another embodiment of the invention, the post-injections in at least one of the cylinders of the internal combustion engine take place in a clocked manner, such that first time periods of a predefinable duration, in which post-injections are carried out in each working cycle of a particular cylinder, alternate in direct succession with second time periods of predefinable duration, in which the post-injections are prevented.
[0022] Depending on the heating requirement, a fairly large number of alternating first time periods that follow one another in direct succession are provided with exhaust gas enrichment or fuel post-injection in at least one cylinder, and second time periods are provided without exhaust gas enrichment or fuel post-injection. Due to this pulsed fuel enrichment of the exhaust gas, and carrying out a post-injection only intermittently in at least one cylinder, it is possible to achieve particularly high NO 2 formation at the oxidation catalytic converter and a particularly high oxidation rate by NO 2 and H 2 O for soot deposited in the particle filter. The CRT effect is thus particularly strong. This is because, among other things, during fuel enrichment of the exhaust gas, i.e., during the first time period, the oxidation catalytic converter is brought to a temperature that allows the highest possible activity of same with regard to oxidation of NO contained in the exhaust gas to NO 2 , which may then also take place in the second time period unhindered and without inhibition of the oxidation catalytic converter by the CO and/or HC. The pulsed exhaust gas enrichment with fuel by post-injection within the engine, in which phases or first time periods with exhaust gas enrichment alternate with phases or second time periods without exhaust gas enrichment, thus results in effective passive soot oxidation of the particle filter, i.e., effective passive regeneration of the particle filter.
[0023] In the first time periods with exhaust gas enrichment or fuel post-injection, the oxidation catalytic converter, the exhaust gas, and the particle filter downstream from the oxidation catalytic converter are heated due to the exothermic oxidation of uncombusted and/or partially combusted fuel in the oxidation catalytic converter. In phases without exhaust gas enrichment or post-injection, NO 2 formation and soot oxidation occur due to the CRT effect. In the process, the oxidation catalytic converter and the particle filter cool down only slightly on account of their heat capacity. The temperature to be provided for regenerating the particle filter may thus be significantly lowered in comparison to an active regeneration with thermal soot burn-off by oxidation with oxygen. This is accompanied by a reduction in the thermal load on the oxidation catalytic converter and the particle filter, which in particular may be a coated, i.e., catalytically active, particle filter.
[0024] Due to the low temperature load, aging of catalytic converters installed in the exhaust gas system, such as the oxidation catalytic converter and the particle filter, and optionally a selective catalytic reduction (SCR) catalytic converter or an ammonia slip catalytic converter, is reduced. This allows a significant reduction in the noble metal loading of the oxidation catalytic converter and/or of the particle filter. The SCR catalytic converter and/or the ammonia slip catalytic converter, which oxidizes ammonia possibly escaping from the SCR, may have correspondingly small dimensions. In addition, particularly inexpensive materials may be used for the SCR catalytic converter.
[0025] In the second time period, in which the exhaust gas is typically free of uncombusted fuel and comparatively rich in oxygen, the catalyst surface of the oxidation catalytic converter is cleaned of absorbed, inhibitive fuel molecules. As a result, the availability and the catalytically active surface of the oxidation catalytic converter are increased.
[0026] Thus, as a whole, all engine components or components of the exhaust gas system are cleaned by being intermittently acted on by exhaust gas enriched with fuel. Due to the cleaning and decontamination of the oxidation catalytic converter, a lowering of the light-off temperature of the oxidation catalytic converter is also achieved. In addition, the temporal separation of the heating, i.e., the enrichment of exhaust gas or the post-injection of fuel during the first time period, from the passive regeneration during the second time period results in a particularly good passive soot burn-off rate.
[0027] In another particularly advantageous embodiment of the invention the duration of the first time period and/or the duration of the second time period is/are predefined as a function of the temperature of the oxidation catalytic converter. The temperature may be measured downstream from the oxidation catalytic converter.
[0028] When the oxidation catalytic converter is comparatively cold, fuel may be introduced into at least one cylinder over a longer first time period than for when the oxidation catalytic converter is still comparatively hot. The first time period itself, i.e., the time period in which exhaust gas enrichment or post-injection is carried out anyway, is preferably in a range of 1 s to 300 s, in particular 3 s to 30 s. The duration of the second time period, during which the enrichment with fuel or post-injection of fuel in a second cylinder is prevented, may be in the range of 0.5 s to 200 s, in particular in a range of 10 s to 60 s. This second time period or post-injection pause is variable, and its duration in principle is also independent of the duration of the first time period. Thus, a shortening or lengthening of the first time period is not necessarily accompanied by a shortening or lengthening of the second time period. With the durations of the time periods described above, it is possible to achieve particularly extensive passive regeneration of the particle filter by means of the CRT effect.
[0029] When the oxidation catalytic converter is comparatively cold, and is heated only slightly above its light-off temperature, it is also advantageous to provide no, or only a very brief, post-injection pause, whereas when the oxidation catalytic converter is already comparatively hot, a correspondingly long post-injection pause may be provided. In particular, it is possible to provide no, or at best only a very brief, post-injection pause in a temperature window of 300° C. to 350° C. of the temperature of the oxidation catalytic converter or downstream therefrom.
[0030] Furthermore, a duration during which individual fuel post-injections are carried out in the at least one cylinder for each power stroke may be set as a function of the temperature. Such a short duration for each power stroke is particularly advantageous when the temperature is already high. Thus, namely the high temperature is easily maintained, and yet wetting of the wall of the at least one second cylinder with fuel is in particular largely prevented. In contrast, to achieve a comparatively large increase in the temperature of the oxidation catalytic converter, a longer overall duration of the post-injections for each power stroke may be provided, over which at least one post-injection is carried out in the at least one cylinder. This results in large injection quantities, which lead to a correspondingly rapid increase in the temperature.
[0031] In another embodiment of the invention, a divided recirculation of exhaust gas of the cylinders of the internal combustion engine into a feed air tract of the internal combustion engine is provided in such a way that exhaust gas only from a first portion of the cylinders is suppliable in an appreciable quantity to the feed air tract of the internal combustion engine, and exhaust gas from the remaining second portion of the cylinders is supplied essentially completely to the oxidation catalytic converter, with no recirculation, wherein post-injections of fuel take place only in at least one of the cylinders of the second portion of the cylinders. In other words, exhaust gas is enriched only for one or more cylinders whose exhaust gas is not recirculated. Stated another way, in general there is no fuel enrichment of exhaust gas by means of post-injection for one or more cylinders whose exhaust gas is recirculated.
[0032] This is based on the finding that fuel enrichment of the exhaust gas with uncombusted and/or partially combusted fuel may result in undesirable so-called sooting of the feed air tract when this exhaust gas is recirculated. This is avoided in the present case, since enrichment of exhaust gas is carried out only for the cylinder/cylinders whose exhaust gas is not able, or at best is able only to a negligible extent, to pass into an exhaust gas recirculation line via which exhaust gas is recirculatable into the feed air tract of the internal combustion engine. Functionally reliable operation of the internal combustion engine may be ensured in a particularly simple manner due to the avoidance of uncombusted fuel acting on the feed air tract, and in particular on a charge air cooler situated in the feed air tract or intake air path.
[0033] In another advantageous embodiment of the invention, for carrying out the post-injections, a control current of the injector is adjusted for actuating a valve needle of the injector as a function of a temperature of the oxidation catalytic converter. Changing the control current allows particularly accurate setting of low post-injection quantities, thus improving setting of the temperature of the particle filter. The method according to the invention is particularly suited for assisting with continuous particle filter regeneration via soot oxidation using NO 2 , corresponding to the CRT effect.
[0034] The injector may be an electromagnetic injector or piezo injector. In the preferred case of an electromagnetic injector, the control current flow through a solenoid, causing the valve needle of the injector to lift up and thus enabling a valve opening for the post-injection of fuel. The duration and height of the needle lift, together with a fuel injection pressure in conjunction with the flow coefficient of the injector, determine the quantity of fuel injected in each post-injection, and thus, the quantity of chemical energy introduced into the exhaust gas that is available for heating after conversion into thermal energy by exothermic oxidation at the oxidation catalytic converter or in the particle filter.
[0035] In another embodiment of the invention, above a predefinable temperature of the oxidation catalytic converter, a post-injection quantity is limited in that, during the post-injections, a needle lift amplitude of the valve needle of the injector is set that is less than a maximum needle lift amplitude. In this case the valve needle is not completely brought into its final position in the opened state of the injector, thus allowing small post-injection quantities to be accurately set. For this purpose, a reduced control current is set to a value below a control current nominal value. In this case, the magnetic force generated for the opening motion of the valve needle is less than with control with the nominal current, and the injector opens somewhat more slowly and with a delay. The valve needle typically drops back immediately after reaching the reduced lift amplitude for depositing the post-injection. The duration of a post-injection within a power stroke is thus comparatively short. This is particularly advantageous when the temperature is already high. Thus, the high temperature is easily maintained, and at the same time, due to the short duration, wetting of the wall of the at least one cylinder, operated with post-injection, with post-injected fuel is largely prevented.
[0036] In another advantageous variant, a similar behavior results when a duration of control of the injector with the control current is decreased for setting the reduced needle lift amplitude. Below a lower limit control duration, for an injector that is controlled with the nominal value of the control current or also with a lower control current, the valve needle no longer reaches the maximum possible lift, but instead reaches a reduced lift, and after reaching this reduced lift amplitude position quickly drops back to the closed state.
[0037] The internal combustion engine according to the invention has an exhaust gas tract in which an oxidation catalytic converter and a particle filter, situated downstream from the oxidation catalytic converter in terms of flow, are situated, and is designed for carrying out a method corresponding to at least one of the variants described above. In particular, appropriate control means such as an electronic control unit and corresponding actuators and sensors are provided for carrying out the control functions.
[0038] The features and feature combinations mentioned above in the description as well as the features and feature combinations mentioned below in the description of the figures and/or only shown in the figures may be used not only in the particular stated combination, but also in other combinations or alone without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0039] Further advantages, features, and particulars of the invention result from the claims, the following description of preferred embodiments, and with reference to the drawings, which show the following:
[0040] FIG. 1 shows an arrangement of an exhaust gas system in an internal combustion engine of a vehicle, fuel being post-injected into only two cylinders of the internal combustion engine, from which no exhaust gas is recirculated;
[0041] FIG. 2 shows the shifting of an opening time and a closing time of an exhaust valve of one of the cylinders of the internal combustion engine, and the change in pressure in the combustion chamber which accompanies this shift;
[0042] FIG. 3 shows a graph illustrating the procedure for advancing exhaust valve control times in conjunction with a setting of post-injection quantities;
[0043] FIG. 4 shows a graph illustrating an advantageous curve of the dependency of a control duration of an injector of the internal combustion engine on the temperature of an oxidation catalytic converter associated with the internal combustion engine;
[0044] FIG. 5 shows curves illustrating the pulsed post-injection of fuel, the associated heating of an oxidation catalytic converter of the exhaust gas system, and the changes in the NO 2 content in the exhaust gas which accompany the pulsed post-injection;
[0045] FIG. 6 shows a graph illustrating the variation over time of a control current and a needle opening when carrying out post-injections;
[0046] FIG. 7 shows another graph in which the full control current is applied over a shorter time period than in the graph according to FIG. 6 ;
[0047] FIG. 8 shows a graph according to FIG. 7 in which, however, an amplitude of the control current is additionally reduced compared to the graph according to FIG. 7 ;
[0048] FIG. 9 shows a graph according to FIG. 7 , but with a further reduced duration over which the control current is applied;
[0049] FIG. 10 shows the increase in the post-injection pause between time periods during which post-injections are carried out, as a function of the temperature of the oxidation catalytic converter; and
[0050] FIG. 11 shows a diagram illustrating an advantageous dependency of the injector control duration and of the post-injection pause on the temperature of the oxidation catalytic converter.
DETAILED DESCRIPTION
[0051] FIG. 1 shows an arrangement 10 of an exhaust gas system 12 in an internal combustion engine 14 , designed as a direct-injection 4-stroke diesel engine, of a vehicle, in particular a utility vehicle. The diesel engine 14 has four cylinders 16 , 18 , 20 , 22 in the present case. A group of two (in the present case) first cylinders 16 , 18 is fluidically coupled to a turbine 26 of an exhaust gas turbocharger via an exhaust gas line 24 . An exhaust gas recirculation line 28 branches off from the exhaust gas line 24 into which the exhaust gas of the two first cylinders 16 , 18 passes. The exhaust gas recirculation line 28 is designed as a high-pressure exhaust gas recirculation line in the present case; however, in addition a low-pressure exhaust gas recirculation may be provided. The quantity of exhaust gas recirculated into a feed air tract (not shown) of the internal combustion engine 14 may be set via an exhaust gas recirculation valve 30 , which is shown only schematically.
[0052] The other two, second cylinders 20 , 22 of the internal combustion engine 14 are fluidically coupled to the turbine 26 via a further exhaust gas line 32 . However, no exhaust gas recirculation line branches off from this second exhaust gas line 32 . Therefore, exhaust gas discharged from the second cylinders 20 , 22 is not able, or at best is able only to a negligible extent, to pass into the exhaust gas recirculation line 28 and to the inlet side of the internal combustion engine 14 . The exhaust gas lines 24 and 32 may be integral parts of an exhaust manifold having a two-part design.
[0053] The exhaust gas system 12 includes an oxidation catalytic converter 34 , in particular a diesel oxidation catalytic converter, situated downstream from the turbine 26 , downstream from which a particle filter 36 , in particular a diesel particle filter, is situated. The particle filter 36 may in particular be a particle filter coated with oxidation catalyst. Downstream from the particle filter 36 , an SCR catalytic converter 44 may be provided in the exhaust gas system 12 , downstream from which an (optional) catalytic converter for oxidizing ammonia, i.e., a so-called ammonia slip catalytic converter 46 , may be situated. If an SCR catalytic converter 44 is provided, upstream from same a metering device 48 meters a reducing agent solution for selective reduction of nitrogen oxides, preferably an aqueous urea solution, from which ammonia is formed in the hot exhaust gas. The ammonia is then reacted in the selective catalytic reduction (SCR) catalytic converter 44 in a selective catalytic reduction reaction with nitrogen oxides contained in the exhaust gas to produce nitrogen and water.
[0054] For operation of the diesel engine 14 , fuel is injected into the cylinders 16 , 18 , 20 , 22 via injectors (not illustrated), for which purpose the injectors are appropriately controlled with a control current by a control unit 50 . Without limiting the universality, it is assumed below that the injectors are those having an electromagnetically actuated valve needle. A plurality of individual fuel injections may be carried out in each working cycle. In the present case, an increase in the temperature of the oxidation catalytic converter 34 is achieved by means of fuel post-injection within the engine, so that the oxidation catalytic converter may oxidize NO present in the exhaust gas to NO 2 in a particularly efficient manner. A fuel post-injection may include multiple, in particular up to five, individual post-injection operations within a power stroke of a cylinder operated with post-injection. The discussion below refers to one post-injection for simplicity. Soot particles that have accumulated on the particle filter 36 may be oxidized by the NO 2 formed at the oxidation catalytic converter 34 , and by H 2 O. This passive regeneration of the particle filter 36 with soot oxidation using NO 2 preferably proceeds in a temperature range above approximately 300° C., i.e., in a temperature range in which thermal aging of the oxidation catalytic converter 34 is limited to a comparatively small extent. A temperature of approximately 450° C. is ideal and particularly preferred.
[0055] If the temperature of the oxidation catalytic converter 34 is below the light-off temperature, post-injection for the heating is not practical, and preferably is not provided or is provided only to a very limited extent. In such a case, heating of the oxidation catalytic converter 34 preferably takes place by shifting the control times of at least one exhaust valve in at least one of the cylinders 16 , 18 , 20 , 22 of the diesel engine 14 . In the present case a phase shifter is preferably used for this purpose. Due to such a variable camshaft control, an opening time 82 and a closing time 84 of an exhaust valve (see FIG. 2 ), in particular of the particular second cylinder 20 , 22 , are advanced. An advance of up to approximately 60° crank angle may be provided.
[0056] This is illustrated in FIG. 2 , in which a curve 86 shows the lift of an exhaust valve during normal operation of the diesel engine 14 . The exhaust valve correspondingly closes when an intake valve opens, the lift of which is depicted by a further curve 88 . Due to the phase shifter, the opening time 82 and the closing time 84 of the exhaust valve are now advanced, as depicted by a further curve 90 in FIG. 2 .
[0057] Correspondingly, a closing time 92 of the exhaust valve is reached before the exhaust stroke of the particular cylinder has ended. This results in an intermediate compression in the combustion chamber of the cylinder, which is depicted in FIG. 2 as the maximum 94 or peak of a further curve 96 which indicates the pressure in the combustion chamber.
[0058] The same as for the closing time 92 , an opening time 98 of the exhaust valve is also advanced. This causes the combustion chamber pressure to drop, specifically in the present case, in the range of approximately 140° crank angle. For illustrating this drop in pressure in the combustion chamber, in FIG. 2 a further curve 100 indicates the pressure conditions in the combustion chamber during normal control of the exhaust valve, corresponding to the curve 86 .
[0059] Due to the temperature increase accompanying the intermediate compression and which is caused by the residual gas still being compressed when the exhaust valve now closes earlier, the oxidation catalytic converter 34 may be brought to its light-off temperature in a particularly simple and uncomplicated way. The phase shifter preferably acts on all cylinders 16 , 18 , 20 , 22 of the diesel engine 14 in the same way.
[0060] However, if a post-injection is carried out in the combustion chamber when the pressure is reduced in the combustion chamber due to the early opening of the exhaust valve, the fuel jet is thus able to spray against the cylinder wall with a higher pulse and a larger mass fraction due to the lower back-pressure in the cylinder. This results in undesirable entry of fuel into the engine oil.
[0061] Therefore, in the present case with active post-injection, there is preferably little or no advancement of the opening time 82 and of the closing time 84 of the exhaust valve when post-injections take place. Conversely, post-injections are carried out anyway, in particular with a larger quantity of fuel 42 , only when the advanced opening time 98 and the advanced closing time 92 have been shifted back toward the normal position.
[0062] In particular in the range of the light-off temperature of the oxidation catalytic converter 34 , an overlap may be provided in such a way that an increasing quantity of fuel 42 is injected by means of the post-injection, while the advanced times are increasingly shifted back toward the normal opening time 82 and the normal closing time 84 . The wetting of the cylinder wall with fuel 42 introduced during a post-injection is thus limited to a minimum.
[0063] An example of a procedure is schematically illustrated in FIG. 3 . In the graph in FIG. 3 , a curve 102 is associated with an advance V, plotted on a left ordinate 106 , of the opening and closing time 82 , 92 , respectively, of a particular exhaust valve. An advance V is provided in a first temperature range, denoted by Δθ1, of the oxidation catalytic converter 34 .
[0064] Starting from low temperatures θ below the light-off temperature, denoted by θ A , of the oxidation catalytic converter 34 , the advance V of 100%, corresponding approximately to a 60° crank angle, is reduced to the normal operation setting with an increasing temperature θ plotted on an abscissa 110 . In particular, the advance is increasingly reduced in the range of the light-off temperature θ A . When an upper range limit Δθ1 o of the first temperature range Δθ1 is reached, the advance V of the control times is completely discontinued, and the normal operation of the diesel engine 14 with regard to the control times of the exhaust valves is achieved. Thus, no advance V of the control times is provided above the upper range limit Δθ1 o of the first temperature range Δθ1. The upper range limit Δθ1 o of the first temperature range Δθ1 preferably approximately corresponds to the light-off temperature θ A of the oxidation catalytic converter 34 , but, as illustrated in FIG. 3 , may also be slightly above same. It may thus be ensured that the oxidation catalytic converter 34 is reliably heated to the light-off temperature θ A or above same via the advance V of the exhaust valve control times. However, it is preferred that the upper range limit Δθ1 o of the first temperature range Δθ1 is not more than approximately 20 K above the light-off temperature θ A .
[0065] Upon reaching the light-off temperature θ A , the oxidation catalytic converter 34 is able to react uncombusted or partially combusted fuel constituents, for which reason further heating may be brought about in at least one of the second cylinders 20 , 22 by means of the above-described post-injection of fuel. A total post-injection quantity m NE for each power stroke, illustrated in FIG. 3 as the curve 104 and plotted on the ordinate 108 , is therefore set in such a way that it initially rises increasingly quickly within a second temperature range Δθ2 with increasing temperature Δθ As the heating requirement decreases and the temperature θ of the oxidation catalytic converter 34 increasingly approaches the target temperature of approximately 450° C., the total post-injection quantity m NE once again decreases. Thus, post-injections take place only in the second temperature range Δθ2. The lower range limit of the second temperature range Δθ2 at least approximately corresponds to the light-off temperature θ A of the oxidation catalytic converter 34 . The predefinable upper range limit Δθ2 o of the second temperature range Δθ2 corresponds to the mentioned target temperature at which an at least approximately optimal CRT effect may be achieved. By combining the advance V of the exhaust valve control times and the post-injection, heating of the oxidation catalytic converter 34 , and thus NO 2 formation, may therefore be achieved in an effective, fuel-conserving manner which allows effective soot oxidation in the particle filter 36 , and therefore largely avoids thermal particle filter regeneration by oxygen-induced soot burn-off.
[0066] It is provided that for the fuel post-injections within the engine in a cylinder operated in each case with post-injection, the control current of the particular injector is set as a function of the temperature θ of the oxidation catalytic converter 34 . This situation is illustrated by way of example by a diagram illustrated in FIG. 4 . In this diagram, a curve 80 depicts the curve of the control current I V , plotted on the ordinate 76 , as a function of the temperature θ of the oxidation catalytic converter 34 plotted on the abscissa 78 . In the present case, upon reaching the light-off temperature θ A of the oxidation catalytic converter 34 with regard to oxidation of hydrocarbons, a respective injector is controlled with the nominal value of the control current I V . To heat up the oxidation catalytic converter 34 as quickly as possible, initially a comparatively large post-injection quantity is preferably deposited, and a control duration of the injector likewise has a corresponding length, so that the valve needle of the injector is fully open during a post-injection operation.
[0067] With increasing temperature θ of the oxidation catalytic converter 34 , the heating requirement becomes increasingly less, and therefore the post-injection quantity decreases. After reaching a predefinable limit temperature θ G of approximately 380° C. to 420° C., in the present case the post-injection quantity is decreased by increasingly reducing the control current I V with further increasing temperature θ. This initially results in the valve needle opening less quickly and in a somewhat delayed manner, for which reason a reduced quantity of fuel is injected for the same control duration. Depending on the control duration, upon further reduction of the control current I V the valve needle no longer reaches its maximum possible lift amplitude. Particularly accurate setting of low post-injection quantities is made possible in this way. The oxidation catalytic converter 34 may therefore be held at an elevated temperature in a particularly effective manner, or heated to a sought target temperature without risk of excessive heating. It is provided to reduce the control current I V to no farther than a minimum value I V,min in order to ensure opening of the valve needle even with a reduced control current I V . With further increasing temperature θ of the oxidation catalytic converter 34 , after reaching the upper range limit Δθ2 o of approximately 450° C. to preferably 480° C. maximum of the second temperature range Δθ2, in which post-injections are provided anyway, no further heating is necessary, and the post-injections are ended. To avoid an undesirable influence on the torque-active main injection and on a pre-injection, which may possibly be provided, when the control current I V is reduced, it is preferably provided to adjust the time and duration of these fuel injections in compensation.
[0068] However, the enrichment of the exhaust gas with uncombusted or partially combusted fuel, brought about by a post-injection, may result in undesirable inhibition or passivation of the oxidation catalytic converter 34 with regard to its NO 2 formation activity. To nevertheless oxidize NO contained in the exhaust gas to NO 2 to the greatest extent possible, it is preferably provided to continually interrupt the post-injection. The inhibition is thus eliminated, and the oxidation catalytic converter 34 is once again able to oxidize NO to NO 2 at an increased rate. To ensure a heating function at the same time, the diesel engine 14 is operated intermittently in alternation with and without post-injection. In other words, in this operating mode, first time periods are provided in which a post-injection takes place, these first time periods alternating in direct succession with second time periods in which a post-injection is prevented. This procedure is explained in greater detail below with reference to FIG. 5 .
[0069] FIG. 5 illustrates a detail of a plurality of alternating time periods that follow one another in direct succession, in which a post-injection is carried out and prevented. In a first phase or time period 38 , post-injections are carried out in the diesel engine 14 in order to increase the temperature of the oxidation catalytic converter 34 . In a subsequent second phase or second time period 40 , no post-injection takes place; i.e., the carrying out of post-injections is prevented. Thus, the post-injections take place in a pulsed or clocked manner in the present case, so that the first time period 38 with post-injections alternates with the second time period 40 without post-injections.
[0070] In the present case, however, a post-injection of fuel 42 is carried out only in the second cylinders 20 , 22 (see FIG. 1 ), whose exhaust gas is not recirculated; these cylinders are thus connected to the second exhaust gas line 32 . In contrast, no post-injection takes place in the two first cylinders 16 , 18 of the diesel engine 14 ; therefore, these cylinders are not acted on by post-injected fuel 42 during the first time period 38 .
[0071] The post-injection of the fuel 42 thus takes place solely in the two second cylinders 20 , 22 , and not in the two first cylinders 16 , 18 , whose exhaust gas is or may be recirculated into the feed air tract to a greater or lesser extent. Action by post-injected, and thus uncombusted, fuel on the exhaust gas recirculation line 28 , on an exhaust gas recirculation cooler (not shown), and on the feed air tract, and therefore so-called sooting, are thus avoided.
[0072] The post-injection preferably takes place in the range of 60° crank angle to 170° crank angle after top dead center in the power stroke of the two second cylinders 20 , 22 . A range of 90° crank angle to 150° crank angle after top dead center is particularly preferred. Depending on the individual post-injection and depending on the temperature of the oxidation catalytic converter 34 , a quantity of 0 mg to 60 mg of fuel 42 per cylinder 20 , 22 and per liter of displacement of the respective cylinder 20 , 22 may be freely set.
[0073] The control unit 50 preferably ensures that no fuel is post-injected into the (in the present case) two first cylinders 16 , 18 during the first time period 38 , while only exhaust gas of the two second cylinders 20 , 22 is enriched with uncombusted hydrocarbons via the post-injection.
[0074] In FIG. 5 , in a first curve 52 , bars 54 depict the quantity of fuel 42 introduced into the two second cylinders 20 , 22 via the post-injection within the engine during the first time period 38 .
[0075] A second curve 56 in FIG. 5 depicts the ratio of NO 2 to NO x downstream from the oxidation catalytic converter 34 due to this intermittent or pulsed operation, i.e., the action by the post-injected fuel 42 on the two second cylinders 20 , 22 , and the subsequent second time period 40 during which primarily the passive regeneration of the particle filter 36 takes place. Consequently, in the heating phase, i.e., during the first time period 38 , there is practically no NO 2 in the exhaust gas. However, a large quantity of NO 2 is formed when no more fuel is post-injected into the second cylinders 20 , 22 of the diesel engine 14 during the second time period 40 . Thus, during the second time period 40 , i.e., in the regeneration mode, a comparatively large quantity of NO 2 is available in the exhaust gas.
[0076] A further curve 58 depicts the temperature of the exhaust gas downstream from the oxidation catalytic converter 34 . This curve fluctuates according to the action by fuel on the exhaust gas in the heating mode, and is thus higher during the first time period 38 than in the subsequent regeneration phase or second time period 40 . However, these fluctuations in the temperature are damped due to the comparatively high heat capacity of the oxidation catalytic converter 34 . The fluctuation in the temperature on the outlet side of the particle filter 36 , which occurs in a time-delayed delayed manner, is even more strongly damped, as depicted by a further curve 60 in FIG. 5 .
[0077] FIG. 6 shows a detailed view of how a particular injector is controlled during the first time period 38 in order to inject the fuel 42 into the two second cylinders 20 , 22 in an individual post-injection operation. T 1 denotes the control duration of the injector for carrying out an individual post-injection operation for each power stroke of the second cylinder 20 , 22 ; the control duration T 1 may in particular be 0.2 ms to 20 ms. However, multiple, typically up to four, individual post-injections may also be carried out during this period.
[0078] In FIG. 6 , T 2 corresponds to the first time period 38 , i.e., a period of time during which fuel 42 is post-injected into a particular second cylinder 20 , 22 during each power stroke. This period of time is in a range of 1 s to 300 s. A post-injection pause corresponds to the second time period 40 , and according to FIG. 6 results from the difference T 3 −T 2 , where T 3 is the time period from the beginning of a first post-injection to the end of the post-injection pause.
[0079] A curve 62 in FIG. 6 indicates the control current I V that causes the injector to open, and causes the valve needle of the injector to lift up and thus enables a valve opening for the post-injection of fuel. A value of the control current I V is indicated on a left ordinate 65 of the graph in FIG. 6 . During the control duration T 1 of an individual post-injection operation, the control current I V is applied to the injector of a particular second cylinder 20 , 22 . FIG. 6 depicts a further time period 64 indicating the time between two power strokes of the second cylinder 20 , 22 , i.e., the time between two control durations T 1 . This time period 64 is correspondingly short at a high speed of the diesel engine 14 .
[0080] In the mode of operation according to FIG. 6 , the particular injector is acted on with a comparatively large control current I V , and for a comparatively long control duration T 1 . Correspondingly, a needle opening or a valve needle lift H of 100%, corresponding to the maximum needle lift amplitude, is reached over a comparatively long time period, as depicted by a curve 63 ; a value of the needle opening H is indicated on an ordinate 66 of the graph in FIG. 6 . Such a setting is advantageous for a sought rapid heating of the oxidation catalytic converter 34 . In particular, at a comparatively high load of greater than approximately 60% of the nominal load of the diesel engine 14 , and/or under highly variable load, at the same time with a relatively long post-injection pause of more than approximately twice the first time period T 2 , a fuel-conserving temperature setting of the oxidation catalytic converter 34 is made possible for achieving a high NO 2 fraction in the exhaust gas.
[0081] A post-injection quantity adapted to a particular heating requirement for the oxidation catalytic converter 34 may advantageously be achieved not only by changing or reducing the control current I V , but also by changing the control duration T 1 . In a mode of operation of the diesel engine 14 depicted in the graph according to FIG. 7 , the control duration T 1 of the control current I V is shortened and the time period 64 is correspondingly longer. A needle opening H of 100% is achieved, but only for a short time. Thus, a smaller quantity of fuel 42 is post-injected into the two second cylinders 20 , 22 . Such a mode of operation is particularly advantageous when only a comparatively small temperature rise of the oxidation catalytic converter 34 is sought, for example when the oxidation catalytic converter 34 already has a comparatively high temperature θ of approximately 400° C. or above. If the engine speed is comparatively low, for example lower than 1500/min, the time period 64 is correspondingly lengthened, and only a comparatively small number of post-injections can be carried out per unit time. In such a case, it is advantageous to shorten the injection pause T 3 −T 2 and to correspondingly lengthen the first time period T 2 , for example to a greater value than the post-injection pause.
[0082] When the control current I V is additionally reduced with a shortened control duration T 1 according to FIG. 7 , the post-injection quantity may be adjusted even more finely, in particular even further reduced. In such a case, depicted in FIG. 8 , the needle lift H no longer reaches the value of the maximum possible needle lift amplitude, but, rather, only reaches a more or less reduced needle lift amplitude corresponding to the reduced height or amplitude 68 of the control current I V . Correspondingly, even a smaller needle opening H than the needle opening H of 100% is achieved only for a very short period.
[0083] In the mode of operation of the internal combustion engine 14 according to FIG. 9 , the reduced needle lift H of less than 100% is achieved by the nominal control current I V acting on the injector, analogously to FIG. 7 , but with a further decreased control duration T 1 .
[0084] Thus, a needle lift amplitude of the valve needle of the injector that is less than a maximum needle lift amplitude may be set by reducing the control current I V and by reducing the control duration T 1 , thus limiting the post-injection quantity. Incomplete opening of the valve needle is attributed to its ballistic properties, and the corresponding state may also be referred to as a ballistic needle lift.
[0085] A quantity of post-injected fuel 42 that is reduced in this way is provided in particular when the oxidation catalytic converter 34 has reached a comparatively high temperature. Then, even though the temperature of the oxidation catalytic converter 34 is in particular largely maintained, undesirable wetting of the walls of the second cylinders 20 , 22 with the post-injected fuel 42 does not occur.
[0086] Full variability of the control duration T 1 and of the amplitude 68 of the control current I V is provided within the first time period 38 , as the result of which the post-injection quantity may be adapted to a heating requirement for the oxidation catalytic converter 34 or the particle filter 36 , and at the same time a strongly pronounced CRT effect may be achieved, flexibly and virtually independently of the engine operating state, but still taking it into account.
[0087] One example of such is depicted in a diagram shown in FIG. 10 , in which a duration of the post-injection pause, which is preferably set as a function of the temperature θ of the oxidation catalytic converter 34 , is illustrated by way of example. The duration of the post-injection pause T 3 −T 2 is indicated on the abscissa 70 , and the temperature θ on the outlet side of the oxidation catalytic converter 34 is indicated on the ordinate 72 . An increasingly lengthening post-injection pause or time period 40 with increasing temperature θ of the oxidation catalytic converter 34 is preferably set, and in particular in a temperature range close to a target temperature of approximately 450° C., corresponding to the curve 74 shown in the diagram. For a less strongly heated oxidation catalytic converter 34 , no, or only a very brief, post-injection pause is set, depending on the heating requirement, while for a comparatively hot oxidation catalytic converter 34 a longer second time period 40 is present.
[0088] Another example of a preferred procedure for setting the pulsed post-injection is depicted in a diagram shown in FIG. 11 , in which the setting of the control duration T 1 (curve 112 ) and of the post-injection pause T 3 −T 2 (curve 114 ) as a function of the temperature θ of the oxidation catalytic converter 34 , plotted on the abscissa 120 , are illustrated. The control duration T 1 is associated with a left ordinate 116 , and the post-injection pause T 3 −T 2 is associated with a right ordinate 118 . Analogously to the curve 74 in FIG. 10 , a duration of the injection pause that increases with increasing temperature θ of the oxidation catalytic converter 34 is set. At the same time, upon exceedance of the light-off temperature θ A of the oxidation catalytic converter 34 a control duration T 1 that initially rises quickly is set. A comparatively large post-injection quantity is thus achieved which allows rapid heating of the oxidation catalytic converter 34 . With increasing temperature θ of the oxidation catalytic converter 34 , the heating requirement decreases and the control duration T 1 is reduced until, upon reaching the predefinable upper range limit Δθ2 o of approximately 450° C. of the second temperature range Δθ2, the post-injection operation is ended. Below a control duration T B , the above-described ballistic behavior of the valve needle develops, with a lift amplitude that is less than the maximum lift amplitude.
[0089] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
LIST OF REFERENCE NUMERALS
[0000]
10 Arrangement
12 Exhaust gas system
14 Internal combustion engine
16 Cylinder
18 Cylinder
20 Cylinder
22 Cylinder
24 Exhaust gas line
26 Turbine
28 Exhaust gas recirculation line
30 Exhaust gas recirculation valve
32 Exhaust gas line
34 Oxidation catalytic converter
36 Particle filter
38 Time period
40 Time period
42 Fuel
44 SCR catalytic converter
46 Ammonia slip catalytic converter
48 Metering device
50 Control unit
52 Curve
54 Bar
56 Curve
58 Curve
60 Curve
62 Curve
63 Curve
64 Time period
65 Ordinate
66 Ordinate
68 Amplitude
70 Abscissa
72 Ordinate
74 Curve
76 Ordinate
78 Abscissa
80 Curve
82 Opening time
84 Closing time
86 Curve
88 Curve
90 Curve
92 Closing time
94 Maximum
96 Curve
98 Opening time
100 Curve
102 Curve
104 Curve
106 Ordinate
108 Ordinate
110 Abscissa
112 Curve
114 Curve
116 Ordinate
118 Ordinate
120 Abscissa
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A method for operating an internal combustion engine involves using an injection valve to post-inject fuel into at least one cylinder of the internal combustion engine in order to help regenerate a particulate filter that is arranged in an exhaust system of the internal combustion engine, downstream of an oxidation catalyst. A closing moment of a discharge valve of a cylinder of the internal combustion engine is advanced when the temperature of the oxidation catalyst is in a first temperature range, and the post-injections are performed when the temperature of the oxidation catalyst is in a second temperature range, an upper limit of the first temperature range having a lower value that an upper limit of the second temperature range.
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BACKGROUND OF THE INVENTION
This invention relates to locks for golf cars and other vehicles not having lockable doors and other locking means.
Previously, golf cars have been almost unprotected against theft unless locked in a building. Steering-wheel locks have been devised for cars but not adequately for golf cars which have too much open space for such rods to be attachable to steering wheels as locks. Also, large power-storage batteries, wiring and other items under seats of golf cars have been relatively unprotected against larceny. Many golf courses to provide some measure of security use chains and locks stretched over the golf cars and through the steering wheels. Unfortunately, removing the chains scrapes and damages the golf cars and still leaves the batteries unprotected from theft. Examples of mere steering-wheel-lock rods are described in U.S. Pat. No. 5,157,951 granted to Chen, et al., issued Oct. 27, 1992; U.S. Pat. No. 5,212,973 granted to van Staden, et al. issued May 25 1993; U.S. Pat. No. 5,239,849 granted to Gallardo, issued Aug. 31, 1993; U.S. Pat. No. 5,121,617 granted to Chen, issued Jun. 16, 1992; U.S. Pat. No. 5,024,069 granted to Hull, Jr., et al., issued Jun. 18, 1991; U.S. Pat. No. 4,103,524 granted to Mitchell, et al., issued Aug. 1, 1978; U.S. Pat. No. 4,304,110 granted to Fain, issued Dec. 8, 1981; and DES 339,974 granted to Wilcox, issued Oct. 5, 1993. No security apparatuses like the present invention exists in the prior patented or commercialized art.
SUMMARY OF THE INVENTION
In light of problems that have existed and that continue to exist in this field, objectives of this invention are to provide golf-car locking devices which:
Protect against theft of the golf car by preventing rotation of a steering wheel of a golf car;
Protect against removal of power-storage batteries and wiring from golf cars; and
Protect against turning of one or more wheels of a golf car.
This invention accomplishes the above and other objectives with a restraining member positioned on a seat of a golf car to prevent access to power-storage batteries and extended from a seat upright member behind the seat and attached member extended from the restraining member to a locking position on a steering wheel. Wheel-locking means are provided optionally in addition.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention is described by appended claims in relation to a description of the preferred embodiments with reference to the following drawings which are described briefly as follows:
FIG. 1 is a side elevation view of this invention attached to a golf car with a sectional cutaway showing a position of batteries being protected under seats of the golf car;
FIG. 2 is a sectional top view of an embodiment with a bifurcated rod locked to a steering wheel;
FIG. 3 is a sectional bottom view of the FIG. 2 illustration;
FIG. 4 is a cutaway sectional side view of the bifurcated rod having an inward hook and attached to a steering wheel with a padlock;
FIG. 5 is a cutaway sectional side view of the bifurcated rod having an outward hook and attached to a steering wheel with a padlock;
FIG. 6 is a cutaway sectional side view of an embodiment with a clamp rod having an outward hook and attached to a steering wheel with a padlock;
FIG. 7 is a cutaway sectional side view of the FIG. 6 embodiment with a clamp rod having an outward hook and with an attachment clamp in open mode unlocked on a steering wheel;
FIG. 8 is a bottom view of the FIG. 6 embodiment having a seat-back attachment extended pivotally;
FIG. 9 is a cutaway sectional side view of an embodiment with a telescopic rod attached to a steering wheel;
FIG. 10 is a top view of the FIG. 9 embodiment having a seat-back attachment extended telescopically;
FIG. 11 is a side view of the FIG. 10 illustration;
FIG. 12 is a sectional top view of a seat-back attachment for either embodiment;
FIG. 13 is a sectional top view of a seat-back attachment particularly constructed for the embodiment with a telescopic rod for attachment to steering wheels;
FIG. 14 is a top view of a seat-back plate for being positioned between a seat-back support and a seat-back attachment.
FIG. 15 is a partially cutaway front view of a wheel-lock clamp attached to and padlocked onto a rim of a golf-car wheel;
FIG. 16 is a top view of the FIG. 15 illustration with a lock pin representative of a padlock shackle or other locking means; and
FIG. 17 is a partially cutaway front view of the wheel-lock clamp in an unlocked mode.
DESCRIPTION OF PREFERRED EMBODIMENTS
Reference is made first to FIG. 1. A seat restraint 1 is positioned on a seat 2 of golf car 3 to prevent lifting of the seat 2 for unauthorized access to a battery 4 and other valuables such as wiring under the seat 2. The seat restraint 1 is attached to a seat-back support 5 with a bifurcated extension 6 of the seat restraint 1 at a rear portion of the seat 2. At a forward portion of the seat 2, the seat restraint 1 is attached to a steering-wheel attachment 7 that is attachable to a steering wheel 8 of the golf car 3. A wheel-lock clamp 9 is attachable to a rim 10 of a wheel 11 and extended radially from a position at an outside periphery of a tire 12 of one or more wheels 11 of the golf car 3. In this manner the golf car 3 is protected against turning of its steering wheel 8, against removal of its expensive storage batteries 4 and against rotation of its wheels 11 by being pushed or towed.
Referring to FIGS. 1-5, the steering-wheel attachment 7 can be a bifurcated rod 13 with a spoke bifurcation 14 extended laterally from a side of a steel rod for fitting on opposite sides of a steering-wheel spoke 15. With the spoke bifurcation 14 positioned on both sides of the steering wheel 8, a padlock shackle 16 of a padlock 17 is inserted into lock apertures 18 at an opposite side of the steering-wheel spoke 15 from the bifurcated rod 13.
In the FIG. 2 top view, the bifurcated rod 13 is shown on top of a score card 19 that is positioned usually on a center of a golf-car steering wheel 8. The score card 19 is shown under the steering wheel 8 in the bottom view FIG. 3. In FIGS. 2-3, opposite sides of the spoke bifurcation 14 are shown on opposite sides of a steering-wheel spoke 15. In FIGS. 4-5, one side of the spoke bifurcation 14 is shown on one side of a steering-wheel spoke 15.
Steering-wheel hooks can be extended inwardly or outwardly from different types of steering-wheel attachments 7. In FIGS. 1-4, an inward steering-wheel hook 20 is extended inwardly from a distal end of the bifurcated rod 13. In FIG. 5, an outward steering-wheel hook 21 is shown extended outwardly from a position near the distal end of the bifurcated rod 13.
Different embodiments of the steering-wheel attachments 7 can be attached variously to the seat restraints 1. In FIGS. 1-3, the bifurcated rod 13 as a form of steering-wheel attachment 7 is shown attached pivotally to the seat restraint 1. In FIG. 1, a single-side pivotal attachment of the steering-wheel attachment 7 to the seat restraint 1 is shown. In FIGS. 2-3, a bifurcate pivotal attachment of the bifurcated rod 13 to the seat restraint 1 is shown. Telescopic and various forms of rigid fastener means can be employed also.
In FIGS. 2-5, the steering-wheel spokes 15 are shown extended in a "Y" formation from a steering rod 22. In FIG. 1, a steering-wheel attachment 7 is shown without particular positioning of the steering-wheel attachment 7 in relation to the steering-wheel spokes 15. This is representative of forms of steering-wheel attachments 7 which are attachable between or which are attachable directly to the steering-wheel spokes 15.
Referring to FIGS. 6-8, a clamp rod 23 is illustrated as an optional form of steering-wheel attachment 7. A clamp jaw 24 is attached pivotally to the clamp rod 23 at a position opposite a circumferential section of the steering wheel 8 from a padlock aperture 18. The clamp jaw 24 is angled and/or curved to fit around the circumferential section of the steering wheel 8 at a position between the steering-wheel spokes 15 in a locked mode with a padlock shackle 16 inserted in matching padlock apertures 18 in the clamp jaw 24 and in the clamp rod 23. As for the bifurcated rod 13 described in relation to FIGS. 1-5, the clamp rod 23 can be attached variously to the seat restraint 1.
Referring to FIGS. 9-14, a telescopic rod 25 can be employed as an alternative steering-wheel attachment 7. The telescopic rod 25 can be a combination of any of a variety of cylindrical rods 26 having lock indentations 27 in sliding relationship to a lock tube 28 with a lock cylinder 29 that locks onto the lock indentations 27 at desired telescopic lengths. Outward steering-wheel hooks 21 are extended oppositely for engagement with circumferentially opposite sections of the steering wheel 8. As for the clamp rod 23 described in relation to FIGS. 6-8, attachment to the steering wheel 8 is between steering-wheel spokes 15.
Different from either the bifurcated rod 13 or the clamp rod 23, however, preferable attachment of the telescopic rod 25 to the seat restraint 1 is telescopic as a result of tubular construction of lock tube 28. For this embodiment, the seat restraint 1 can be a cylindrical seat restraint 30 having an angular extension 31 that is positioned in the lock tube 28. The bifurcated extension 6 of the seat restraint 1 can be either a cylindrical bifurcate 32 as shown in FIGS. 11 and 13 or a rectangular bifurcate 33 as shown in FIGS. 10 and 12. For the cylindrical bifurcate 32, a back-rest support 34, shown in FIG. 14, can be positioned intermediate the seat-back support 5 and a bifurcation of the cylindrical bifurcate 32.
Referring to FIGS. 1 and 15-17, the wheel-lock clamp 9 that is attachable to the rim 10 of the wheel 11 prevents rotation of the wheel 11 as a result of a block condition in relation to a ground surface 35 and prevention of passage between the tire 12 and an undercarriage 36 of the golf car 3, regardless of whether the tire 12 is inflated. The wheel-lock clamp 9 has an outside clamp jaw 37 with an outside clamp hook 38 and an inside clamp jaw 39 with an inside clamp hook 40. The outside clamp hook 38 is attachable to an underside of an outside rim extension 41 of the wheel rim 10. The inside clamp hook 40 is attachable to an underside of an inside rim extension 42 of the wheel rim 10. A clamp-lock lever 43 has a clamp end 44 and a handle end 45. The clamp end 44 is attached pivotally to an inside end of an outside-jaw step 46 at an inside pivotal position 47 on the inside end of the outside-jaw step 46. At an outside pivotal position 48 on the clamp-lock lever 43, the clamp-lock lever 43 is attached pivotally to an inside end of an inside-jaw step 49 on the inside clamp jaw 39. A jaw-lock aperture 50 sized and shaped to receive a lock pin 51 is provided at a design distance from the inside pivotal position 47 on the outside end of the outside jaw 37. A lever-lock aperture 52 sized and shaped to receive the lock pin 51 is provided at a distance from the clamp end 44 of the clamp-lock lever 43 that positions the lever-lock aperture 52 concentrically with the jaw-lock aperture 50 when the clamp-lock lever 43 is at a design position of circumferential travel in relation to the outside-jaw step 46 for insertion of the lock pin 51 shown in FIG. 16 or for insertion of a padlock shackle 16 of a padlock 17 as shown in FIG. 15.
As shown in FIG. 16, the clamp-lock lever 43 can have two plates juxtaposed with the outside clamp jaw 37 and the inside clamp jaw 39 positioned pivotally between the two juxtaposed plates. The outside clamp jaw 37 can be attached pivotally to the clamp-lock lever 43 with an inside axle 53 that is riveted to the clamp-lock lever 43 at the inside pivotal position 47. The inside clamp jaw 39 can be attached pivotally to the clamp-lock lever 43 with an outside axle 54 that is riveted to the clamp-lock lever 43 at the outside pivotal position 48.
To attach the wheel-lock clamp 9 to the rim 10 of the wheel 11, the clamp-lock lever 43 is first pivoted clockwise as shown in FIG. 17 to spread the outside clamp jaw 37 and the inside clamp jaw 39 apart. Then the clamp hooks 38 and 40 are positioned under the rim extensions 41 and 42 respectively. Pivotal direction of the clamp-lock lever 43 is then reversed to counterclockwise to tighten the clamp hooks 38 and 40 onto the rim. Finally, when the jaw-lock aperture 50 and the lever-lock aperture 52 are in-line concentrically, a lock pin 51 such as a padlock shackle 16 is inserted into the apertures 50 and 52.
Although several embodiments of new and useful golf-car security apparatuses have been described hereinabove, all modifications, adaptations, substitutions of equivalents, combinations of parts, applications and forms thereof as described by the following claims are included in this invention.
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Golf car locking apparatuses having a restraining member (1) positioned on a seat (2) of a golf car (3) to prevent access to power-storage batteries (4) and extended from a seat upright member (5) behind the seat (2) and an attached member (7) extending from the seat restraining member (1) to a locking position on a steering wheel (8). Wheel-locking structure is provided optionally in addition with a wheel-lock clamp (9).
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BACKGROUND OF THE INVENTION
The Ras gene is found activated in many human cancers, including colorectal carcinoma, exocrine pancreatic carcinoma, and myeloid leukemias. Biological and biochemical studies of Ras action indicate that Ras functions like a G-regulatory protein, since Ras must be localized in the plasma membrane and must bind with GTP in order to transform cells (Gibbs, J. et al., Microbiol. Rev. 53:171-286 (1989). Forms of Ras in cancer cells have mutations that distinguish the protein from Ras in normal cells.
At least 3 post-translational modifications are involved with Ras membrane localization, and all 3 modifications occur at the C-terminus of Ras. The Ras C-terminus contains a sequence motif termed a "CAAX" or "Cys-Aaa 1 -Aaa 2 -Xaa" box (Aaa is an aliphatic amino acid, the Xaa is any amino acid) (Willumsen et al., Nature 310:583-586 (1984)). Other proteins having this motif include the Ras-related GTP-binding proteins such as Rho, fungal mating factors, the nuclear lamins, and the gamma subunit of transducin.
Farnesylation of Ras by the isoprenoid farnesyl pyrophosphate (FPP) occurs in vivo on Cys to form a thioether linkage (Hancock et al., Cell 57:1167 (1989); Casey et al., Proc. Natl. Acad. Sci. USA 86:8323 (1989)). In addition, Ha-Ras and N-Ras are palmitoylated via formation of a thioester on a Cys residue near a C-terminal Cys farnesyl acceptor (Gutierrez et al., EMBO J. 8:1093-1098 (1989); Hancock et al., Cell 57:1167-1177 (1989)). Ki-Ras lacks the palmitate acceptor Cys. The last 3 amino acids at the Ras C-terminal end are removed proteolytically, and methyl esterification occurs at the new C-terminus (Hancock et al., ibid). Fungal mating factor and mammalian nuclear lamins undergo identical modification steps (Anderegg et al., J. Biol. Chem. 263:18236 (1988); Farnsworth et al., J. Biol. Chem. 264:20422 (1989)).
Inhibition of Ras farnesylation in vivo has been demonstrated with lovastatin (Merck & Co., Rahway, N.J.) and compactin (Hancock et al., ibid; Casey et al., ibid; Schafer et al., Science 245:379 (1989)). These drugs inhibit HMG-CoA reductase, the rate limiting enzyme for the production of polyisoprenoids and the farnesyl pyrophosphate precursor. It has been shown that a farnesyl-protein transferase using farnesyl pyrophosphate as a precursor is responsible for Ras farnesylation. (Reiss et al., Cell, 62:81-88 (1990); Schaber et al., J. Biol. Chem., 265:14701-14704 (1990); Schafer et al., Science, 249:1133-1139(1990); Manne et al., Proc. Natl. Acad. Sci USA, 87:7541-7545 (1990)).
Inhibition of farnesyl-protein transferase and, thereby, of farnesylation of the Ras protein, blocks the ability of Ras to transform normal cells to cancer cells. The compounds of the invention inhibit Ras farnesylation and, thereby, generate soluble Ras which, as indicated infra, can act as a dominant negative inhibitor of Ras function. While soluble Ras in cancer cells can become a dominant negative inhibitor, soluble Ras in normal cells would not be an inhibitor.
A cytosol-localized (no Cys-Aaa 1 -Aaa 2 -Xaa box membrane domain present) and activated (impaired GTPase activity, staying bound to GTP) form of Ras acts as a dominant negative Ras inhibitor of membrane-bound Ras function (Gibbs et al., Proc. Natl. Acad. Sci. USA 86:6630-6634(1989)). Cytosollocalized forms of Ras with normal GTPase activity do not act as inhibitors. Gibbs et al., ibid, showed this effect in Xenopus oocytes and in mammalian cells.
Administration of compounds of the invention to block Ras farnesylation not only decreases the amount of Ras in the membrane but also generates a cytosolic pool of Ras. In tumor cells having activated Ras, the cytosolic pool acts as another antagonist of membrane-bound Ras function. In normal cells having normal Ras, the cytosolic pool of Ras does not act as an antagonist. In the absence of complete inhibition of farnesylation, other farnesylated proteins are able to continue with their functions.
Farnesyl-protein transferase activity may be reduced or completely inhibited by adjusting the compound dose. Reduction of farnesyl-protein transferase enzyme activity by adjusting the compound dose would be useful for avoiding possible undesirable side effects resulting from interference with other metabolic processes which utilize the enzyme.
These compounds and their analogs are inhibitors of farnesyl-protein transferase. Farnesyl-protein transferase utilizes farnesyl pyrophosphate to covalently modify the Cys thiol group of the Ras CAAX box with a farnesyl group. Inhibition of farnesyl pyrophosphate biosynthesis by inhibiting HMG-CoA reductase blocks Ras membrane localization in vivo and inhibits Ras function. Inhibition of farnesyl-protein transferase is more specific and is attended by fewer side effects than is the case for a general inhibitor of isoprene biosynthesis.
Previously, it has been demonstrated that tetrapeptides containing cysteine as an amino terminal residue with the CAAX sequence inhibit Ras farnesylation (Schaber et al., ibid; Reiss et. al., ibid; Reiss et al., PNAS, 88:732-736 (1991)). Previously described CA 1 A 2 X-type FPTase inhibitors contain acyclic amino acids in the second position. Incorporation of proline in the A 1 position in such inhibitors has been shown to be the least well tolerated amino acid substitution in that position (Reiss et al., PNAS (1991)). Such inhibitors may inhibit while serving as alternate substrates for the Ras farnesyl-transferase enzyme, or may be purely competitive inhibitors (U.S. Pat. No. 5,141,851, University of Texas).
It has also been demonstrated that certain inhibitors of farnesyl-protein transferase selectively block the processing of Ras oncoprotein intracellularly (N. E. Kohl et al., Science, 260:1934-1937 (1993) and G. L. James et al., Science, 260:1937-1942 (1993)).
Recently, it has been shown that an inhibitor of farnesyl-protein transferase blocks the growth of ras-dependent tumors in nude mice (N. E. Kohl et al., Proc. Natl. Acad. Sci U.S.A., 91:9141-9145 (1994)).
Inhibitors of Ras farnesyl-protein transferase (FPTase) have been described in two general classes. The first are analogs of farnesyl diphosphate (FPP), while the second class of inhibitors is related to the protein substrate for the enzyme, Ras. Almost all of the peptide derived inhibitors that have been described are cysteine containing molecules that are related to the CAAX motif that is the signal for protein prenylation. The exception to this generalization is a class of natural products known as the pepticinnamins (Omura, et al., J. Antibiotics 46:222 (1993)).
It is, therefore, an object of this invention to develop tetrapeptide-based compounds which incorporate a cyclic amino acid in the second position, and which will inhibit farnesyl transferase and the post-translational functionalization of the oncogene Ras protein. It is a further object of this invention to develop chemotherapeutic compositions containing the compounds of this invention and methods for producing the compounds of this invention.
SUMMARY OF THE INVENTION
The present invention comprises dipeptide analogs that inhibit the farnesylation of Ras. These compounds differ from those previously described as preferred inhibitors of Ras farnesyl transferase in that, in addition to being dipeptide-like, they incorporate a cyclic amine moiety in the position corresponding to the second amino acid of the dipeptide-like structure. Further contained in this invention are chemotherapeutic compositions containing these farnesyl transferase inhibitors and methods for their production.
The compounds of this invention are illustrated by the formulae:
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention inhibit the farnesylation of Ras. In a first embodiment of this invention, the Ras farnesyl transferase inhibitors are illustrated by the formula I: ##STR2##wherein: R 1 is selected from:
a) hydrogen,
b) R 5 S(O) 2 --, R 5 C(O)--, (R 5 ) 2 NC(O)-- or R 6 OC(O)--, and
c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, R 5 O--, R 5 S(O) m --, R 5 C(O)NR 5 --, CN, (R 5 ) 2 N--C(NR 5 )--, R 5 C(O)--, R 5 OC(O)--, N 3 , --N(R 5 ) 2 , or R 6 OC(O)NR 5 --;
R 2a and R 2b are independently selected from:
a) hydrogen,
b) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocycle, cycloalkyl, alkenyl, R 5 O--, R 5 S(O) m --, R 5 C(O)NR 5 --, CN, (R 5 ) 2 N--C(NR 5 )--, R 5 C(O)--, R 5 OC(O)--, N 3 , --N(R 5 ) 2 , or R 6 OC(O)NR 5 --, and
c) aryl, heterocycle, cycloalkyl, alkenyl, R 5 O--, R 5 S(O) m --, R 5 C(O)NR 5 --, CN, NO 2 , (R 5 ) 2 N--C(NR 5 )--, R 5 C(O)--, R 5 OC(O)--, N 3 , --N(R 5 ) 2 , or R 6 OC(O)NR 5 --,
R 3 is selected from:
a) unsubstituted or substituted aryl,
b) unsubstituted or substituted heterocycle,
c) unsubstituted or substituted cycloalkyl, and
d) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
X-Y is ##STR3##R 4a is selected from
a) hydrogen,
b) unsubstituted or substituted aryl,
c) unsubstituted or substituted heterocycle,
d) unsubstituted or substituted cycloalkyl, and
e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
R 4b is selected from
a) hydrogen,
b) unsubstituted or substituted aryl,
c) unsubstituted or substituted heterocycle,
d) unsubstituted or substituted cycloalkyl,
e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl,
f) a carbonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl, and
g) a sulfonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
R 5 is independently selected from hydrogen, C 1 -C 6 alkyl andaryl;
R 6 is independently selected from C 1 -C 6 alkyl and aryl;
Z is independently H 2 or O;
m is 0, 1 or 2, provided that m is 0 when R 5 =hydrogen;
n is 0, 1, 2, 3 or 4; and
t is 3, 4 or 5;
or the pharmaceutically acceptable salts thereof.
In a more preferred embodiment of this invention, the Ras farnesyl transferase inhibitors are illustrated by the formula I: ##STR4##wherein: R 1 is selected from:
a) hydrogen,
b) R 5 S(O) 2 --, R 5 C(O)--, (R 5 ) 2 NC(O)-- or R 6 OC(O)--, and
c) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocyclic, cycloalkyl, alkenyl, alkynyl, R 5 O--, R 5 S(O) m --, R 5 C(O)NR 5 --, CN, (R 5 ) 2 N--C(NR 5 )--, R 5 C(O)--, R 5 OC(O)--, N 3 , --N(R 5 ) 2 , or R 6 OC(O)NR 5 --;
R 2a and R 2b are independently selected from:
a) hydrogen,
b) C 1 -C 6 alkyl unsubstituted or substituted by aryl, heterocycle, cycloalkyl, alkenyl, R 5 O--, R 5 S(O) m --, R 5 C(O)NR 5 --, CN, (R 5 ) 2 N--C(NR 5 )--, R 5 C(O)--, R 5 OC(O)--, N 3 , --N(R 5 ) 2 , or R 6 OC(O)NR 5 --, and
c) aryl, heterocycle, cycloalkyl, alkenyl, R 5 O--, R 5 S(O) m --, R 5 C(O)NR 5 --, CN, NO 2 , (R 5 ) 2 N--C(NR 5 )--, R 5 C(O)--, R 5 OC(O)--, N 3 , --N(R 5 ) 2 , or R 6 OC(O)NR 5 --,
R 3 is selected from:
a) unsubstituted or substituted aryl,
b) unsubstituted or substituted heterocycle,
c) unsubstituted or substituted cycloalkyl, and
d) C 1 -C 6 alkyl substituted with an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
X-Y is ##STR5##R 4a is selected from
a) hydrogen,
b) unsubstituted or substituted aryl,
c) unsubstituted or substituted heterocycle,
d) unsubstituted or substituted cycloalkyl, and
e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
wherein heterocycle is selected from pyrrolidinyl, imidazolyl, pyridinyl, thiazolyl, pyridonyl, 2-oxopiperidinyl, indolyl, quinolinyl, isoquinolinyl, and thienyl;
R 4b is selected from
a) hydrogen,
b) unsubstituted or substituted aryl,
c) unsubstituted or substituted heterocycle,
d) unsubstituted or substituted cycloalkyl,
e) C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl,
f) a carbonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl, and
g) a sulfonyl group which is bonded to an unsubstituted or substituted group selected from aryl, heterocycle, cycloalkyl and C 1 -C 6 alkyl substituted with hydrogen or an unsubstituted or substituted group selected from aryl, heterocycle and cycloalkyl;
wherein heterocycle is selected from pyrrolidinyl, imidazolyl, pyridinyl, thiazolyl, pyridonyl, 2-oxopiperidinyl, indolyl, quinolinyl, isoquinolinyl, and thienyl;
R 5 is independently selected from hydrogen, C 1 -C 6 alkyl andaryl;
R 6 is independently selected from C 1 -C 6 alkyl and aryl;
Z is independently H 2 or O;
m is 0, 1 or 2, provided that m is 0 when R 5 =hydrogen;
n is 0, 1, 2, 3 or 4; and
t is 3, 4 or 5;
or the pharmaceutically acceptable salts thereof.
The preferred compounds of this invention are as follows:
N-[2(R)-Amino-3-mercaptopropyl]-L-proline-2,3-dichlorobenzylamide
N-[2(R)-Amino-3-mercaptopropyl]-L,proline-1-naphthylmethyl amide
N-[2(R)-Amino-3-mercaptopropyl]-L-pipecolyl-2,3-dichlorobenzamide
N-[2(R)-Amino-3-mercaptopropyl]-L-3-trans-ethylproline-2,3-dichlorobenzamide
N-[2(R)-Amino-3-mercaptopropyl]-D-3-trans-ethylproline-2,3-dichlorobenzamide
N-[2(R)-Amino-3-mercaptopropyl]-L-3-cis-ethylproline-2,3-dichlorobenzamide
N-[2(R)-Amino-3-mercaptopropyl]-D-3-cis-ethylproline-2,3-dichlorobenzamide
N-[2(R)-Amino-3-mercaptopropyl]-L-3-trans-ethylproline- 1-naphthylmethyl amide
N-[2(R)-Amino-3-mercaptopropyl]-D-3-trans-ethylproline-1-naphthylmethyl amide
N-[2(R)-Amino-3-mercaptopropyl]-L-proline-2,3-dimethylphenyl amide
N-[2(R)-Amino-3-mercaptopropyl]-L-3-trans-ethylproline-2,3-dimethylphenyl amide
N-[2(R)-Amino-3-mercaptopropyl]-D-3-trans-ethylproline-2,3-dimethylphenyl amide
or the pharmaceutically acceptable salts thereof.
The most preferred compounds of the invention are: ##STR6##or the pharmaceutically acceptable salts thereof.
In the present invention, the amino acids which are disclosed are identified both by conventional 3 letter and single letter abbreviations as indicated below:
______________________________________Alanine Ala AArginine Arg RAsparagine Asn NAspartic acid Asp DAsparagine or Asx BAspartic acidCysteine Cys CGlutamine Gln QGlutamic acid Glu EGlutamine or Glx ZGlutamic acidGlycine Gly GHistidine His HIsoleucine Ile ILeucine Leu LLysine Lys KMethionine Met MPhenylalanine Phe FProline Pro PSerine Ser SThreonine Thr TTryptophan Trp WTyrosine Tyr YValine Val V______________________________________
The compounds of the present invention may have asymmetric centers and occur as racemates, racemic mixtures, and as individual diastereomers, with all possible isomers, including optical isomers, being included in the present invention.
As used herein, "alkyl" is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specifiednumber of carbon atoms.
As used herein, "cycloalkyl" is intended to include non-aromatic cyclic hydrocarbon groups having the specified number of carbon atoms. Examples of cycloalkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like.
"Alkenyl" groups include those groups having the specified number of carbonatoms and having one or several double bonds. Examples of alkenyl groups include vinyl, allyl, isopropenyl, pentenyl, hexenyl, heptenyl, cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclohexenyl, 1-propenyl, 2-butenyl, 2-methyl-2-butenyl, isoprenyl, farnesyl, geranyl, geranylgeranyl and the like.
As used herein, "aryl" is intended to include any stable monocyclic, bicyclic or tricyclic carbon ring(s) of up to 7 members in each ring, wherein at least one ring is aromatic. Examples of aryl groups include phenyl, naphthyl, anthracenyl, biphenyl, tetrahydronaphthyl, indanyl, phenanthrenyl and the like.
The term heterocycle or heterocyclic, as used herein, represents a stable 5- to 7-membered monocyclic or stable 8- to 11-membered bicyclic or stable11-15 membered tricyclic heterocycle ring which is either saturated or unsaturated, and which consists of carbon atoms and from one to four heteroatoms selected from the group consisting of N, O, and S, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached at any heteroatom or carbon atom which results in the creationof a stable structure. Examples of such heterocyclic elements include, but are not limited to, azepinyl, benzimidazolyl, benzisoxazolyl, benzofurazanyl, benzopyranyl, benzothiopyranyl, benzofuryl, benzothiazolyl, benzothienyl, benzoxazolyl, chromanyl, cinnolinyl, dihydrobenzofuryl, dihydro-benzothienyl, dihydrobenzothiopyranyl, dihydrobenzothio-pyranyl sulfone, furyl, imidazolidinyl, imidazolinyl, imidazolyl, indolinyl, indolyl, isochromanyl, isoindolinyl, isoquinolinyl,isothiazolidinyl, isothiazolyl, isothiazolidinyl, morpholinyl, naphthyridinyl, oxadiazolyl, 2-oxoazepinyl, 2-oxopiperazinyl, 2-oxopiperidinyl, 2-oxopyrrolidinyl, piperidyl, piperazinyl, pyridyl, pyridyl N-oxide, pyridonyl, pyrazinyl, pyrazolidinyl, pyrazolyl, pyrimidinyl, pyrrolidinyl, pyrrolyl, quinazolinyl, quinolinyl, quinolinyl N-oxide, quinoxalinyl, tetrahydrofuryl, tetrahydroisoquinolinyl, tetrahydro-quinolinyl, thiamorpholinyl, thiamorpholinyl sulfoxide, thiazolyl, thiazolinyl, thienofuryl, thienothienyl, and thienyl.
As used herein, the terms "substituted aryl", "substituted heterocycle" and "substituted cycloalkyl" are intended to include the cyclic group which issubstituted with 1 or 2 substitutents selected from the group which includes but is not limited to F, Cl, Br, NH 2 , N(C 1 -C 6 alkyl) 2 , NO 2 , (C 1 -C 6 alkyl)O--, --OH, (C 1 -C 6 alkyl)S(O) m --, (C 1 -C 6 alkyl)C(O)NH--, CN, H 2 N--C(NH)--, (C 1 -C 6 alkyl)C(O)--, (C 1 -C 6 alkyl)OC(O)--, N 3 , (C 1 -C 6 alkyl)OC(O)NH-- and C 1 -C 20 alkyl.
The following structure: ##STR7##represents a cyclic amine moiety having 5 or 6 members in the ring, such a cyclic amine which may be optionally fused to a phenyl or cyclohexyl ring.Examples of such a cyclic amine moiety include, but are not limited to, thefollowing specific structures: ##STR8##It is also understood that substitution on the cyclic amine moiety by R 2a and R 2b may be on different carbon atoms or on the same carbon atom.
The pharmaceutically acceptable salts of the compounds of this invention include the conventional non-toxic salts of the compounds of this invention as formed, e.g., from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include those derived from inorganic acids such as hydrochloric, hydrobromic, sulfuric, sulfamic, phosphoric, nitric and the like: and the salts prepared from organic acidssuch as acetic, propionic, succinic, glycolic, stearic, lactic, malic, tartaric, citric, ascorbic, pamoic, maleic, hydroxymaleic, phenyl-acetic, glutamic, benzoic, salicylic, sulfanilic, 2-acetoxy-benzoic, fumaric, toluenesulfonic, methanesulfonic, ethane disulfonic, oxalic, isethionic, trifluoroacetic and the like.
It is intended that the definition of any substituent or variable (e.g., R 5 , etc.) at a particular location in a molecule be independent of its definitions elsewhere in that molecule. Thus, --N(R 5 ) 2 represents --NHH, --NHCH 3 , --NHC 2 H 5 , etc. It is understoodthat substituents and substitution patters on the compounds of the instant invention can be selected by one of ordinary skill in the art to provide compounds that are chemically stable and that can be readily synthesized by techniques known in the art as well as those methods set forth below.
The pharmaceutically acceptable salts of the compounds of this invention can be synthesized from the compounds of this invention which contain a basic moiety by conventional chemical methods. Generally, the salts are prepared by reacting the free base with stoichiometric amounts or with an excess of the desired salt-forming inorganic or organic acid in a suitablesolvent or various combinations of solvents.
The compounds of the invention can be synthesized from their constituent amino acids by conventional peptide synthesis techniques, and the additional methods described below. Standard methods of peptide synthesis are disclosed, for example, in the following works: Schroeder et al., "ThePeptides", Vol. I, Academic Press 1965, or Bodanszky et al., "Peptide Synthesis", Interscience Publishers, 1966, or McOmie (ed.) "Protective Groups in Organic Chemistry", Plenum Press, 1973, or Barany et al., "The Peptides: Analysis, Synthesis, Biology" 2, Chapter 1, Academic Press, 1980, or Stewart et al., "Solid Phase Peptide Synthesis", Second Edition, Pierce Chemical Company, 1984. The teachings of these works are hereby incorporated by reference.
Abbreviations used in the description of the chemistry and in the Examples that follow are:
Ac 2 O Acetic anhydride;
Boc t-Butoxycarbonyl;
DBU 1,8-diazabicyclo[5.4.0]undec-7-ene;
DMAP 4-Dimethylaminopyridine;
DME 1,2-Dimethoxyethane;
DMF Dimethylformamide;
EDC 1-(3-dimethylaminopropyl)-3-ethyl-carbodiimidehydrochloride;
HOBT 1-Hydroxybenzotriazole hydrate;
Et 3 N Triethylamine;
EtOAc Ethyl acetate;
FAB Fast atom bombardment;
HOOBT 3-Hydroxy- 1,2,2-benzotriazin-4(3H)-one;
HPLC High-performance liquid chromatography;
MCPBA m-Chloroperoxybenzoic acid;
MsCl Methanesulfonyl chloride;
NaHMDS Sodium bis(trimethylsilyl)amide;
Py Pyridine;
TFA Trifluoroacetic acid;
THF Tetrahydrofuran.
Compounds of this invention are prepared by employing the reactions shown in the following Reaction Schemes A-F, in addition to other standard manipulations such as ester hydrolysis, cleavage of protecting groups, etc., as may be known in the literature or exemplified in the experimentalprocedures. ##STR9##where X is OH or an ester.
In Reaction Scheme A, coupling of a protected amino acid with the appropriate amine is accomplished using standard peptide coupling conditions. The resulting amino acid amide is deprotected and the primary amine is reductively alkylated with a protected cysteine-derived aldehyde using sodium cyanoborohydride or sodium triacetoxyborohydride. Finally, removal of the protecting groups provides the compounds of interest.
In Reaction Scheme B, a different strategy for synthesis is described. Reductive alkylation of an amino acid provides a protected dipeptide isostere. The same versatile intermediate can be obtained by reductive alkylation of an amino acid ester followed by saponification. This intermediate can be coupled with any of a number of amines using standard peptide coupling conditions. Deprotection provides the active farnesyl transferase inhibitors.
The choice of protecting groups shown in the scheme is not unique and the chemical reactions employed in these syntheses are compatible with other amine and sulfur protecting groups commonly used in peptide synthesis.
Certain compounds of this invention wherein X-Y is an ethenylene or ethylene unit are prepared by employing the reaction sequences shown in Reaction Schemes C and D. Reaction Scheme C outlines the preparation of the alkene isosteres utilizing standard manipulations such as Wittig reaction, peptide coupling reaction, reductive alkylation, etc., as may beknown in the literature or exemplified in the Experimental Procedure. For simplicity, substituents R 2a and R 2b on the cyclic amine moiety are not shown. It is, however, understood that the reactions illustrated are also applicable to appropriately substituted cyclic amine compounds. In Step B of Scheme C, the cysteinyl amino terminus sidechain, designated R x is incorporated using coupling reaction A and proR x COOH; or the alkylation reaction C using proR x CHO and a reducing agent. The R x sidechain is exposed by deprotection of the sulfur moiety.
The alkane analogs are prepared in a similar manner by including an additional catalytic hydrogenation step as outlined in Reaction Scheme D. ##STR10##
The oxa isostere compounds of this invention are prepared according to the routes outlined in Schemes E and F. Referring to Scheme E, an aminoalcohol1 is persilylated with trimethylsilyl chloride and then selectively desilylated with limited methanol to yield amine 2. The nitrogen of the amine 2 is then protected and the alcohol unblocked with excess aqueous methanol to provide 3. Alkylation of 3 with R 3 X L , where X L is a leaving group such as Br - , I - or Cl - in the presence ofa suitable base, preferably NaH, affords 4. Deprotection of alkylated compound 4 provides 5, which undergoes reductive alkylation in the presence of an aldehyde proR x CHO (6) and a reducing agent (e.g., sodium cyanoborohydride); or acylation in the presence of proR x COOH (7) and a peptide coupling reagent affording, after deprotection of the sulfhydryl moiety, the products 8 and 9.
An alternative method for the preparation of the prolyl oxa isostere (compounds 8 and 9) is illustrated in Scheme F. Referring to Scheme F, theaminoalcohol 1 is protected with trifluoroacetic anhydride and the blocked compound 10 treated with diphenyl disulfide in the presence of tributylphosphine to provide the thioether 11. Chlorination of compound 11provides compound 12 which can be reacted with a variety of alcohols, R 3 OH, in the presence of silver perchlorate and tin (II) chloride, to afford the mixed acetal 4. Removal of the phenylmercapto moiety with Raney nickel followed by deprotection of alkylated compound 14 provides the free amine intermediate, which undergoes reductive alkylation in the presence of an aldehyde proR x CHO (6) and a reducing agent (e.g., sodium cyanoboro-hydride); or acylation in the presence of proR x COOH(7) and a peptide coupling reagent affording, after deprotection of the sulfhydryl moiety, the products 8 and 9.
Yet another alternative method for the preparation of the prolyl oxa isostere (compounds 8 and 9) is described in the literature [Ruth E. TenBrink, J. Org. Chem., 52:418-422 (1987)]. ##STR11##
The thia, oxothia and dioxothia isostere compounds of this invention are prepared in accordance to the route depicted in Scheme G. Aminoalcohol 1 is derivatized with trifluoroacetic anhydride to give 9. Mesylation of 9 provided 15 which is reacted with an appropriate mercaptan to provide 16. The sulfide 16 is readily oxidized to either the sulfoxide or the sulfone by the use of MCPBA (m-chloroperoxybenzoic acid). Removal of the triflate group in 16 with aqueous HCl the amine 17. This amine hydrochloride 17 undergoes reductive alkylation in the presence of an aldehyde R x CHO (6) and a reducing agent (e.g., sodium cyanoborohydride); or acylation in the presence of R x COOH (7) and a peptide coupling reagent to afford,after deprotection of the sulfhydryl moiety, the products 18 and 19. ##STR12##
The compounds of this invention inhibit Ras farnesyl transferase which catalyzes the first step in the post-translational processing of Ras and the biosynthesis of functional Ras protein. These compounds are useful as pharmaceutical agents for mammals, especially for humans. These compounds may be administered to patients for use in the treatment of cancer. Examples of the type of cancer which may be treated with the compounds of this invention include, but are not limited to, colorectal carcinoma, exocrine pancreatic carcinoma, and myeloid leukemias.
The compounds of this invention may be administered to mammals, preferably humans, either alone or, preferably, in combination with pharmaceutically acceptable carriers or diluents, optionally with known adjuvants, such as alum, in a pharmaceutical composition, according to standard pharmaceutical practice. The compounds can be administered orally or parenterally, including the intravenous, intramuscular, intraperitoneal, subcutaneous, rectal and topical routes of administration.
For oral use of a chemotherapeutic compound according to this invention, the selected compound may be administered, for example, in the form of tablets or capsules, or as an aqueous solution or suspension. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch, and lubricating agents, such as magnesium stearate, are commonly added. For oral administration in capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions are required for oral use, the active ingredient is combined with emulsifying and suspending agents. If desired, certain sweetening and/or flavoring agents may be added. For intramuscular, intraperitoneal, subcutaneous and intravenous use, sterile solutions of the active ingredient are usually prepared, and the pH of the solutions should be suitably adjusted and buffered. For intravenous use, the total concentration of solutes should be controlled in order to render the preparation isotonic.
The present invention also encompasses a pharmaceutical composition useful in the treatment of cancer, comprising the administration of a therapeutically effective amount of the compounds of this invention, with or without pharmaceutically acceptable carriers or diluents. Suitable compositions of this invention include aqueous solutions comprising compounds of this invention and pharmacologically acceptable carriers, e.g., saline, at a pH level, e.g., 7.4. The solutions may be introduced into a patient's intramuscular blood-stream by local bolus injection.
When a compound according to this invention is administered into a human subject, the daily dosage will normally be determined by the prescribing physician with the dosage generally varying according to the age, weight, and response of the individual patient, as well as the severity of the patient's symptoms.
In one exemplary application, a suitable amount of compound is administeredto a mammal undergoing treatment for cancer. Administration occurs in an amount between about 0.1 mg/kg of body weight to about 20 mg/kg of body weight per day, preferably of between 0.5 mg/kg of body weight to about 10mg/kg of body weight per day.
The compounds of the instant invention are also useful as a component in anassay to rapidly determine the presence and quantity of farnesyl-protein transferase (FPTase) in a composition. Thus the composition to be tested may be divided and the two portions contacted with mixtures which comprisea known substrate of FPTase (for example a tetrapeptide having a cysteine at the amine terminus) and farnesyl pyrophosphate and, in one of the mixtures, a compound of the instant invention. After the assay mixtures are incubated for an sufficient period of time, well known in the art, to allow the FPTase to farnesylate the substrate, the chemical content of theassay mixtures may be determined by well known immunological, radiochemicalor chromatographic techniques. Because the compounds of the instant invention are selective inhibitors of FPTase, absence or quantitative reduction of the amount of substrate in the assay mixture without the compound of the instant invention relative to the presence of the unchanged substrate in the assay containing the instant compound is indicative of the presence of FPTase in the composition to be tested.
It would be readily apparent to one of ordinary skill in the an that such an assay as described above would be useful in identifying tissue samples which contain farnesyl-protein transferase and quantitating the enzyme. Thus, potent inhibitor compounds of the instant invention may be used in an active site titration assay to determine the quantity of enzyme in the sample. A series of samples composed of aliquots of a tissue extract containing an unknown amount of farnesyl-protein transferase, an excess amount of a known substrate of FPTase (for example a tetrapeptide having acysteine at the amine terminus) and farnesyl pyrophosphate are incubated for an appropriate period of time in the presence of varying concentrations of a compound of the instant invention. The concentration of a sufficiently potent inhibitor (i.e., one that has a Ki substantially smaller than the concentration of enzyme in the assay vessel) required to inhibit the enzymatic activity of the sample by 50% is approximately equalto half of the concentration of the enzyme in that particular sample.
EXAMPLES
Examples provided are intended to assist in a further understanding of the invention. Particular materials employed, species and conditions are intended to be further illustrative of the invention and not limitative ofthe reasonable scope thereof.
The standard workup referred to in the examples refers to solvent extraction and washing the organic solution with 10% citric acid, 10% sodium bicarbonate and brine as appropriate. Solutions were dried over sodium sulfate and evaporated in vacuo on a rotary evaporator.
EXAMPLE 1
N-[2(R)-Amino-3-mercaptopropyl-L-proline-2,3-dichlorobenzamide
Step A: 2(R)-t-Butoxycarbonylamino-3-triphenylmethylmercaptopropanal
The aldehyde was synthesized by the method described in U.S. Pat. No. 5,238,922 (Col. 10).
1 H NMR (CDCl 3 ) δ 9.64 (s, 1H), 7.42 (m, 6H), 7.28 (m, 9H),2.45 (m, 2H), 2.38 (m, 2H).
Step B: [2(R)-(t-butyloxycarbonyl)amino-3-triphenylmethylmercaptopropyl]-L-prolinemethyl ester
Proline methyl ester hydrochloride (0.166 g, 1 mmol) and 2-t-butoxycarbonylamino-3-triphenylmethylmercaptopropanal (0.538 g, 1.2 mmol) were dissolved in MeOH (8 mL), treated with 3A molecular sieves (0.16 g), KOAc (0.98 g, 1 mmol) and solid sodium cyanoborohydride (0.094 g, 1.5 mmol), then stirred at ambient temperature for 24 hr. The reaction mixture was filtered, concentrated, then the residue was partitioned between EtOAc and aq satd NaHCO 3 soln. The organic layer was washed with brine, dried (Na 2 SO 4 ), filtered and concentrated to provide the title compound after chromatography (SiO 2 ) with EtOAc: hexane, 1:5. 1 H NMR (CDCl 3 ) δ 7.2-7.4 (m, 15H), 4.75-4.85(m, 1H), 3.67 (s, 3H), 3.6-3.75 (m, 1H), 3.18-3.28 (m, 1H), 2.9-3.0 (m, 1H), 2.35-2.65 (m, 4H), 1.75-2.0 (m, 4H), 1.45 (s, 9H), 1.2-1.4 (m, 1H).
Step C: [2(R)-(t-butoxycarbonyl)amino-3-triphenylmethylmercaptopropyl]-L-proline
[2(R)-(t-butyloxycarbonyl)amino-3-triphenylmethylmercaptopropyl]-L-proline methyl ester (0.325 g, 0.58 mmol) was dissolved in MeOH (12 mL) and 1N NaOH solution (2.3 mL, 2.3 mmol) with stirring at ambient temperature. After 24 hrs, the reaction mixture was concentrated to remove MeOH, then dissolved in H 2 O, neutralized with 1N HCl (2.3 mL, 2.3 mmol), and extracted with EtOAc (3×10 mL). The organics were combined, washed with brine and dried (Na 2 SO 4 ). Filtration and concentration to dryness provided the title compound. 1 H NMR (CD 3 OD) δ 7.2-7.5 (m, 15H), 3.7-3.85 (m, 1H), 3.5-3.7 (m, 2H), 2.9-3.15 (m, 3H), 2.2-2.6 (m, 3H), 1.8-2.2 (m, 3H), 1.48 (s, 9H).
Step D: N-[2(R)-t-Butoxycarbonylamino-3-triphenylmethylmercaptopropyl]-L-proline-2,3-dichlorobenzamide
[2(R)-(t-butoxycarbonyl)amino-3-triphenylmethylmercaptopropyl]-L-proline (0.08 g, 0.153 mmol), 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide (EDC) (0.035 g, 0.184 mmol), and 1-hydroxybenzotriazole hydrate (HOBT) (0.025 g,0.184 mmol) were dissolved in DMF (2 mL), treated with 2,3-dichlorobenzylamine (0.025 mL, 0.184 mmol), and brought to pH 7 with Et 3 N (0.026 mL, 0.184 mmol). After stirring at ambient temperature for 18 h the mixture was concentrated to dryness, and the residue was partitioned between EtOAc and H 2 O, the organic layer separated, washed with aq satd NaHCO 3 , brine, and dried (Na 2 SO 4 ). Filtration and concentration provided the title compound. 1 H NMR (CD 3 OD) δ 7.1-7.5 (m, 18H), 4.53 (d, 1H, J=8 Hz), 4.26 (d, 1H,J=8 Hz), 3.64-3.76 (m, 1H), 2.96-3.14 (m, 2H), 2.52-2.66 (m, 1H), 2.1-2.5 (m, 5H), 1.6-1.9 (m, 3H), 1.45 (s, 9H).
Step E: N-[2(R)-Amino-3-mercaptopropyl]-L-proline- 2,3-dichlorobenzamide
N-[2(R)-t-Butoxycarbonylamino-3-triphenylmethylmercaptopropyl]-L-proline-2,3-dichlorobenzamide (0.097 g, 0.14 mmol) was dissolved in CH 2 Cl 2 (3 mL), CF 3 CO 2 H (1 mL) at ambient temperature, treated with triethylsilane (0.088 mL, 0.55 mmol) and stirred for 1 h. The reaction mixture was triturated with 0.1% TFA in H 2 O, filtered, concentrated and chromatographed by RP-HPLC and lyophilized. The residue was dissolved in MeOH (1 mL), treated with concd HCl, concentrated and triturated with Et 2 O to provide the title compound as the his hydrochloride salt. 1 H NMR (CD 3 OD) δ 7.50 (d, 1H, J=6 Hz), 7.27-7.4 (m, 2H),4.60 (ABq, 2H), 4.25-4.7 (m, 1H), 3.3-3.9 (m, 5H), 2.99 (d, 2H, J=5 Hz), 2.5-2.7 (m, 1H), 2.0-2.3 (m, 3H).
Anal. calcd for C 15 H 21 N 3 OSCl 2 ·2.75 HCl: C,38.97; H, 5.18, N, 9.09; found C, 38.63; H, 5.21; N, 8.86.
Using the methods described in Example 1, but a different cyclic amino acidin Step B or a different amine in Step D the following compound were prepared:
N-[2(R)-Amino-3-mercaptopropyl]-L-proline-1-naphthylmethyl amide
Anal. calcd for C 19 H 25 N 3 OS·2.1 CF 3 CO 2 H·0.1 H 2 O: C, 47.66; H, 4.71; N, 7.19; found C, 47.68; H, 4.57; N, 7.02.
N-[2(R)-Amino-3-mercaptopropyl]-L-pipecolyl-2,3-dichlorobenzamide
Anal. calcd for C 16 H 23 N 3 OSCl 2 ·2.5 CF 3 CO 2 H: C, 38.13; H, 3.89, N, 6.35; found C, 38.20; H, 3.65; N, 6.68.
N-[2(R)-Amino-3-mercaptopropyl]-L-3-trans-ethylproline-2,3-dichlorobenzamid
MS (M+1)=390.
N-[2(R)-Amino-3-mercaptopropyl]-D-3-trans-ethylproline-2,3-dichlorobenzamide
Anal. calcd for C 17 H 25 N 3 OSCl 2 ·2.75 CF 3 CO 2 H: C, 38.39; H, 3.97; N, 5.97; found C, 38.39; H, 3.97; N, 6.27.
N-[2(R)-Amino-3-mercaptopropyl]-L-3-cis-ethylproline-2,3-dichlorobenzamide
Anal. calcd for C 17 H 25 N 3 OSCl 2 ·2.75 CF 3 CO 2 H: C, 38.39; H, 3.97; N, 5.97; found C, 38.51; H, 4.18; N, 6.28.
N-[2(R)-Amino-3-mercaptopropyl]-D-3-cis-ethylproline-2,3-dichlorobenzamide
Anal. calcd for C 17 H 25 N 3 OSCl 2 ·2.5 CF 3 CO 2 H: C, 39.12; H, 4.10; N, 6.22; found C, 39.03; H, 4.22; N, 6.47.
N-[2(R)-Amino-3-mercaptopropyl]-L-3-trans-ethylproline-1-naphthylmethyl amide
Anal. calcd for C 21 H 29 N 3 OS·2.25 CF 3 CO 2 H: C, 48.76; H, 5.02; N, 6.69; found C, 48.63; H, 5.10; N, 6.89.
N-[2(R)-Amino-3-mercaptopropyl]-D-3-trans-ethylproline-1-naphthylmethyl amide
Anal. calcd for C 21 H 29 N 3 OS·85 CF 3 CO 2 H: C, 50.93; H, 5.34; N, 7.21; found C, 50.88; H, 5.43; N, 7.41.
EXAMPLE 2
N-[2(R)-Amino-3-mercaptopropyl]-L-proline-2,3-dimethylphenyl amide
Step A: N-[2(R)-t-butoxycarbonylamino-3-triphenyl methylmercaptopropyl]-L-proline-2,3-dimethylphenyl amide
To a solution of 2,3-dimethylaniline (0.05 mL, 0.41 mmol) and diisopropylethylamine (0.12 mL, 0.69 mmol) in CH 2 Cl 2 (4 mL) wasadded N-[2(R)-t-butoxycarbonylamino-3-triphenylmethyl mercaptopropyl]-L-proline (Example 1, Step C) (0.18 g, 0.34 mmol) followedby bis(2-oxo-3-oxazolidinyl)phosphinic chloride (BOP-Cl) (0.175 g, 0.69 mmol) with stirring under argon at ambient temperature. After stirring for20 h the solution was concentrated to dryness, and taken up in H 2 O (30 mL) and extracted with EtOAc (3×20 mL). The organics were combined, washed with aq citric acid soln, aq satd NaHCO 3 soln, brineand dried (Na 2 SO 4 ). Filtration and concentration followed by chromatography (SiO 2 ) (CH 2 Cl 2 : MeOH, 98:2)) provided the title compound. 1 H NMR (CD 3 OD) δ 7.0-7.42 (m, 18H), 3.78-3.88 (m, 1H), 3.06-3.19 (m, 2H), 2.14-2.7 (m, 6H), 2.26 (s, 3H), 1.93 (s, 3H), 1.66-1.99 (m, 3H), 1.41 (s, 9H).
Step B: N-[2(R)-Amino-3-mercaptopropyl]-L-proline-2,3-dimethylphenylamide
N-[2(R)-t-butoxycarbonylamino-3-triphenylmethylmercapto-propyl]-L-proline-2,3-dimethylphenyl amide (0.124 g, 0.19 mmol) was dissolved in CH 2 Cl 2 (3 mL) and CF 3 CO 2 H (1 mL) at ambient temperature, treated with triethylsilane (0.121 mL, 0.76 mmol) and stirred for 2 h. Thereaction mixture was concentrated, triturated with 0.1% aq TFA soln, the solid precipitate filtered off, and the filtrate lyophilized to provide the title compound. 1 H NMR (CD 3 OD) δ 7.10 (s, 3H), 3.55-3.68 (m, 1H), 3.32-3.45 (m, 2H), 2.75-3.19 (m, 5H), 2.5-2.65 (m, 1H),2.31 (s, 3H), 2.15 (s, 3H), 1.9-2.15 (m, 3H).
Anal. calcd for C 16 H 25 N 3 OS·2.7 CF 3 CO 2 H: C, 41.77; H, 4.54; N, 6.83; found: C, 41.70; H, 4.81; N, 7.17.
Using the methods described in Example 2 the following compounds were prepared:
N-[2(R)-Amino-3-mercaptopropyl]-L-3-trans-ethylproline-2,3-dimethylphenyl amide
Anal. calcd for C 18 H 29 N 3 OS·3 CF 3 CO 2 H: C, 42.54; H, 4.76; N, 6.20; found C, 42.16; H, 5.06; N, 6.64.
N-[2(R)-Amino-3-mercaptopropyl]-D-3-trans-ethylproline-2,3-dimethylphenyl amide
Anal. calcd for C 18 H 29 N 3 OS·2.5 CF 3 CO 2 H: C, 44.51; H, 5.12, N, 6.77; found C, 44.80; H, 5.19; N, 6.83.
EXAMPLE 3
In vitro inhibition of ras farnesyl transferase
Assays of farnesyl-protein transferase. Partially purified bovine FPTase and Ras peptides (Ras-CVLS, Ras-CVIM and RAS-CAIL) were prepared as described by Schaber et al., J. Biol. Chem. 265:14701-14704 (1990), Pompliano, et al., Biochemistry 31:3800 (1992) and Gibbs et al., PNAS U.S.A. 86:6630-6634 (1989). Bovine FPTase was assayed in a volume of 100 μl containing 100 mM N-(2-hydroxy ethyl) piperazine-N'-(2-ethane sulfonic acid) (HEPES), pH 7.4, 5 mM MgCl 2 , 5 mM dithiothreitol (DTT), 100 mM [ 3 H]-farnesyl diphosphate ([ 3 H]-FPP; 740 CBq/mmol, New England Nuclear), 650 nM Ras-CVLS and 10 μg/ml FPTase at 31° C. for 60 min. Reactions were initiated with FPTase and stoppedwith 1 ml of 1.0M HCL in ethanol. Precipitates were collected onto filter-mats using a TomTec Mach II cell harvestor, washed with 100% ethanol, dried and counted in an LKB β-plate counter. The assay was linear with respect to both substrates, FPTase levels and tinge; less than10% of the [ 3 H]-FPP was utilized during the reaction period. Purified compounds were dissolved in 100% dimethyl sulfoxide (DMSO) and were diluted 20-fold into the assay. Percentage inhibition is measured by the amount of incorporation of radioactivity in the presence of the test compound when compared to the amount of incorporation in the absence of the test compound.
Human FPTase was prepared as described by Omer et al., Biochemistry 32:5167-5176 (1993). Human FPTase activity was assayed as described above with the exception that 0.1% (w/v) polyethylene glycol 20,000, 10 μM ZnCl 2 and 100 nm Ras-CVIM were added to the reaction mixture. Reactions were performed for 30 min., stopped with 100 μl of 30% (v/v) trichloroacetic acid (TCA) in ethanol and processed as described above forthe bovine enzyme.
The compounds of the instant invention were tested for inhibitory activity against human FPTase by the assay described above and were found to have IC 50 of <10 μM.
EXAMPLE 4
In vivo ras farnesylation assay
The cell line used in this assay is a v-ras line derived from either Rat1 or NIH3T3 cells, which expressed viral Ha-ras p21. The assay is performed essentially as described in DeClue, J. E. et al., Cancer Research 51:712-717, (1991). Cells in 10 cm dishes at 50-75% confluency are treatedwith the test compound (final concentration of solvent, methanol or dimethyl sulfoxide, is 0.1%). After 4 hours at 37° C., the cells are labelled in 3 ml methionine-free DMEM supple-meted with 10% regular DMEM, 2% fetal bovine serum and 400 mCi[ 35 S]methionine (1000 Ci/mmol). After an additional 20 hours, the cells are lysed in 1 ml lysis buffer (1% NP40/20 mM HEPES, pH 7.5/5 mM MgCl 2 /1 mM DTT/10 mg/ml aprotinen/2 mg/ml leupeptin/2 mg/ml antipain/0.5 mM PMSF) and the lysates cleared by centrifugation at 100,000×g for 45 min. Aliquots of lysates containing equal numbers of acid-precipitable counts are bought to1 ml with IP buffer (lysis buffer lacking DTT) and immunoprecipitated with the ras-specific monoclonal antibody Y13-259 (Furth, M. E. et al., J. Virol. 43:294-304, (1982)). Following a 2 hour antibody incubation at 4° C., 200 ml of a 25% suspension of protein A-Sepharose coated with rabbit anti rat IgG is added for 45 min. The immunoprecipitates are washed four times with IP buffer (20 nM HEPES, pH 7.5/1 mM EDTA/1% Triton X-100.0.5% deoxycholate/0.1%/SDS/0.1M NaCl) boiled in SDS-PAGE sample buffer and loaded on 13% acrylamide gels. When the dye front reached the bottom, the gel is fixed, soaked in Enlightening, dried and autoradiographed. The intensities of the bands corresponding to farnesylated and nonfarnesylated ras proteins are compared to determine the percent inhibition of farnesyl transfer to protein.
EXAMPLE 5
In vivo growth inhibition assay
To determine the biological consequences of FPTase inhibition, the effect of the compounds of the instant invention on the anchorage-independent growth of Rat1 cells transformed with either a v-ras, v-raf, or v-mos oncogene is tested. Cells transformed by v-Raf and v-Mos maybe included inthe analysis to evaluate the specificity of instant compounds for Ras-induced cell transformation.
Rat 1 cells transformed with either v-ras, v-raf, or v-mos are seeded at a density of 1×10 4 cells per plate (35 mm in diameter) in a 0.3% top agarose layer in medium A (Dulbecco's modified Eagle's medium supplemented with 10% fetal bovine serum) over a bottom agarose layer (0.6%). Both layers contain 0.1% methanol or an appropriate concentration of the instant compound (dissolved in methanol at 1000 times the final concentration used in the assay). The cells are fed twice weekly with 0.5 ml of medium A containing 0.1% methanol or the concentration of the instant compound. Photomicrographs are taken 16 days after the cultures are seeded and comparisons are made.
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The present invention comprises dipeptide analogs that inhibit the farnesylation of Ras. These farnesyl-protein transferase inhibitors are characterized by the inclusion of a cyclic amine in the backbone of the dipeptide. Further contained in this invention are chemotherapeutic compositions containing these farnesyl transferase inhibitors and methods for their production.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus, systems and methods for reducing vortex-induced-vibrations (“VIV”), current drag, low frequency drift oscillations due to random waves, and low frequency wind induced resonant oscillations. In another aspect, the present invention relates to apparatus, systems and methods comprising enhancement of VIV suppression devices for control of vortex-induced-vibrations, current drag, low frequency drift oscillations due to random waves, and low frequency wind induced resonant oscillations. In even another aspect, the present invention relates to apparatus, systems and methods comprising modified and improved performance fairings for reducing VIV, current drag, low frequency drift oscillations due to random waves, and low frequency wind-induced resonant oscillations. In still another aspect, the present invention relates to methods and apparatus for the “S-Lay” installation of pipe. In even still another aspect, the present invention relates to methods and apparatus installation of VIV suppression during the “S-Lay” installation of pipe.
2. Description of the Related Art
When a bluff body, such as a cylinder, in a fluid environment is subjected to a current in the fluid, it is possible for the body to experience vortex-induced vibrations (VIV). These vibrations are caused by oscillating hydrodynamic forces on the surface which can cause substantial vibrations of the structure, especially if the forcing frequency is at or near a structural natural frequency. The vibrations are largest in the direction transverse to flow, however, in-line vibrations can also cause stresses which are sometimes larger than those in the transverse direction.
Drilling for and/or producing hydrocarbons or the like from subterranean deposits which exist under a body of water exposes underwater drilling and production equipment to water currents and the possibility of VIV. Equipment exposed to VIV includes the smaller tubes and cables of a riser system, umbilical elements, mooring lines, anchoring tendons, marine risers, lateral pipelines, the larger underwater cylinders of the hull of a minispar or spar floating production system.
There are generally two kinds of water current induced stresses to which all the elements of a riser system are exposed. The first kind of stress as mentioned above is caused by vortex-induced alternating forces that vibrate the underwater structure in a direction perpendicular to the direction of the current. These are referred to as vortex-induced vibrations (VIV). When water flows past the structure, vortices are alternately shed from each side of the structure. This produces a fluctuating force on the structure transverse to the current. If the frequency of this harmonic load is near the resonant frequency of the structure, large vibrations transverse to the current can occur. These vibrations can, depending on the stiffness and the strength of the structure and any welds, lead to unacceptably short fatigue lives. Stresses caused by high current conditions have been known to cause structures such as risers to break apart and fall to the ocean floor.
The second type of stress is caused by drag forces which push the structure in the direction of the current due to the structure's resistance to fluid flow. The drag forces are amplified by vortex induced vibrations of the structure. For instance, a riser pipe which is vibrating due to vortex shedding will disrupt the flow of water around it more so than a stationary riser. This results in greater energy transfer from the current to the riser, and hence more drag.
Many methods have been developed to reduce vibrations of subsea structures. Some of these methods operate by modifying the boundary layer of the flow around the structure to prevent the correlation of vortex shedding along the length of the structure. Examples of such methods include the use of helical strakes around a structure, or axial rod shrouds and perforated shrouds. Other methods to reduce vibrations caused by vortex shedding from subsea structures operate by stabilization of the wake. These methods include use of fairings, wake splitters and flags.
VIV is also a common problem for subsea pipelines, especially the portions of the pipe line that span canyons or trenches on the ocean floor. These canyons or trenches can act as conduits and magnify the effects of currents at or near the ocean floor. As with vertical risers/tendons, the solution is to install VIV suppression such as fairings, wake splitters and flags.
Installation of VIV suppression after the laying of the pipe line very expensive, laborious, and dangerous. Ideally, VIV suppression would be installed on the pipe at the lay vessel as it is being laid.
There as two main methods of laying pipe, the “J-Lay” and “S-Lay.”
With “J-Lay,” a vertical lay vessel is utilized, in which pipe leaves the traveling vessel vertically, with the pipe essentially forming a “J” as it is being laid on the ocean floor. With J-Lay installation, VIV suppression is easily applied to the pipe at the vessel during installation.
With “S-Lay,” pipe leaves the lay vessel in an essentially horizontal position, and rolled off of a radially shaped “stinger” mounted aft, with the pipe essentially forming an “S” as it is being laid on the ocean floor. The stinger cross-section is a “V” shaped trough conveyor comprising a series of rollers across which the pipe passes. As the stinger is “V” shaped, only a portion of the pipe engages rollers. The problem with installing VIV during an S-Lay, is that the stinger will tend to shear off anything that extends radially from the pipe at those places where it engages the pipe.
Thus, there is a need in the art for apparatus, systems and methods for suppressing VIV and reducing drag of a marine element.
There is another need in the art for apparatus, systems and methods for suppressing VIV and reducing drag of a subsea pipeline, which can be installed during the laying of the pipeline.
There is even another need in the art for apparatus, systems and methods for laying a subsea pipeline with VIV.
These and other needs of the present invention will become apparent to those of skill in the art upon review of this specification, including its drawings and claims.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide for apparatus, systems and methods for suppressing VIV and reducing drag of a marine element.
It is another object of the present invention to provide for apparatus, systems and methods for suppressing VIV and reducing drag of a subsea pipeline, which can be installed during the laying of the pipeline.
It is even another object of the present invention to provide for laying a subsea pipeline with VIV.
These and other objects of the present invention will become apparent to those of skill in the art upon review of this specification, including its drawings and claims.
According to one embodiment of the present invention, there is provided a fairing for reducing vortex-induced-vibrations in a cylindrical marine element. The fairing includes a main body defining a circular passage for receiving the marine element, and comprising a tail section. A locking member is supported by the main body, wherein the member is positionable and lockable in the circular passage against any marine element in the passage to move the tail section away from any marine element in the passage, wherein at least a portion of the locking member comprises material that will degrade in a marine environment and upon degradation disengage from the marine element.
According to another embodiment of the present invention, there is provided a modified pipe, which includes a pipe section, a fairing having a tail section, and rotatably mounted on the pipe. Also included is a locking member interposed between the pipe section and the fairing, biasing the fairing against rotating, and positioning the tail section radially away from the pipe section, wherein at least a portion of the locking member comprises material that will degrade in a marine environment and upon degradation will no longer bias the fairing against rotating, and no longer position the tail section away from the pipe section.
According to even another embodiment of the present invention, there is provided a method of modifying a pipe having a fairing rotatably mounted thereon. The method includes positioning a locking member between the pipe and the fairing sufficient to bias the fairing against rotating, and position a portion of the fairing radially away from the pipe section, wherein at least a portion of the locking member comprises material that will degrade in a marine environment and upon degradation will no longer bias the fairing against rotating, and no longer position the fairing radially away from the pipe section. A further embodiment of this embodiment includes, placing the pipe, fairing and locking member in a marine environment, and allowing the locking member to degrade.
According to still another embodiment of present invention, there is provided a method of passing a pipe with a rotatably mounted fairing over a roller, wherein the fairing comprises a tail section. The method includes (A) positioning the fairing such that the tail section will not touch the roller as it passes over the roller. The method also includes (B) passing the pipe and fairing over the roller. A further embodiment of this embodiment includes, in step (A), further comprising positioning a locking member between the pipe and the fairing sufficient to bias the fairing against rotating, wherein at least a portion of the locking member comprises material that will degrade in a marine environment and upon degradation will no longer bias the fairing against rotating.
According to yet another embodiment of the present invention, there is provided a collar for securing a fairing rotatably mounted on a pipe. The collar includes a circular segment of less than 2Π radians, and a circular shaped band positioned around the segment.
Other embodiments include modifying a pipe by applying the collar to the pipe, passing a pipe with the collar over a roller by positioning the circular segment so that it clears the rollers.
Even other embodiments include modifying a pipe by applying both the collar and fairing of the present invention to the pipe, and passing a pipe with both the collar and fairing over a roller.
Still other embodiments include S-laying of pipe by utilizing the fairing and/or collar.
These and other embodiments of the present invention will become apparent to those of skill in the art upon review of this specification, including its drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a “J-Lay” installation of a subsea pipeline, showing vessel 10 moving in direction 5 at ocean surface 18 , laying pipe 12 onto ocean floor 16 .
FIG. 2 is a schematic representation of an “S-Lay” installation of a subsea pipeline, showing vessel 20 moving in direction 5 at ocean surface 18 , laying pipe 12 utilizing stinger 22 onto ocean floor 16 .
FIG. 3 is a cross-sectional representation of stinger 22 of FIG. 2 , showing pipe 12 positioned and rolling across rollers 25 .
FIG. 4 is an isometric representation, showing pipe 12 , having VIV fairing 15 and collar 13 , positioned and rolling across stinger 22 in direction 7 .
FIG. 5 is a cross-sectional representation of FIG. 4 . taken at 5 - 5 , showing pipe 12 , having VIV fairing 15 and collar 13 , positioned and rolling across stinger 22 .
FIG. 6 is a cross-sectional representation showing fairing 15 mounted on pipe 12 , showing gap 3 formed as a result of gravity.
FIG. 7 is a cross-sectional representation showing fairing 15 mounted on pipe 12 , showing a substantially smaller gap 3 that can be achieved by lifting fairing 15 in direction 4 .
FIGS. 8 and 9 are a cross-sectional representations showing fairing 15 mounted on pipe 12 , showing fairing 15 lifted and held in place by positioning lock 30 .
FIGS. 10 and 11 are cross-sectional representations of stinger 22 , showing collar 13 mounted on pipe 12 .
FIG. 12 is a cross-sectional representation of stinger 22 , showing fairing 15 mounted on pipe 12 .
FIG. 13 is an isolated representation of collar 13 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention is best understood by first making reference to the prior art, and understanding the problem of installing VIV suppression during an S-Lay installation of pipe.
Referring to FIG. 1 , there is shown a schematic representation of a prior art “J-Lay” installation of a subsea pipeline, showing vessel 10 moving in direction 5 at ocean surface 18 , laying pipe 12 onto ocean floor 16 . The name “J-Lay” comes from the “J” shape made by pipe 12 during installation. As shown, VIV suppression is being installed at those locations where pipeline 12 will span channels/trenches 17 . Fairings 15 and collars 13 are very easily added during installation.
Referring now to FIG. 2 , there is shown a schematic representation of a prior art “S-Lay” installation of a subsea pipeline, showing vessel 20 moving in direction 5 at ocean surface 18 , laying pipe 12 utilizing stinger 22 onto ocean floor 16 . The name “S-Lay” comes from the “S” shape made by pipe 12 during installation.
Referring additionally to FIG. 3 , there is shown a cross-sectional representation of stinger 22 of FIG. 2 , showing pipe 12 without suppression positioned and rolling across rollers 25 .
Referring additionally to FIGS. 4 and 5 , there are shown, respectively, an isometric representation and a cross-sectional representation, of pipe 12 , having VIV fairing 15 and collar 13 , with pipe 12 positioned and rolling across stinger 22 in direction 7 .
The problem with the prior art is best understood as follows. As pipe 12 rolls across stinger 22 in direction 7 , any attached suppression, i.e., collar 13 and fairing 15 , will encounter stinger 22 at point 40 , resulting in such collar 13 and fairing 15 either being broken or sheared off of pipe 12 , or held back at point 40 while pipe 12 passes through the collars and fairings.
According to the present invention, if the tail end of the fairing could be oriented to avoid stinger 22 , then it could pass over stinger 22 intact.
However, in addition to the fairing tail engaging the stinger, gravity will tend to pull the fairing away from the pipe allowing that portion of the fairing to fall below the pipe and also engage the stinger. This problem can be seen by reference to FIG. 6 , which is a cross-sectional representation showing fairing 15 mounted on pipe 12 , showing gap 3 formed as a result of gravity. Obviously, as this fairing 15 approaches the stinger, the portion of the fairing sagging below the pipe will engage the stinger, and the fairing will either be sheared/knocked off, or held back while the pipe passes through.
Thus, the present invention additionally provides that if the portion of the fairing that sags below the pipe and engages the stinger could be abutted firmly against the pipe, that portion of the fairing could pass easily over the stinger.
Referring now to FIG. 7 , there is shown a fairing with its tail oriented to avoid the stinger, and that has been abutted firmly against the pipe. FIG. 7 is a cross-sectional representation showing fairing 15 mounted on pipe 12 , showing fairing tail 15 oriented to avoid stinger 22 , and showing that a substantially smaller gap 3 that can be achieved by lifting fairing 15 in direction 7 .
Of course, once fairing 15 has been lifted in direction 7 is must be held in place so that it can pass safely over stinger 22 . The present invention utilizes a positioning lock 30 to keep fairing 15 abutted in place. It should be understood that any suitable positioning lock 30 may be utilized.
One non-limiting embodiment of positioning lock 30 can be seen by reference to FIG. 9 , in which a wedge 39 has been inserted into the upper gap between fairing 15 and pipe 12 to minimize gap 30 and abut fairing 15 against pipe 12 . It is envisioned that any suitable number of wedges may be utilized, and that such wedges may comprise any suitable shape.
Another positioning lock embodiment utilizes a set screw/bolt, with two non-limiting embodiments shown in FIG. 8 . Referring now to FIG. 8 there is shown a cross-sectional representations showing fairing 15 mounted on pipe 12 , showing fairing 15 lifted and held in place by positioning lock 30 . Threaded passages 33 are provided in fairing 15 for receiving set screws/bolts 35 and 37 . As shown, set screw/bolt 37 engages pipe 12 directly, whereas, set screw/bolt 35 engages a pipe contact member 38 , which in turn engages pipe 12 .
Once fairing 15 passes over stinger 22 , fairing 15 must now be made to freely rotate around pipe 12 . Of course, positioning lock 30 prevents such free rotation. According to another embodiment of the present invention, position lock 30 will comprises materials which will degrade in the aquatic environment and allow free rotation of fairing 15 around pipe 12 . The materials are selected to degrade in the aquatic environment at a rate slow enough to allow for installation, but fast enough so that the fairing will properly operate not too long after installation. The materials must have physical properties suitable to allow fairing 15 to be locked into place, and to withstand the rigors in pipe installation, and travel across the stinger.
Not all of positioning lock 30 need be comprised of degradable materials. As one non-limiting example, pipe contact member 38 comprises a degradable material. As another non-limiting example, set screw/bolt 37 comprises a degradable material. It should be easy to see, that even bolt 37 does not have to be made entirely of degradable materials. As non-limiting examples, only the tip of set screw 37 in contact with pipe 12 need comprises degradable material, or perhaps the threads of screw/bolt 37 will degrade. Alternatively, the threads of threaded passages 33 can be made to degrade, freeing set screw 38 . As even another non-limiting example, a positioning lock 30 with a degradable locking pin can be easily envisioned.
Materials that will degrade in marine environments and that will have adequate physical properties are well known to those of the materials art. Preferably, such materials will be degradable thermoplastics and theermosets, most preferably biodegradable thermoplastics and thermosets.
The present invention utilizes unique collars 13 to secure fairings 15 to pipe 12 . Specifically, the collars of the present invention are designed to avoid colliding with stinger 22 . Referring now to FIGS. 10 and 11 , there are shown cross-sectional representations of stinger 22 , showing two embodiments of collar 13 mounted on pipe 12 . More clearer details are provided by additional reference to FIG. 13 , which is an isolated representation of collar 13 . Point 63 is the center of pipe 12 cross-section and of collar 13 cross-section. Assuming a uniform circular collar 13 , the interfering radial portion 65 of collar 13 is that portion which would engage stinger 22 , and is that portion 65 of collar 13 between points 61 and 62 , defining angle Θ. Within this Θ radius, collar 13 must be made thin enough to pass over stinger 22 , and in a preferred embodiment is merely a thin band 51 . Interfering portion 65 of collar 13 that does not engage stinger 22 defines an angle 2Π-Θ radians. Thus, in the present invention, for a stinger having an interference angle with a collar of Θ radians, the main body of collar of the present invention is less than or equal to 2Π-Θ radians, with at least a Θ radian portion of the collar comprising a thin section having a thickness that will not interfere with passage over the stinger. The main body of collar 13 must extend radially away from pipe 12 sufficient to secure fairing 15 in place. It is preferred that collar 13 be provided with a band groove 54 for receiving band 51 . In some embodiments, a band locking/tightening mechanism, such as locking bolt/nut 55 are provided.
Referring now to FIG. 12 , there is shown a cross-sectional representation of stinger 22 , showing fairing 15 mounted on pipe 12 .
While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which this invention pertains.
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Methods and apparatus for the installation of VIV suppression during the S-Lay installation of a subsea pipeline. A locking member will be interposed between a pipe and a fairing rotatably mounted on the pipe, sufficient to bias the fairing against rotating. Upon marine application, the locking member will degrade, thereby releasing the fairing.
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FIELD OF THE INVENTION
The present invention relates to a thermostat valve used in a cooling system of an automobile, more particularly, to an adjustable electronic thermostat valve.
BACKGROUND OF THE INVENTION
In general, a thermostat valve is installed between the automobile engine and radiator and functions to maintain the temperature of coolant in a preferred range by controlling the flow of coolant to the engine in accordance with change of the temperature of the coolant. The thermostat valve can eventually control the temperature of the engine by control of the amount of flow of the coolant.
A conventional thermostat valve that is widely used is a mechanical operating type that opens or closes the valve in accordance with up and down movement of a piston through which the expansion and contraction of a thermal expandable element is transferred. For example a thermostat of the mechanical operating type may include a wax activator. When the temperature of the coolant rises above a threshold value (approximately 80˜90° C.), the wax in a solid state is changed into liquid. Subsequently, the actuating force generated by the expansion of the volume of the wax is transferred to a valve mechanism.
However, the above-described conventional thermostat valve is disadvantageous in that there is a limit to the ability to control the temperature of the coolant considering, for example, driving conditions because the opening and closing operation of the valve only depends on the preset temperature of the coolant. While a cooling system of an automobile is generally designed to satisfy the toughest driving condition such as full load, high ambient temperature, and etc., actual driving is, however, typically conducted with about 70% of full load. Accordingly, overcooling of the engine can occur, which results in increasing consumption of fuel and exhaust containing excessive pollutants.
For the foregoing reason, there is a need for a thermostat valve that can optimize a temperature of coolant to engine by raising the temperature of a coolant while the engine is operating with partial load and lowering the temperature of a coolant while the engine is operating with full road. In order to overcome drawbacks of the prior art, attempts to provide an adjustable electronic thermostat valve that optimizes a temperature of coolant to engine have been made. Ideally, such an adjustable electronic thermostat valve would maintain an engine under the optimized cooling condition by controlling the temperature of coolant to the engine based on driving conditions and load conditions, whereby decrease of exhaust gas and fuel consumption can be expected.
In prior attempts to address this problem, thermostat valves have been provided with heating means to cooperate with the expandable wax element. Such an electronic thermostat valve comprises basically same elements as a conventional mechanical thermostat valve with the addition of the heating means. Power supplied to the heater is controlled based on driving conditions such as speed of an automobile, temperature of intake air, and loading conditions.
However, the above-described electronic thermostat valve is disadvantageous in that the parts of the valve are relatively easily damaged by high temperature caused by heating means, and further, the response time is slow. The specific drawbacks of prior electronic thermostat valves include, for example, heating defects created in the wax or other elements of the valve, and delay in operating the valve in response to the supply electric power to the heater because of the time delay to heat up the heater and expand the wax. Also, in the process of sealing the thermostat valve case, electric wires for supplying electric power to the heater can be damaged. Even if the sealing process is completed without any defect in the electric wires, the sealing material such as epoxy is easily degraded or destroyed due to the vibration of a engine. In the event that the thermostat valve is operated in safe-mode due to the failure of electronic parts, the engine continues to overheat potentially resulting in critical damage to the engine.
SUMMARY OF THE INVENTION
Embodiments of the present invention provide an adjustable electronic thermostat valve comprising an actuating means provided with a rod for stroking a chamber of an expendable thermal element. With this arrangement, the temperature at which the thermostat valve opens and closes, can be easily adjusted based on driving conditions by changing the volume of the chamber of the expendable thermal element, whereby a cooling efficiency of the engine is maintained in optimized range. As a result, emission of exhaust gas and consumption of fuel is significantly reduced.
Further, preferred embodiments of the present invention include actuating means capable of directly changing the volume of the chamber of the expendable thermal element, so that the operation of the valve in response to a control signal is promptly accomplished. This can provide a rapid response characteristic, whereby temperature of coolant to an engine can be accurately controlled.
Also, a fail-safe device is preferably included so that the thermostat valve properly functions with only the expandable thermal element operating when the actuating means of the valve is unable to operate due to the failure of supplying electric power.
Preferably an adjustable electronic thermostat valve according to the invention comprised an actuating means employing a screw-feeding method to obtain sufficient displacement of the valve even though the stroke of the actuating means is relatively small.
Also, preferred embodiments unintended movement of the valve such as a fluctuation or vibration by fixing the expandable thermal element of the valve, whereby the valve is more accurately opened or closed.
An adjustable electronic thermostat valve according to further preferred embodiments of the present invention comprises an actuating means that operates in response to control signals concerning driving conditions, with the actuating means having a screw-feeding rod. A chamber accommodating an expandable thermal element begins to expand at preset temperature wherein the volume of the chamber is changed by the screw-feeding rod. A piston is operatively connected to the chamber and opens or closes a valve plate in accordance with the change of volume of the chamber. A power-delivering liquid and diaphragm transfers expansion force of the expandable element to the piston.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned aspects and other features of the present invention will be explained in the following description, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is an exploded view of an adjustable electronic thermostat valve according to an embodiment of the present invention;
FIG. 2 is a perspective, sectional view of an adjustable electronic thermostat valve according to an embodiment of the present invention;
FIG. 3 is a sectional view showing open state of an adjustable electronic thermostat valve according to an embodiment of the present invention;
FIG. 4 is a sectional view showing close state of an adjustable electronic thermostat valve according to an embodiment of the present invention; and
FIG. 5 is a graph showing the variation of an opening and closing temperature of an adjustable electronic thermostat valve of the present invention in accordance with change of the stroke of a rod.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Hereinafter, a preferred embodiment of the present invention is described in detail with reference to the accompanying drawings. As shown in FIGS. 1 and 2, an adjustable electronic thermostat valve according to one embodiment of the invention is provided with an actuating means 20 controlled by an electronic control unit (ECU) of an automobile (not shown) and a case 26 having a chamber 25 accommodating an expandable thermal element 23 . A rod 27 of the actuating means 20 is partially inserted into the chamber 25 and is engaged to an upper part of the case 26 with screw thread. Accordingly, rotating movement generated by the actuating means 20 is transformed to linear movement of the rod 20 by means of screw thread formed at the part of the rod 27 and the case 26 . The actuating means 20 for generating a movement in response to input of electric power may be selected by a person skilled in the art. Suitable devices include, for example, a linear step motor, a DC motor or a linear solenoid, which have a rapid response. In the event that the liner solenoid is adopted as an actuating means, then the screw engagement mentioned in the above embodiment is not required because the linear movement generated from the linear solenoid can be directly applied to the rod 27 . Namely, a slide connection can be used instead of screw connection.
The actuating means 20 and the case 26 are installed onto a housing 100 and a supporting element 110 downwardly extending, respectively. The actuating means 20 is mounted on the top of the housing 100 having the rod 27 passed through supporting element 110 , the rod being partially inserted into the case 26 . And an upper part of the case 26 is inserted into the supporting element 110 and secured thereto.
Further, the thermostat valve according to a preferred embodiment of the present invention is provided with a piston 24 and a moveable case 28 for moving a valve plate 21 . The piston 24 guided by a piston case 34 moves up and down in accordance with the expansion and contraction of the expandable thermal element. The movable case 28 contacting the piston 24 and the valve plate 21 at the both ends thereof, controls the valve plate 21 in response to the movement of the piston 24 .
A diaphragm 29 and a power-delivering liquid 30 of gel type are preferably provided in order to transform the expansion of the thermal element into a linear motion that is acceptable to the piston 24 . The diaphragm 29 encloses the chamber 25 of the expandable thermal element and transfers the expansion of volume in the chamber to the power-delivering liquid 30 . Subsequently, the power-delivering liquid 30 filled in the space between the piston 24 and the diaphragm 29 , moves the piston 24 in accordance with the movement of the diaphragm 29 . For sealing the power-delivering liquid 30 in airtight manner, it is preferable to dispose packing 31 made of rubber material at the end of the piston.
A stopper 32 and a supplementary spring 33 are disposed at the lower end of the movable case 28 for opening or closing a bypass passage. A valve plate 21 is disposed beneath the flange of the movable case 28 and elastically supported by the spring 22 mounted on a supporting bridge 120 .
Hereinafter, the operation of an embodiment according to the present invention is disclosed.
Under the isothermal circumstance, even if the volume of the expandable thermal element is constant, volume of the chamber of the expandable thermal element can be changed by the stroke of the rod. Namely, the volume of the chamber can be controlled by changing the depth of the rod, which is inserted into the chamber. In order to clarify the relationship between the stroke of the rod and the displacement of the valve plate, an example is disclosed below.
For example, if
Stroke of the rod: ΔL=2 mm;
Outer diameter of the rod: D=8 mm;
Outer diameter of the piston: D′=4 mm;
Then, the change of the chamber: ΔV=ΔL·π·D 2 /4=100.48 mm 2 .
Therefore, stroke of the piston: ΔL′=ΔV/(π·D′ 2 /4)=8 mm.
As noticed from the above example, with small stroke of the rod, it is able to obtain enough displacement of the piston. In addition, the displacement of the piston can be properly changed by changing the ratio of the diameter of the rod to the diameter of the piston. Consequently, enough amount of coolant to maintain the engine in optimal range of temperature is supplied to the engine even though the stroke of the rod is quite small.
Further, the thermostat valve of the present invention can precisely control the temperature of an engine because the many factors concerning the driving condition are taken into consideration in operation of the valve. The cooling system of an automobile can be optimized by employing an actuating means, such as a step motor, which readily control the amount of the displacement of the valve plate. Accordingly, the coolant supplied to the engine can be precisely controlled and thus, it is possible to overcome the drawbacks in a conventional thermostat of mechanical type, such as delayed responding time and fixed cooling ability regardless of the change of driving conditions. For example, under the certain circumstances of driving conditions requiring significant coolant such as full load condition or high speed driving, the thermostat valve of the present invention promptly, precisely controls the displacement of the valve plate in response to the condition by means of the rod stroke of the step motor.
As shown in FIGS. 3, 4 and 5 , by controlling the stroke of the rod by means of the ECU that generates control signals based on load state of the engine, engine RPM (revolution per minute), coolant temperature, and temperature of intake air the present invention can change the volume of the chamber of the thermal element, so that a range of temperatures at which the valve operates can be changed in accordance with the driving conditions. The range of temperature is generally between about 85° C. and 105° C. For example, in the event that prompt supply of coolant to an engine is required due to the increase of load, as shown in FIG. 3 and FIG. 5, the rod is deeply inserted into the chamber of the thermal element, so that the temperature at which the valve plate opens lowers, for example, about to about 85° C. In the opposite case (partial load), as shown in FIG. 4 and FIG. 5, the rod is pulled out from the chamber of the thermal element, so that the temperature at which the valve plate opens is increased to about 105° C. Referring to FIG. 5, opening or closing operation of the valve plate is selectively conducted at the region depicted in the figure as a gray solid in accordance with the movement of the rod. The thermostat valve according to the present invention is able to maintain a cooling system of an automobile in optimized state by controlling the flow of the coolant to an engine in response to the driving conditions in real-time base.
Further, the embodiment of the present invention employs a unique mechanism for accurate operation. An expandable thermal element having flexibility in its structure is designed not to directly involve in the operation of a valve plate. Instead, the operation of the valve plate is done by movement of a moveable case and a piston, which move relative to the fixed thermal element. In other words, a case accommodating the thermal element is physically fixed to a valve housing, and only provides expanding force with other elements. An actual movement of the valve plate is accomplished by the piston and the moveable case where the expanding force is transferred. Accordingly, the thermostat valve according to the present invention can precisely control the valve plate without the any mechanical malfunction because of exclusion of the thermal elements having flexibility.
Further, the embodiment of the present invention is provided with fail-safe device in case of disconnecting electric power. When electric power supplied to an actuating means is unexpectedly disconnected with some reason, a critical damage to engine would be caused if there is no fail-safe device in the thermostat valve. Because embodiments of the present invention comprise an expandable thermal element therein, the basic function of thermostat valve is operable without the supply of electric power. Embodiments of the present invention are further provided with an elastic element for returning a rod without any electric power, such as a torsion spring. With the torsion spring, the rod is return to an initial position when electric power is disconnected. It means the operation of the thermostat valve of the present invention become identical with that of the conventional thermostat of mechanical type.
As described above, a cooling system of an automobile is significantly affected by driving conditions and a circumstance. A thermostat valve of mechanical type according to the prior art is, however, not provided with a function or elements to take into those influencing factors. Even an electronic thermostat valve having a heating means, which is widely used in recent, has some disadvantages causing a heating damage to elements.
Thus, an adjustable electronic thermostat valve of the present invention is advantageous at last in that:
1) heat damage of elements and sealing problems are eliminated by excluding additional heating means; 2) in structure, mechanical malfunction is significantly reduce by fixing the thermal element having flexibility; and 3) the cooling system of an automobile is maintained in an optimized state by controlling a displacement of a valve plate in response to control signals from an ECU that memorize best cooling mode based on the driving condition and circumstance.
Consequently, by employing the thermostat valve according to the present invention, it is possible to increase output power and endurance of an engine, to reduce exhaust gas and consumption of fuel.
Even though one embodiment of the present invention has been disclosed in the above specification, other embodiments and modifications will of course be apparent to those skilled in the art without departing from the scope of the appended claims.
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The present invention relates to an adjustable electronic thermostat valve comprising an actuating means provided with a rod for stroking a chamber of an expendable thermal element, so that temperature at which the thermostat valve opens can be easily adjustable based on driving condition of an automobile by changing the volume of the chamber of the expendable thermal element, whereby a cooling efficiency of the engine is maintained in optimized range. As a result, emission of exhaust gas and consumption of fuel is significantly reduced.
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The United States Government may enjoy rights in this invention under U.S. Army Contract DAAE0784CR086.P4.
BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to a method for improving mechanical and chemical properties of styrene-butadiene rubber (SBR) and the improved rubber produced thereby.
2. Background of the Prior Art:
SBR is well known as a synthetic alternative to natural rubber (cispolyisoprene) developed in response to rubber shortages encountered during World War II. To improve physical characteristics for many applications, such as tires and the like, specific and selective curing processes have been employed with SBR. Two processes currently tend to dominate the market place.
In a first process, the SBR is modified by the addition of a chemical improver, generally sulfur, and the rubber is cured in the presence of the improver and moderate heat. This is the traditional method of curing SBR for industrial applications such as tires, hoses and the like.
An alternative method begins with limited or "light" irradiation of the polymer, followed by the chemical/thermal curing described above. This process is generally used in the production of components of tires for automobiles, etc. In this process, the initial light irradiation is used to produce a limited crosslink density, which increases "green strength" sufficiently, such that the irradiated preform can withstand the handling in the subsequent tire fabrication process. The major amount of crosslinking, and therefore, curing of the SBR is achieved through the second, heat/sulfur cure stage.
A third class of alternatives includes some variations, either in chemical additives, heating, or irradiation. These combinations and permutations are generally selected with regard to the ultimate end-use of the elastomer, and the particular nature of the elastomer (i.e., styrene content, etc.)
Neither of the dominant methods, nor any known combinations, have been employed in the modification of SBR for the purpose of improving tear strength or ozone resistance.
NR is the focus of U.S. Pat. No. 2,933,441. Therein, a combination of processes, beginning with an accelerated heat cure, using sulfur and a small amount of accelerator, is the first step in the production of a tire. The partially cured preform is treated so as to retain its shape under subsequent irradiation and handling treatments. Thereafter, it is irradiated under an intense, localized beam. The reference discloses such a treatment improves abrasion resistance. It does not discuss ozone resistance or tear strength.
Other references specifically directed to SBR, as opposed to the NR of the reference discussed above, include U.S. Pat. Nos. 4,122,137; 4,230,649 and 4,233,013 all to Bohm et al. These references are directed to the curing of SBR, through a sulfur/heat treatment, followed by irradiation. As suggested in Example 3 of U.S. Pat. No. 4,122,137, the process calls for a relatively large amount of accelerator (1.8 phr) and a reduced irradiation dosage. U.S. Pat. No. 4,230,649 differs from that disclosure principally in using a microwave irradiation step subsequent to the sulfur cure. These patents are all directed to improving the processing efficiency, i.e., reducing in-mold time, and do not focus on the improvement of specific characteristics, such as ozone resistance and hot tear strength. SBR is frequently employed in situations where improved overall wear resistance, tear strength, crack initiation and growth resistance and, in particular, ozone resistance, are of importance, such as in pads for military track vehicles, and the like. In the particular situation of pads for track vehicles, the pads must be of a compound resistant to constant wear over asphalt/concrete surfaces, and cracking and pitting over hilly or cross-country terrain. Suitable materials are routinely evaluated by the military in field tests. Thus, a need continues to exist for a method for improving the mechanical strengths and ozone resistance of SBR for such applications.
SUMMARY OF THE INVENTION
It has now been discovered that exposing SBR, particularly a 1500 type SBR, to a two-step process, first introducing to the polymer a small amount of sulfur and a small amount of multifunctional crosslinking agent and exposing the material, in an appropriate mold, to a moderate heat treatment, followed by relatively significant irradiation of 5-25 Mrad with either 10 MeV electrons or cobalt 60 gamma rays, any other radiation means with similar linear energy transfer properties, results in a substantial increase in hot tear strength, and extraordinary improvements in ozone resistance. This is particularly surprising in view of the fact that it is the general standard of the art that radiation crosslinking does not give the same degree of improvement relative to sulfur-cured SBR.
DETAILED DESCRIPTION OF THE INVENTION
SBR is well known, and generally available from a variety of sources. Most SBR contains about 23% styrene, although alternative formulations contain differing amounts, including, significantly less styrene, down to about 15%. These variations are embraced within the invention set forth herein.
To process the SBR according to the claimed invention, the polymer is first heat treated with sulfur and a sulfur cure accelerator together with an appropriate multifunctional crosslinking agent. The used additives such as carbon black, zinc oxide, stearic acid, an anti-ozidant (antiozite 2) and antioxidants ordinarily used in rubber formulation with sulfurs are of course included in the butadiene-styrene copolymer composition. These additives do not constitute a novel aspect of the invention. To obtain the results desired, the amount of sulfur and chemical accelerator, as well as multifunctional cross-linking agents, must be carefully controlled. A typical sulfur addition is 0.5 phr, and the accelerator may be present in amounts of about 0.1 phr. These values may range from 0.1 to 0.8 phr for sulfur, and 0 to 0.5 phr for the chemical accelerator. A preferred chemical accelerator is Santocure™, although alternative, commercially available accelerators may be used. A multi-functional crosslinking agent must be selected to impact a moderate degree of crosslinking, without interfering with the radiation curing, and will therefore be selected on the basis of polymer miscibility, cost and reactivity relative to sulfur and the reaction conditions. A preferred agent is 3,9-divinyl-2,4,8,10 tetraoxyspiro-[5,5]undecane, (DTUD), available from SIGMA chemical. It may be used from 0.05 phr up to about 2 phr. An exemplary value is about 0.1 phr. Those of ordinary skill in the art will select particular accelerators and crosslinking agents based on specific formulations, and properties other than wear resistance, crack initiation and growth resistance, tear strength and ozone resistance, as desired. This combination is then placed in the desired mold, and heated, to preliminarily cure the SBR formulation, under the applications of moderate heat, e.g., about 300° F. The exposure time is about 70 minutes, but may range from 35-120 minutes. The temperature may similarly range from 280° to 320° F.
The preformed material has sufficient "strength" to resist deformation upon handling, etc. To bring the modified SBR to full cure, the preform is exposed to radiation, an exemplary dose being about 5-25 Mrad of 10 MeV electrons, cobalt 60 gamma rays, or equivalent radiation means with similar linear energy transfer properties. Of course, the actual instrument used, and length of irradiation, will vary to achieve this irradiation level. The effects are independent of the dosage rate provided heat is removed, especially at high dosage rates and thick samples, and the radiation atmosphere is inert when the samples are irradiated at low dose rates.
In following the above process, i.e., 0.5 phr sulfur, 0.1 phr DTUD, exposure to 300° F. in the mold of about 70 minutes, followed by the given irradiation dosage, hot tear strength is increased 15-20% over comparison based on the commercially used sulfur-cure, discussed above. As the relevant information in the industry suggests irradiation does not improve physical properties such as tear strength, this is clearly unexpected.
Further dramatic evidence of the improvement in the SBR treated according to this invention can be observed by reference to the ozone resistance test. A standard ozone test comprises exposing the SBR to the following conditions:
ASTM-D-1149, Specimen B (bent loop test at 40° C. with ozone concentration of 50 pphm).
Commercially available SBR (Belvoir Research Development Center Standard 15 SBR 26) fails, under the standard ozone test, in less than 7 days. Product processed as indicated above resists and survives under the same conditions for at least 35 days, without any evidence of ozone corrosion. This is a phenomenal improvement of at least 500% in ozone resistance, and is particularly meaningful in terms of military application and industrial applications under severe conditions.
Absolute values for the tear strength of the example of the invention discussed above are 180-183 lbs./in. as opposed to the conventional sulfur cured compound value of 132-167 lbs./in. As ozone resistance is given in the standard test in terms of days of survival without failure, the product of this invention has yet to exhibit any failure at all. Wear resistance, and resistance to crack initiation and propagation were also sharply improved.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. In particular, it is noted that radiation dosage for a thick sample will be distributed over a variable range. The dosage figures given herein are idealized for thin sample situations. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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SBR is treated with sulfur, an optional chemical accelerator and a crosslinking agent, under mild heat, to form a preform having sufficient strength to resist handling. The preform is exposed to substantial irradiation on the order of 5-25 Mrad dose of 10 MeV electrons equivalent, which significantly improves wear resistance, tear strength, crack initiation and growth resistance and ozone resistance.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to fences, particularly those used for residential purposes, and in particular, to devices and methods to deter vegetation growth under the fences.
2. Problems in the Art
Property owners many times erect fences to delineate property boundaries, to obtain privacy, or to restrict either access to or egress out of the property at that location. The most popular types of fences, particular for residential properties, are chain link fences and wooden board fences.
Both types generally include fence posts secured in the ground at regularly spaced intervals. The fence itself is usually built between posts and above the ground. It is usually intended and desired that the bottom of the fence extend to the ground or as close to the ground as possible to provide a barrier to entry or exit of even smaller animals or pets.
Several problems face the fence owner. First, when installing the fence there are limitations as to how close to the ground the fence can be placed, especially if there are changes in the contour of the ground along the fence. Chain length fencing has some ability to follow such contours, but if the fence is to be held tight between posts, such flexibility is limited. Wooden fences can be customized as to each board's length, and thus theoretically could adapt to any contour. However, realistically, most fences come premanufactured with boards of the same length. It is usually desired to have the top of the fence relatively uniform, and therefore, varying the height of several boards to meet a depression or raised portion of the ground is not desirable.
Secondly, trimming grass and weeds and other vegetation around the fence bottom can be difficult and time consuming. While labor-reducing devices such as string trimmers are in wide use, it is still time consuming to trim along fences, and most fences tend to wear away the string of such trimmers at a substantial rate.
Thus there is a need for a solution to the problems of building a fence only to have gaps between portions of the fence bottom and the ground, especially where there are undulations or changes in the contour of the ground along the fence, especially between fence posts, and of building a fence and facing the task of keeping it free from vegetation or having an unsightly fence row.
Somewhat surprisingly, there are a significant number of issued patents that address the issue of providing a barrier to vegetation along a fence bottom. Examples can be found at:
______________________________________PATENT NUMBER ISSUE DATE PATENTEE______________________________________2,826,398 3/11/58 MILLER3,515,873 6/02/70 ABBE3,713,624 1/30/73 NIEMANN3,806,096 4/23/74 ECCLESTON ET AL.4,349,989 9/21/82 SNIDER, JR.4,497,472 02/05/85 JOHNSON5,178,369 01/12/93 SYX4,907,783 3/13/90 FISK ET AL4,964,619 10/23/90 GLIDDEN, JR.5,285,594 2/15/94 PENNY5,328,156 7/12/94 HOKE______________________________________
However, none of these patents address satisfactorily the first problem discussed above; namely, how to block gaps that exist or form between the bottom of a fence and the ground. Patents such as Abbe are buried in the ground, and therefore follow the ground contour, but have no upwardly extending portion. Therefore, big gaps would remain. Others are too structurally rigid to bend, once installed, or do not have anyway to bend to follow a ground contour.
Moreover, many of the patents are complex, expensive to make or install, or otherwise have deficiencies that could allow improvement. A subtle deficiency in some prior art attempts is that part of the installation would have to occur on the adjoining property owner's land, which sometimes is not possible or will not be permitted.
Therefore, despite a seemingly substantial number of attempts at solving the problems with the bottoms of fences, a real need in the art has been identified. It is therefore a principle object of the present invention to overcome the problems and deficiencies in the art.
Still further objects of the present invention are to provide an improved gap blocker and vegetation barrier for fence bottoms which:
1. can be conformed to a wide variety of ground contours and fence bottoms while maintaining both functions of blocking any gaps and deterring vegetation growth.
2. is strong and durable, even when stepped by persons or animals and run over by mowers.
3. is easy to install.
4. is economical.
5. is flexibly adaptable regarding type of fence, type of barrier desired, coverage of barrier desired, size and length of fencing, number of corners of fencing, and other characteristics of fences, ground and environment.
6. can be retrofitted to existing fences of many different types or installed with the installation of a new fence.
7. is effective to block gaps and deter vegetation growth at the bottom of fences.
8. is aesthetically pleasing.
These and other objects, features, and advantages of the present invention will become more apparent with reference to the accompanying specification and claims.
SUMMARY OF THE INVENTION
The present invention is a gap blocker and vegetation barrier for the space between a fence bottom and the ground. It comprises an elongated member which includes a vertical riser having securing members that allow it to be secured to the fence in a manner that the riser can be kept relatively stationary from vertical movement. A ground cover portion extends from the riser generally horizontally and serves to cover and deter vegetation growth. The ground cover portion can either extend in one direction from the riser so that it covers the ground on only one side of the fence, or can extend in both directions, with one side of the cover portion slideable under the fence and covering a portion of ground on the opposite side of the fence.
The apparatus is made from a material and of a structural characteristic that it can flex along its longitudinal axis to follow a large majority of ground contour changes or undulations. The ability to secure the riser to the fence allows the apparatus to be drawn up or pushed down relative to different locations along the bottom of the fence to follow a differing contour of the ground, and then secured in place. The riser then extends between the fence and the ground as a blocking member for what otherwise might be gaps between the bottom of the fence and the ground, and the ground cover portion of the apparatus is a barrier against vegetation growth to save the time and effort of having to trim directly under the fence.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a multi-section apparatus according to the present invention installed with respect to a chain link fence.
FIG. 2 is an enlarged perspective view of a single section of the apparatus of FIG. 1 relative to a chain link fence.
FIG. 3 is an enlarged perspective view of a section of the apparatus according to an alternative embodiment of the present invention installed to a wood fence.
FIG. 4 is an enlarged end elevation view of FIG. 3.
FIG. 4A is similar to FIG. 4 but shows the apparatus according to the preferred embodiment of the present invention blocking a gap between the fence bottom and the ground.
FIG. 5 is a still further enlarged, isolated end elevation view of a removable ground cover section of the apparatus of FIG. 1.
FIG. 6 is a partial sectional, front elevation view illustrating how the apparatus according to the present invention can be installed relative to a fence to follow contours of the ground.
FIG. 7 is a top plan view of an interconnecting member to interconnect sections of the apparatus of FIG. 1 and to interconnect said sections and cover the ground around fence posts.
FIG. 8 is a top plan view of the interconnecting member of FIG. 7 installed relative to fence posts and corners in the fence of FIG. 1.
FIGS. 9 and 10 are top plan views of optional interconnecting members to that of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
To assist in a better understanding of the invention, one embodiment the invention can take will now be described in detail. Frequent reference will be taken to the drawings. Reference numbers will be used to indicate certain parts or locations in the drawings. The same reference numerals will be used to indicate the same parts and locations throughout all the drawings unless otherwise stated.
FIG. 1 shows an apparatus according to the present invention which will hereafter be referred to generally as barrier 10 installed in position relative to a chain link fence 12. Fence 12 includes fence posts 14 secured into the ground at spaced apart positions, top rails 16 secured between posts 14, and the chain link fabric or web 18 strung between poles 14. Barrier 10 is positioned under the bottom of web 18 of fence 12 along its entire length. It is to be understood that barrier 10 will be discussed mainly in the context of use with a chain link fences, such as are well known well, but it can be used with other types of fences. Some examples will be discussed later.
Barrier 10 is produced in elongated sections 11, ideally of lengths that span just about the distance between posts 14. For example, if the standard distance between posts 14 was ten feet, each barrier section 11 would be made slightly under ten feet long so that it could be inserted between the posts 14 with a little space left. However, obviously, sections 11 could be made to any length and could have variable length.
Each section 11 of barrier 10 has a riser 20 and ground cover portion 22. As seen in FIG. 1, when installed risers 20 extend generally vertically along one side of web 8 and cover portions 22 extend generally horizontally over the ground below or near the bottom of web 18. Spacers 24 are insertable between sections 11 of barrier 10 to cover the ground between those sections, particularly around fence posts 14.
As can be seen in FIG. 1, barrier 10 not only covers and deters vegetation growth under fence 12 and for a distance to the side of fence 12, but also blocks any gaps between the bottom of web 18 and the ground. It also gives the appearance of a foundation or base which is aesthetically appeasing. It is to be understood that barrier 10 could be made of different colors, including to match the color of the fence or to match the color of vegetation, such a green for grass, to assist in the aesthetic appearance.
More detail of the structure and installment of barrier 10 can be seen in FIG. 2. Each riser 20 has a number of apertures 23 along its length, preferably near its top edge (e.g. elongated holes through riser 20 approximately 3/16" to 1/4" in dimensions and spaced apart approximately 4" on center). Securing loops 25 are placed through apertures 23 and then around at least one strand of web 18 of fence 12. Generally, not every aperture 23 would have a securing loop 25. For example, perhaps one securing lop would be used every sixth aperture 23 (if apertures 23 were 4" apart), unless securement at other locations was needed or desired. In this embodiment, ground cover portion 22 consists of panels 26 and 28, forming a T-shape cross section for barrier 10. Panel 26 extends under web 18 to the opposite side of fence 12 from the side of riser 20, whereas panel 28 extends away from riser 20 on the same side of the fence as riser 20.
Riser 20 and panels 26 and 28 are made from 1/16" thick plastic, preferably PVC or polyethylene with UV resistance. Such materials can be made to have substantial strength but yet have some flexibility. Note that the top of riser 20 has a bead 32 for strength. The bottom of riser 20 has a thickened portion 34 for strength without unduly limiting the flexibility. Panel 28 is integral with portion 34, whereas in this embodiment, panel 26 is a separate piece that can be mounted to portion 34 by sliding bead 36 of panel 28 longitudinally into and along a channel 42 along the length of riser 20.
Note too that panels 26 and 28 are concave with respect to the ground and have turned under edges 38. This combination allows some resilient springing action of the ground cover portion of barrier 10 relative to riser 20 when barrier is either pressed down (e.g. by persons or animals stepping on or mowers moving over a panel 26 or 28) or when the barrier is intentionally pressed down and secured into place relative to fence 12. This therefore assists in blocking any gaps between the fence bottom and the ground and deterring vegetation growth by securely covering the ground without sunlight.
Securing loops 25 are conventional plastic tie downs available from a wide variety of sources. They have a toothed surface along at least a portion of their length (e.g. 4" long) that is pulled through a piece, and like a ratchet, the loop that is formed can be cinched down (reduced in size) and maintained in place, and can not move back to a larger size without destroying the tie down. These are well known. They are inexpensive, easy to install, flexible in characteristic and in the length which they can be, and are durable. Other securing loops are possible. One example would be bungy cords (FIG. 2 at 27) or other elastic devices with hooks or other end point securement means. Other types of securing members are also possible.
FIG. 3 illustrates how barrier 10 could be used with a wood fence 12A. It is more likely that a wood fence 12A would extend all the way to the ground or that it would not be easy to slide a panel 26 under the fence. Because the opposite side of the fence can not be seen, it may not be desired to utilize panel 26. Therefore, panel 26 can be removed (or never be installed) and, as shown in FIG. 4, riser 20 could be brought up against the wood fence 12A, and wood screws, nails, or other fasteners 30 placed through apertures 23 and into the wood. Barrier 10 would be held securely in position, including against any vertical movement. Thus, even though the fence bottom or top or both are level, for example, barrier 10 could be pushed down or pulled up along its length at various points, and secured in place on the fence. As with the prior example, the flexibility of barrier 10, along with the ability to secure riser 20, would allow barriers 10 to be flexed to follow the contour of the ground, even if the fence did not follow it. Therefore, any gaps could be taken care of by barrier 10. Compare FIGS. 4 and 4A.
Barrier sections 11 can have the following general approximate dimensions--overall length of ten feet (but trimmable to different lengths); two to three inches tall (the height of riser 20); and six to eight inches wide (the width of both panels 26 and 28). FIG. 5 illustrates removable panel 26 in more detail. The dimensions of panel 26 are: A=0.50",; B=3.38"; C=0.64". Radius R1 is based upon a 14.4" radius; radius R2=0.120"; and radius R3=0.20". Bead 36 of panel 26 fits within a 0.125" diameter round channel 42 along portion 34 of riser 20. Slot 44 extends out form channel 42 to allow passage of panel 26 out of portion 34 and to prevent it from tilting up or down. Similar dimensional relationships exist for panel 28. Bead 32 on riser 20 is approximately 1/4" in diameter and extends on one side of riser 20.
FIG. 6 illustrates how barrier 10 can follow bends in the bottom of fence 10 or changes on contour of the ground. Securing loops 25 can be used to tie riser 20 to varying positions along fence web 18. Therefore, if barrier 10 needs to be drawn down somewhat to follow a depression in the ground or the bottom of fence 10, riser 10 is simply drawn down and tied to web 18 at a lower point than other parts of barrier 10. Plastic ties as securing loops 25 allow the installer some leeway because it may require that the plastic tie reach quite a ways up or down on web 18 to draw barrier 10 to the required position (see reference numbers 60 and 62 and compare how they and where they are tied to fence web 18. The flexibility to flex riser 20 along its length is such that it can bend several inches per linear foot of length.
FIGS. 7 and 8 illustrate the spacers 24 that can cover the area around fence posts 14 or simply be used to bridge between two sections 11 of barriers 10. In one form, spacer 24 is a flat square piece of plastic having a cut out 52 sized for insertion around a round fence pole 14. Dashed line 52A indicates that a punch out or cut out line could be manufactured into the spacer to allow easy modification of spacer 24, if needed, for bigger poles.
FIG. 8 shows that spacer 24 would be inserted around pole 14 and then slid into the turned under edges 38 of panels 26 and 28 on one side of post 4. The other barrier section 11 would simply be brought near or into abutment with spacer 24 and secured into position. All areas under fence web 18 would then be at least substantially covered. Spacer 24 is sized so that its width slides into and is captured in turned down edges 38 of panels 26 and 28 of ground cover portion 22. It can be approximately 6" to 8" width and can be approximately 10" long and 1/16" thick.
FIG. 9 illustrates that alternatively, cut out 52C could be square to accommodate square fence posts, such as some wood posts. FIG. 10 shows another embodiment of spacer 24. A square or rectangular piece could have merely a slit 54 that leads to one or more cutouts. The dashed lines indicate knock out or punch out cuts 56A, 56B, 56C, and 56D on the piece. The installer would knock out the center to the diameter needed (e.g. 15/8", 2", 21/2", 3"). Spacer 24 could be pulled around the post via the slit 54 and then installed as discussed with regard to FIG. 8.
The included preferred embodiment is given by way of example only, and not by way of limitation to the invention, which is solely described by the claims herein. Variations obvious to one skilled in the art will be included within the invention defined by the claims.
For example, barrier 10 can be made out of a number of materials. Plastics are generally preferred. Examples are PVC, polypropylene and polyethylene. The characteristics needed are set forth above including being able to flex, being able to survive all types of environmental conditions out of doors, and being able to take mowers and people and animals stepping on it. Plastic could be molded to the shape indicated herein.
As previously mentioned, the size and shape can vary. It can be manufactured by a number of methods widely known in the art. An example is injection molding.
The Figures show each section 11 to be two-piece; one piece comprising riser 20 and panel 28 integral with one another; the other piece comprising removable panel 26. Section 11 could be all one piece (riser 20 and panels 26 and 28) or riser 20 could be separate with each panel 26 and 28 removable.
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An improved blocking member and vegetation barrier for the bottom of fences includes a riser portion that runs along one side of the fence. The riser is somewhat flexible and is securable to the fence in a manner that allows the installer to adjust the riser vertically relative to the fence or other portions of the riser, if necessary, and restrain it from any substantial vertical movement once secured. A ground covering member extends transversely from the lower part of the riser. Thus, the ground covering member can be placed directly on the ground even if the ground undulates relative to the fence bottom, and can be kept in that position once the riser is secured to the fence. The ground covering member can be resilient and create reactionary force if it is pressed against the ground. This can further assist in maintaining the blocking member and vegetation barrier in a fixed position relative the ground and the fence. The device can be made in lengths that can be interconnected by spacers that extend between the lengths.
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CROSS-REFERENCE TO RELATED PATENT APPLICATION
This patent application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/916,432, titled “SELF-LATCHING PIEZOCOMPOSITE ACTUATOR.” filed on Dec. 16, 2013, the contents of which are hereby incorporated by reference in their entirety. The present application is also related to U.S. Pat. No. 6,629,341, titled “METHOD OF FABRICATING A PIEZOELECTRIC COMPOSITE APPARATUS,” the entire contents of which are incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
The invention described herein was made in the performance of work under a NASA contract and by employees of the United States Government and is subject to the provisions of Public Law 96-517 (35 U.S.C. §202) and may be manufactured and used by or for the Government for governmental purposes without the payment of any royalties thereon or therefore. In accordance with 35 U.S.C. §202, the contractor elected not to retain title.
BACKGROUND OF THE INVENTION
Piezoelectric actuators typically require constant control and management of electric fields to set and hold deflections. Without constant application of the controlling electrical field, for example, in the event of a power failure, the piezoelectric actuator will return to a neutral or near-neutral deflection state. For quasistatic deflection or shape control applications, electrical efficiency and fault tolerance of the piezoelectric system (integrated structure, actuators, and controls) could be improved by eliminating the need to maintain electrical power and active control on the piezoelectric actuator components once a desired deflection is achieved.
SUMMARY OF THE INVENTION
One aspect of the present invention is a device that manipulates the remnant strain behavior present in certain ferroelectric ceramics to set or adjust quasistatic extensional or flexural deflections in a composite structure without the application of a persistent controlling electrical field. Potential aeronautics applications include adaptive-camber airfoils, trim tabs, deformable engine inlets, and adaptive or adjustable vortex generators. Space applications include active optics and reflector systems.
One aspect of the present invention is a method of controlling a self-latching piezocomposite actuator having a layer of shape memory ceramic fibers and first and second layers that include conductive patterns. The first and second layers are disposed on opposite sides of the layer of shape memory ceramic fibers. The method includes causing the shape memory ceramic fibers to have a first strain state by at least partially poling the shape memory ceramic fibers utilizing a first electric field that is induced by causing a voltage difference in the conductive patterns of the first and second layers. The method farther includes removing the voltage difference whereby the shape memory ceramic fibers remain in the first strain state. The shape memory ceramic fibers are then at least partially de-poled utilizing a second electric field having a polarity that is substantially opposite a polarity of the first electric field to thereby cause the shape memory ceramic fibers to have a second strain state that is not equal to the first strain state.
Another aspect of the present invention is a method of controlling the shape of a structure that is capable of defining at least first and second shapes. The method includes providing a self-latching piezocomposite actuator comprising a plurality of aligned shape memory ceramic fibers defining first and second strained states. The self-latching piezocomposite actuator is operably connected to the structure. The strain state of the shape memory ceramic fibers is changed from the first strain state to a second strain state by applying a first electric field to the shape memory ceramic fibers such that the shape of the structure changes from the first shape to the second shape. The first electrical field is removed after the fibers are in the second strain state, and wherein the actuator continues to maintain the structure in the second shape after the first electrical field is removed. A second electrical field is then applied to the shape memory ceramic fibers to cause the shape memory ceramic fibers to change from the second strain state to a third strain state that is between the first and second strain states or equal to the first strain state. The structure defines a third shape corresponding to the third strain state that is between the first and second shapes or is the same as the first shape. The structure is maintained in the third shape after the second electrical field is removed whereby the shape memory ceramic fibers of the actuator are maintained in the third strain state.
Another aspect of the present invention is a method of controlling a self-latching piezocomposite actuator. The method includes providing a self-latching piezocomposite actuator comprising a plurality of aligned shape memory ceramic fibers defining first and second strain states and a plurality of intermediate strain states between the first and second strain states. The method includes determining a required intermediate strain state of the shape memory ceramic fibers corresponding to a required shape of a structure incorporating the actuator. The method further includes determining a present strain state of the shape memory ceramic fibers, and changing the strain state of the shape memory ceramic fibers from the present strain state to the required intermediate strain state by applying an electrical field to the shape memory ceramic fibers. The electrical field is removed after the fibers are in the required strain state, and the shape memory ceramic fibers remain in the required strain state.
These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an exploded isometric view of a self-latching piezocomposite actuator according to one aspect of the present invention;
FIG. 2 is an isometric view of a self-latching piezocomposite actuator according to another aspect of the present invention;
FIG. 3 is a graph showing field-induced strain curves for a shape memory ceramic material that switches from an antiferroelectric to a ferroelectric state;
FIG. 4 is partially schematic isometric view of active fiber composite plies that may be utilized in constructing an active structure accordingly to one aspect of the present invention;
FIG. 5 is a partially fragmentary isometric view of a portion of a helicopter rotor having active twist control according to another aspect of the present invention;
FIG. 6 is a partially schematic isometric view of a helicopter rotor having active blade twist control for vibration reduction according to another aspect of the present invention;
FIG. 7 is a graph showing voltage that can be applied to a self-latching piezocomposite actuator to control remnant strain by partial poling/de-poling of the shape memory material;
FIG. 8 is a graph showing longitudinal strain versus voltage;
FIG. 9 is a graph showing longitudinal transverse strain versus voltage;
FIG. 10 is a graph showing remnant strain versus hack voltage;
FIG. 11 is a graph showing strain versus electric field for a 8/65/35 PLZT shape memory material according to another aspect of the present invention;
FIG. 12 is a partially schematic end view of a wing having a variable camber according to another aspect of the present invention;
FIG. 13 is a partially schematic cross sectional view showing the root of the wing of FIG. 12 ;
FIG. 14 is a partially schematic cross sectional view showing the tip of the wing of FIG. 13 ;
FIG. 15 is a partially schematic cross sectional view of the wing of FIGS. 12-14 wherein the actuators are in an unlatched state;
FIG. 16 is a partially schematic cross sectional view of the wing of FIGS. 12-14 wherein the actuators are in a latched state to increase the camber of the wing;
FIG. 17 is a partially schematic plan view of an aircraft including self-latching actuators and aerodynamic surfaces that change shape upon actuation of the self latching piezocomposite actuator;
FIG. 18 is a side elevational view of the aircraft of FIG. 17 ; and
FIG. 19 is a partially schematic cross sectional view of an aircraft engine having self-latching piezocomposite actuators that change the shape of the inlet of the engine;
FIG. 20 is a perspective view of an active composite reflector including self-latching shape memory actuators according to another aspect of the present invention; and
FIG. 21 is a perspective view of a solid reflector having a plurality of self-latching piezocomposite actuators according to another aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
With reference to FIG. 1 , a self-latching piezocomposite actuator 10 according to one aspect of the present invention includes a first sheet 12 and second sheets 14 A and 14 B. The first sheet 12 comprises machined piezoceramic fibers 8 having rectangular cross sectional shapes, and the second sheets 14 A and 14 B comprise polyimide films 16 A and 16 B having interdigitated electrodes 18 A and 18 B. Structural epoxy matrix material 20 A and 20 B is disposed between the first sheet 12 and the second sheets 14 A and 14 B. Epoxy matrix material 20 C is also disposed between the piezoceramic fibers 8 of first sheet 12 . The actuator 10 may be fabricated utilizing the processes described in U.S. Pat. No. 6,629,341.
A piezocomposite actuator 10 A according to another aspect of the present invention includes a first sheet or layer 22 including a plurality of cylindrical piezoceramic fibers 28 , and second sheets 24 A and 24 R that comprise epoxy material 30 and electrodes 32 .
The fibers 8 ( FIG. 1 ) and fibers 28 ( FIG. 2 ) comprise a shape memory ceramic material. The shape memory ceramic material of fibers 8 and 28 changes shape when an electrical field is applied to the shape memory ceramic material, and the shape memory ceramic material remains in the changed shape even after the electrical field is no longer applied. A reverse electrical field can then be applied to return the shape memory ceramic to its initial state/shape. Fibers 8 and 28 may comprise a PZT 5H material defining a d33 mode along the fibers whereby the fibers increase in length when actuated. The electrical fields can be selectively applied utilizing the interdigitated electrodes 18 A and 18 B to cause the actuator 10 to curve or bend due to increasing strain on one side of fibers 8 while simultaneously decreasing strain of the material of fibers 8 along an opposite side of first sheet 12 . Alternatively, the overall lengths of the fibers 8 may be increased and decreased by inducing substantially uniform strain states on opposite sides of fibers 8 by controlling the electrical fields generated as a result of electrical current traveling through the electrodes 18 A and 18 B.
With further reference to FIG. 3 , a shape memory ceramic material such as a lead zirconate stannate based Pb0.99Nb0.02((ZrxSn1-x)1-yTiy)0.98O3 system exhibits shape memory characteristics. The material begins at an unlatched state 34 wherein no electrical power (electric field) is applied to the material. If an electric field is applied to the material, the state of the material travels from the unlatched state 34 to an unpoling state 36 as shown by the arrow “A.” When the electric field is removed, the state of the material changes from the unpoling state 36 to the power-off, latched state 38 as shown by the arrow “B.” Significantly, the strain of the material changes in magnitude as shown by the dimension “S,” and the material remains in the power-off latched strain state. If a reverse electric field is applied, the state of the material changes from the power-off latched state 38 to the re-poling reset state 40 as shown by the arrow “C.” When the reverse electric field is removed, the material changes from the re-poling reset state 40 back to the original unlatched state 34 as shown by the arrow “D,” thereby causing a change in the magnitude of the strain as shown by the dimension “S 2 .” The shape memory ceramic fibers 8 and/or 28 comprise various a shape memory ceramic materials having field-induced strain characteristics. It will be understood that FIG. 3 provides an example of a shape memory material, but the present invention is not limited to this specific material. As discussed in more detail below in connection with FIGS. 8-12 , the fibers 8 and 28 may also comprise other types of shape memory ceramic materials.
The actuators 10 and 10 A may be either partially or fully unlatched as required. Referring again to FIG. 3 , if the piezoelectric ceramic material is in a latched state 38 , and if a weaker (i.e. between 0 and 40 kV/cm) reverse electric field is applied, the material will not change all the way to the re-poling reset state 40 when the reverse electric field is removed, and the ceramic material will instead return to a strain state 34 A that is between the unlatched state 34 and the power-off latched state 38 . Also, when the material is at the power-off unlatched state, a weaker electric field (i.e. between −20 and 0 kV/cm) can be applied and removed to shift the material to a power-off latched state 38 A that is between the power-off latched state 38 and the power-off unlatched state 34 . Thus, by controlling the electric field applied to the fibers 8 of actuator 10 , the actuator 10 can take on different states between the unlatched state 34 and the latched state 38 as required for a particular operating condition or application.
Referring again to FIGS. 1 and 2 , the characteristics of the piezocomposite actuators 10 and 10 A may be selected as required for a particular application. As discussed above, the fibers 8 and/or 28 may be fabricated such that the d33 mode extends along the fibers, whereby the fibers decrease in length when changing from the power-off unlatched state 34 ( FIG. 3 ) to the power-off latched state 38 . Conversely, the fibers 8 and/or 28 may be fabricated with the d31 mode extending along the length of the fibers whereby the fibers increase in length when shifting from a power-off unlatched state to a power-off latched state. Accordingly, it will be understood that the strain states (e.g. FIG. 3 ) depend on the material selected, and the orientation of the mode of the fibers 8 and/or 28 .
With further reference to FIG. 4 , the actuators 10 and 10 A of FIGS. 1 and 2 , respectively, may be utilized to form active fiber composite plies 42 by incorporating the actuators into conventional fiber composite plies. With further reference to FIGS. 5 and 6 , a helicopter rotor blade 45 includes conventional fiber composite laminates 44 , and may include a core 48 comprising foam or other lightweight material. The fiber composite laminate 44 may comprise known materials such as carbon fibers and an epoxy matrix or other suitable materials. The active fiber plies 42 are disposed over at least a portion of the fiber composite laminate 44 . A flex circuit 50 extends between the upper side 52 of rotor blade 45 and lower side 54 of rotor blade 45 . An optional flex circuit 50 comprises piezoelectric material elements whereby the flex circuit 50 generates electricity as rotor blade 45 flexes. The electrical current from the flex circuit 50 may be applied to the actuator 10 of active fiber composite ply 42 to thereby latch and/or unlatch the actuator 10 to control the shape of the rotor blade 45 . It will be understood that the electrical power supplied to the active fiber composite plies 42 may come from a battery or other suitable electrical power source rather than flex circuit 50 .
With further reference to FIG. 6 , in use aerodynamic forces acting on rotor blade 45 generate a first moment “M 1 .” In FIG. 6 , the moment M 1 is shown as acting at end 56 of rotor blade 45 . However, it will be understood that the moment M 1 actually acts along the length of the blade 45 due to the aerodynamic forces acting on the rotor blade 45 . A counter acting moment “M 2 ” at base end 58 of rotor blade 45 results from moment M 1 . Actuators 10 (or 10 A) and/or active fiber composite plies 42 can be oriented such that actuation of the actuators 10 generates threes within active fiber composite plies 42 tending to counteract the twist resulting from the applied moments M 1 and M 2 . Furthermore, the shape of rotor blade 45 can be varied utilizing actuators 10 to provide a desired rotor shape in use that optimizes lift, reduces noise, and/or provides other results as required for a particular application.
The magnitude of the moments M 1 and M 2 may be related to helicopter operating conditions. For example, when the rotor blade 45 experiences a relatively large aerodynamic force, the moments M 1 and M 2 may tend to be larger. The amount of electric current and resulting electric field that is applied to the actuator 10 can be varied as required to compensate for the variation in the applied moment M 1 . For example, a plurality of strain sensors 60 may be imbedded in the fiber composite laminate 44 and/or the active fiber 42 on the upper side 52 and/or lower side 54 of rotor blade 45 . The strain data from strain sensors 60 may be utilized by a controller (not shown) to determine the magnitude of an electrical field to be applied to the actuator 10 . Referring again to FIG. 3 , in the illustrated example, if an electric field of less than −20 kV/cm is applied to the fibers, the magnitude of the change in strain will be less than “S.” Thus, a variable electric field can be applied to the actuators 10 of rotor 45 ( FIGS. 4-6 ) to thereby control the twist of the rotor 45 as required for a particular operating condition.
With further reference to FIG. 7 , positive and negative voltages can be applied to the shape memory ceramic fibers 8 . FIGS. 8-10 show the strain versus voltage characteristics of a PZT-5H shape memory ceramic material resulting from the voltages of FIG. 7 . Specifically, application of the voltages of FIG. 7 results in longitudinal strain as shown in FIG. 8 , and transverse strain as shown in FIG. 9 . As shown in FIG. 10 , weaker back field voltages (i.e. weaker negative voltages in FIG. 7 ) cause partial depoling which reduces remnant strain. However, as the back (negative) voltage is increased, the material re-poles and remnant strain increases as also shown in FIG. 10 .
With further reference to FIG. 11 , a 8/65/35 PLZT material also exhibits self-latching characteristics. It will be understood that various shape memory ceramic materials may be utilized to form a self-latching piezocomposite actuator 10 according to the present invention.
With further reference to FIGS. 12-16 , an aircraft wing 62 defines a tip profile 64 ( FIG. 14 ) and a root profile 66 ( FIG. 13 ). Wing 62 also includes an internal spar structure 68 , an upper layer or sheet of material 70 , and a lower layer or sheet of material 72 . The layers/sheets 70 and 72 extend over the spar structure 68 from a leading edge “LE” of wing 62 to a trailing edge “TE” of wing 62 . The spar structure 68 is substantially rigid and defines a region having a fixed boundary “FB 1 ” The upper and lower layers/sheets 70 and 72 , respectively, are connected to the spar structure 68 in the fixed boundary region FB 1 such that the sheets 70 and 72 do not change shape in the fixed boundary region FB 1 . An internal space 74 is defined between the upper and lower sheets 70 and 72 in a free boundary region “FB 2 ” of wing 62 . The internal space 74 may be substantially empty, or it may comprise a flexible and/or compressible lightweight filler material. The layers/sheets 70 and 72 are at least somewhat flexible and capable of changing shape in the free boundary region FB 2 of wing 62 .
A plurality of self-latching piezocomposite actuators 10 are disposed on or incorporated into, the upper and lower layers/sheets 70 and/or 72 in the free boundary region FB 2 of wing 62 . It will be understood that the thickness of the actuators 10 is exaggerated in FIGS. 13-16 for purposes of showing the location of the actuators 10 . Sheets 70 and/or 72 may comprise carbon fiber/epoxy matrix material, and the actuators 10 may adhesively attached to inner or outer surfaces of the layers/sheets 70 , 72 , or the actuators 10 may be embedded in the composite material. If the layers/sheets 70 , 72 comprise metal, the actuators 10 may be adhesively bonded to the inner or outer surfaces of the layers/sheets 70 , 72 .
A shape-changing/morphing flexible region 76 is defined between lines “L 1 ” and “L 2 .” Actuators 10 may be configured to span across the region. 76 such that first ends 78 of actuators 10 are positioned in front of the line L 1 , and second ends 80 of actuators 10 are positioned to the rear of the line L 2 . In use, the actuators 10 on the upper and/or lower sides of wing 62 can be actuated to thereby vary the camber of the wing 62 in the free boundary region FB 2 to change the lift generated by the wing 62 as required for a particular operating condition. For example, lower sheet 72 may flex from the shape of FIG. 15 to the shape of FIG. 16 to provide increased concave curvature 76 A ( FIG. 16 ), and the upper sheet 70 may flex to provide increased convex curvature 76 B ( FIG. 16 ). By increasing the camber, the lift of the wing can be increased for takeoff and landing, and to provide increased lift if the aircraft is carrying a heavy cargo and/or has a relatively low airspeed. Conversely, the camber can be decreased to reduce lift and drag if the aircraft loading and/or flight conditions do not require increased lift.
The actuators 10 may be actuated simultaneously or separately as required to provide a desired camber to optimize the lift of the wing 62 for a given flight condition/lift requirement. As discussed above, actuators 10 may be configured to shift from a flat (unlatched) configuration to a curved (latched) configuration. Actuators 10 on (or in) lower sheet 72 may be actuated to form a concave outer surface contour at the same time the actuators 10 on (or in) upper sheet 72 are actuated to provide increased convex curvature. By selectively actuating the actuators 10 to varying degrees (e.g. corresponding to strain states at or between unlatched state 34 and power-off latch state 38 of FIG. 3 ) various camber and resulting lift/drag characteristics can be provided.
Self-latching actuators 10 according to the present invention may be utilized in other types of active/morphing wing structures in addition to the active/variable camber wing 62 of FIGS. 13-15 . For example, the self-latching actuators of the present invention may be utilized to provide an active leading wing edge that changes shape to prevent stalling when the wing is at a high angle of attack during takeoff and/or landing operations. Self-latching actuators may also be utilized to change the shape of the wing from a conventional airfoil to a supercritical airfoil to reduce the formation of shock waves at the surface of the wing during transonic flight conditions.
With further reference to FIGS. 17 and 18 , an aircraft 100 may include wings 62 having variable camber and/or other morphing features as discussed above in connection with FIGS. 12-16 . Horizontal stabilizers 62 A of aircraft 100 may include elevators or other control surfaces that are controlled utilizing one or more self/latching piezocomposite actuators 10 according to the present invention. Similarly, aircraft 100 may include a vertical stabilizer 62 B having a rudder 84 that can be controlled utilizing actuators 10 on opposite sides of the rudder 84 . Self-latching actuators 10 may be utilized in connection with flexible aerodynamic surfaces to provide integrated elevators and/or flaps to thereby eliminate the gaps between the flaps and the primary wine structures that are formed by conventional control surfaces such as flaps.
Aircraft 100 may also include one or more turbo fan or turbo jet engines 86 that provide thrust. With further reference to FIG. 19 , engine 86 includes an inlet 88 that is defined by a forward portion 90 of engine nacelle structure 92 . Actuators 10 may be incorporated into engine structure 92 adjacent forward portion 90 to thereby change the shape of forward portion 90 to increase or decrease the size and shape of inlet 88 . For example, actuators 10 may be actuated to shift the forward portion 90 inwardly as shown by the dashed line 90 A, or outwardly as shown by the dashed line 90 B. It will be understood that the dashed lines 90 A and 90 B represent exaggerated movement/shape change for purposes of illustrating changes to the size and/or shape of the inlet 88 .
With further reference to FIG. 20 , a composite reflector 94 according to another aspect of the present invention includes a curved primary structure 96 that is fabricated from carbon fiber or other composite materials. A front reflective/mirror surface 98 of primary structure 96 is concave to provide predefined optical reflective properties (e.g. magnification). The reflector 94 may be utilized for space-based optical systems. For example, the composite reflector 94 may be utilized in a spacecraft 95 as a component of a telescope.
The composite reflector 94 includes a plurality of self-latching piezocomposite actuators 10 that are disposed on a rear surface 102 of primary structure 96 . Actuators 10 may be adhesively bonded to rear surface 102 , or they may be integrally formed with the composite materials of the primary structure 96 . In the illustrated example, actuators 10 extend between junctions 104 to form a hexagonal pattern. However, the actuators 10 may be oriented in any suitable configuration. The actuators 10 may be operably connected to a power source and a controller (not shown) whereby the shape of the front surface 98 is changed/controlled by the actuators 10 . The actuators 10 thereby compensate for distortions in front surface 98 due to thermal effects, stress, or other environmental influences. The actuators 10 may also be utilized to compensate for imperfections in front surface 98 that may occur as a result of the fabrication process utilized to form main structure 96 .
With further reference to FIG. 21 an optical reflector 105 according to another aspect of the present invention comprises a main body 106 that is generally disc-shaped, and forms a reflective front surface 108 . The body 106 may comprise glass, ceramic, or other material, and the reflective front surface 108 may be coated with a reflective metal material or the like to form an optical mirror. A plurality of self-latching piezocomposite actuators 10 are disposed on rear surface 110 of body 106 . Actuators 10 may be operably connected to an electrical power source (not shown) by wires or other suitable conductors not shown), and a controller (not shown) may be utilized to control the electrical power supplied to the actuators 10 . One or more of the actuators 10 may be actuated to generate a force acting on the body 106 to thereby change the shape of reflective front surface 108 . In this way, distortions in the front surface 108 due to thermal effects, applied loads, or other environmental factors can be actively corrected utilizing the actuators 10 .
The reflector 94 and reflector 105 of FIGS. 20 and 21 , respectively, may be controlled utilizing open loop or closed loop control systems. For example, sensors may be utilized to measure the shape of the reflective surfaces, and the actuators 10 may be selectively actuated to compensate for the measured distortions in the reflective surfaces. Alternatively, empirical data and/or analytical calculations may be utilized to predict the shapes of the reflective surfaces under various thermal and other environmental conditions. The temperature can then be measured or estimated, and the actuators 10 can be actuated as required to compensate for the estimated distortions in the reflective surfaces.
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A self-latching piezocomposite actuator includes a plurality of shape memory ceramic fibers. The actuator can be latched by applying an electrical field to the shape memory ceramic fibers. The actuator remains in a latched state/shape after the electrical field is no longer present. A reverse polarity electric field may be applied to reset the actuator to its unlatched state/shape. Applied electric fields may be utilized to provide a plurality of latch states between the latched and unlatched states of the actuator. The self-latching piezocomposite actuator can be used for active/adaptive airfoils having variable camber, trim tabs, active/deformable engine inlets, adaptive or adjustable vortex generators, active optical components such as mirrors that change shapes, and other morphing structures.
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[0001] This application claims priority from copending provisional application Serial No. 60/283,262, filed Apr. 12, 2001, the entire disclosure of which is hereby incorportated by reference.
[0002] This invention concerns novel tricyclic pyridyl carboxamides which act as oxytocin receptor antagonists, as well as methods of their manufacture, methods of treatment and pharmaceutical compositions utilizing these compounds. The compounds of the present invention are useful therapeutic agents in mammals, particularly in humans. More specifically, they can be used in the prevention and/or suppression of preterm labor, for the suppression of labor at term prior to caesarean delivery, to facilitate antinatal transport to a medical facility, and for the treatment of dysmenorrhea. These compounds also useful in enhancing fertility rates, enhancing survival rates and synchronizing estrus in farm animals; and may be useful in the prevention and treatment of disfunctions of the oxytocin system in the central nervous system including obsessive compulsive disorder (OCD) and neuropsychiatric disorders.
BACKGROUND OF THE INVENTION
[0003] Premature labor remains the leading cause of perinatal mortality and morbidity. Infant mortality dramatically decreases with increased gestational age. The survival rate of prematurely born infants increases from 20% at 24 weeks to 94% at 30 weeks. Moreover the cost associated with the care of an infant born prematurely is very high. While many agents have been developed for the treatment of premature labor in the last 40 years, the incidence of pre-term births and low birth weight infants has remained relatively unchanged. Therefore there remains an unmet need for the development of a safe and effective treatment of preterm labor.
[0004] Tocolytic (uterine relaxing) agents currently in use include β 2 adrenergic receptor agonists such as Ritodrine which is moderately effective in suppressing preterm labor, but it is associated with maternal hypotension, tachycardia, and metabolic side effects. Several other agents have been used to suppress premature labor, including other β 2 adrenergic agonists (terbutaline, albuterol), magnesium sulfate, NSAIDs (indomethacin), and calcium channel blockers. The consensus is that none of these agents is very effective; there is no clinical evidence showing that these compounds can prolong gestation for more than 7 days (Johnson, Drugs, 45, 684-692 (1993)). Furthermore, their safety profile is not ideal. Adverse effects include respiratory depression and cardiac arrest (magnesium sulfate), hemodynamic effects (calcium channel blockers), premature closure of the ductus arteriosus and oligohydramnios (NSAIDS; prostaglandin synthase inhibitors). Therefore there is an unmet need for safer and more efficacious agents for the treatment of preterm labor with better patient tolerability. Specific requirements with regard to safety include a product with no or low rates of tachycardia, limited anxiety, improved fetal safety, and few, if any, adverse cardiovascular effects.
[0005] One target of interest is the oxytocin receptor in the uterus, and a selective oxytocin receptor antagonist has been proposed as an ideal tocolytic agent. While the exact role of oxytocin (OT) in parturition has not been clearly defined, there is evidence strongly suggesting that it may play a critical role in the initiation and progression of labor in humans (Fuchs et al. Science 215, 1396-1398 (1982); Maggi et al. J. Clin. Endocrinol. Metab. 70, 1142-1154 (1990); Åkerlund, Reg. Pept 45,187-191 (1993); Åkerlund, Int. Congr. Symp. Semin. Ser., Progress in Endocrinology 3, 657-660 (1993); Åkerlund et al., in Oxytocin, Ed. R. Ivell and J. Russel, Plenum Press, New York, pp 595-600 (1995)). Preliminary clinical trials with oxytocin receptor antagonists support the concept that a blockade of OT receptors reduces uterine myometrial activity and delays the onset of labor (Åkerlund et al., Br. J. Obst. Gynaecol. 94, 1040-1044, (1987); Andersen et al., Am. J. Perinatol. 6, 196-199 (1989); Melin, Reg. Pept. 45, 285-288 (1993)). Thus, a selective oxytocin antagonist is expected to block the major effects of oxytocin exerted mainly on the uterus at term, and to be more efficacious than current therapies for the treatment of preterm labor. By virtue of its direct action on the receptors in the uterus an oxytocin antagonist is also expected to have fewer side effects and an improved safety profile.
[0006] The following references describe peptidic oxytocin antagonists: Hruby et al., Structure-Activity Relationships of Neurohypophyseal Peptides, in The Peptides: Analysis, Synthesis and Biology; Udenfriend and Meienhofer Eds., Academic Press, New York, Vol. 8, 77-207 (1987); Pettibone et al., Endocrinology, 125, 217 (1989); Manning et al., Synthesis and Some Uses of Receptor-Specific Agonists and Antagonists of Vasopressin and Oxytocin, J. Recept. Res., 13, 195-214 (1993); Goodwin et al., Dose Ranging Study of the Oxytocin Antagonist Atosiban in the Treatment of Preterm Labor, Obstet. Gynecol., 88, 331-336 (1996). Peptidic oxytocin antagonists suffer from a lack of oral activity and many of these peptides are non-selective antagonists since they also exhibit vasopressin antagonist activity. Bock et al. [ J. Med. Chem. 33, 2321 (1990)], Pettibone et al. [ J. Pharm. Exp. Ther. 256, 304 (1991)], and Williams et al. [ J. Med. Chem., 35, 3905 (1992)] have reported on potent hexapeptide oxytocin antagonists which also exhibit weak vasopressin antagonistic activity in binding to V 1 and V 2 receptors.
[0007] Various non-peptidic oxytocin antagonists and/or oxytocin/vasopressin (AVP) antagonists have recently been reported by Pettibone et al., Endocrinology, 125, 217 (1989); Yamamura et al., Science, 252, 572-574 (1991); Evans et al., J. Med. Chem., 35, 3919-3927 (1992); Pettibone et al., J. Pharmacol. Exp. Ther, 264, 308-314 (1992); Ohnishi et al., J. Clin. Pharmacol. 33, 230-238, (1993); Evans et al., J. Med. Chem. 36, 3993-4006 (1993); Pettibone et al., Drug Dev. Res. 30, 129-142 (1993); Freidinger et al., General Strategies in Peptidomimetic Design: Applications to Oxytocin Antagonists, in Perspect. Med. Chem. 179-193 (1993), Ed. B. Testa, Verlag, Basel, Switzerland; Serradeil-LeGal, J. Clin. Invest., 92, 224-231 (1993); Williams et al., J. Med. Chem. 37, 565-571 (1994); Williams et al., Bioorg. Med. Chem. 2, 971-985 (1994); Yamamura et al., Br. J. Pharmacol., 105, 546-551 (1995); Pettibone et al., Advances in Experimental Medicine and Biology 395, 601-612 (1995); Williams et al., J. Med. Chem. 38, 4634-4636 (1995); Hobbs et al., Biorg. Med. Chem. Lett. 5, 119 (1995); Williams et al., Curr. Pharm. Des. 2, 41-58 (1996); Freidinger et al., Medicinal Research Reviews, 17, 1-16 (1997); Pettibone et al., Biochem. Soc. Trans. 25 (3), 1051-1057 (1997); Bell et al., J. Med. Chem. 41, 2146-2163 (1998); Kuo et al., Bioorg. Med. Chem. Lett. 8, 3081-3086 (1998); Williams et al., Biorg. Med. Chem. Lett. 9, 1311-1316 (1999).
[0008] Certain carbostyril derivatives and bicyclic azepines are disclosed as oxytocin and vasopressin antagonists by Ogawa et al. in WO 94/01113 (1994); benzoxazinones are disclosed as oxytocin and vasopressin receptor antagonists by Sparks et al. in WO 97/25992 (1997); Williams et al. disclose piperidine oxytocin and vasopressin receptor antagonists in WO 96/22775 (1996); Bock et al. disclose benzoxazinone and benzopyrimidinone piperidines useful as oxytocin and vasopressin receptor antagonists in U.S. Pat. No. 5,665,719 (1997); piperazines and spiropiperidines useful as oxytocin and vasopressin receptor antagonists are disclosed by Evans et al. in U.S. Pat. No. 5,670,509 (1997) and by Bock et al. in U.S. Pat. No. 5,756,504 (1998); Bell et al. disclose piperazine oxytocin receptor antagonists in UK Patent Application, GB 2 326 639 A (1998); Bell et al. disclose benzoxazinone and quinolinone oxytocin and vasopressin receptor antagonists in UK Patent Application GB 2 326 410 A (1998); Bell et al. disclose benzoxazinone oxytocin and vasopressin receptor antagonists in U.S. Pat. No. 5,756,497 (1998); Matsuhisa et al. disclose difluoro tetrahydrobenzazepine derivatives as oxytocin antagonists in WO 98/39325 (1998); Ogawa et al. disclose heterocyclic bisamides with vasopressin and oxytocin antagonist activity in U.S. Pat. No. 5,753,644 (1998); and Ogawa et al. disclose benzazepine derivatives with anti-vasopressin activity, oxytocin antagonistic activity and vasopressin agonist activity, useful as vasopressin antagonists, vasopressin agonists and oxytocin antagonists in WO 97/22591 (1997) and U.S. Pat. No. 6,096,736 (2000).
[0009] Trybulski et al. disclose 3-carboxamide derivatives of pyrrolobenzodiazepine bisamides with vasopressin antagonist activity in U.S. Pat. No. 5,880,122 (1999); bicyclic thienoazepines with vasopressin and oxytocin receptor antagonist activity are disclosed by Albright et al. in WO 96/22294 (1996) and U.S. Pat. No. 5,654,297 (1997); and tricyclic benzazepines with vasopressin and oxytocin receptor antagonist activity are disclosed by Albright et al. in WO 96/22282 (1996) and U.S. Pat. No. 5,849,735 (1998).
[0010] Albright et al. broadly disclose tricyclic benzazepine compounds which possess antagonistic activity at the V 1 and/or V 2 receptors and exhibit in vivo vasopressin antagonistic activity, as well as antagonistic activity at the oxytocin receptors.
[0011] Venkatesan et al. broadly disclose tricyclic benzazepines with vasopressin and oxytocin antagonist activity in U.S. Pat. No. 5,521,173 (1996), WO 96/22292 (1996), and in U.S. Pat. No. 5,780,471 (1998).
[0012] Oxytocin antagonists can be useful for the treatment and/or prevention and/or suppression of preterm labor, for the suppression of term labor prior to a caesarian delivery, and to facilitate antinatal transport to a medical facility. They also can produce contraception in mammals given that oxytocin antagonists have been shown to inhibit the release of oxytocin-stimulated luteneizing hormone (LH) from pituitary cells (Rettori et al., Proc. Nat. Acad. Sci. U.S.A. 94, 2741-2744 (1997); Evans et al., J. Endocrinol., 122, 107-116 (1989); Robinson et al., J. Endocrinol. 125, 425-432 (1990)).
[0013] Oxytocin antagonists also have the ability to relax uterine contractions induced by oxytocin in mammals and thus can be also useful for the treatment of dysmenorrhea, a condition characterized by pain during menstruation (Åkerlund, Int. Congr. Symp. Semin. Ser., Progress in Endocrinology 3, 657-660 (1993); Åkerlund, Reg. Pept. 45, 187-191 (1993); Melin, Reg. Pept. 45, 285-288 (1993)). Primary dysmenorrhea is associated with ovulatory cycles, and it is the most common complaint of gynecologic patients. Myometrial hypercontractility and decreased blood flow to the uterus are thought to be causative factors for the symptoms of primary dysmenorrhea (Åkerlund, Acta Obstet. Gynecol. Scand. 66, 459-461 (1987). In particular, vasoconstriction of small uterine arteries by vasopressin and oxytocin is thought to produce tissue ischemia and pain (Jovanovic et al., Br. J. Pharmacol. 12, 1468-1474 (91997); Chen et al., Eur. J. Pharmacol. 376, 25-51 (1999)).
[0014] The administration of oxytocin receptor antagonists to farm animals after fertilization has been found to enhance fertility rates by blocking oxytocin induced luteolysis leading to embryonic loss (Hickey et al., WO 96/09824 A1 (1996), Sparks et al., WO 97/25992 A1 (1997); Sparks et al., U.S. Pat. No. 5,726,172 A (1998)). Thus, oxytocin receptor antagonists can be useful in farm animal husbandry to control timing of parturition and delivery of newborns resulting in enhanced survival rates. They can also be useful for the synchronization of estrus by preventing oxytocin induced corpus luteum re.g.ression and by delaying estrus (Okano, J. Reprod. Dev. 42 (Suppl.), 67-70 (1996)). Furthermore oxytocin receptor antagonists have been found to have a powerful effect in inhibiting oxytocin-induced milk ejection in dairy cows (Wellnitz et al., Journal of Dairy Research 66, 1-8 (1999)).
[0015] Oxytocin is also synthesized in the brain and released in the central nervous system. Recent studies have established the importance of central oxytocin in cognitive, affiliative, sexual and reproductive behavior, and in regulating feeding, grooming and response to stress in animals. Oxytocin may also influence normal behavior in humans. Modulators of oxytocin binding to its receptors in the central nervous system may be useful in the prevention and treatment of disfunctions of the oxytocin system, including obsessive compulsive disorder (OCD) and other neuropsychiatric disorders (Kovacs et al., Psychoneuroendocrinology 23, 945-962 (1998); McCarthy et al., U.K. Mol. Med. Today 3, 269-275 (1997); Bohus, Peptidergic Neuron, [Int Symp. Neurosecretion], 12 th (1996), 267-277, Publ. Birkhauser, Basel, Switz.; Leckman et al., Psychoneuroendocrinology 19, 723-749 (1994)).
[0016] Compounds which act as competitive inhibitors against vasopressin binding to its receptors are useful in the treatment or prevention of state diseases involving vasopressin disorders in mammals, which include vasodilation and aquaresis (free-water diuresis), treating hypertension and inhibiting platelet aggregation. They are useful in the treatment of congestive heart failure, cirrhosis with ascites, and in the syndrome of inappropriate secretion of antidiuretic hormone (SIADH). Furthermore, vasopressin receptor antagonists have been found to be useful in treating disturbances or illnesses of the inner ear, particularly those related to Meniere's disease (Zenner et al., WO 99/24051-A2 (1999)); and for the prevention and treatment of ocular circulatory disorders, particularly intraocular hypertension or glaucoma and vision disorders such as shortsightedness (Ogawa et al., WO 99/38533-A1 (1999)).
SUMMARY OF THE INVENTION
[0017] This invention relates to novel compounds selected from those of Formula (I):
[0018] wherein:
[0019] R 1 and R 2 are, independently, selected from hydrogen, (C 1 -C 6 )lower alkyl, halogen, cyano, trifluoromethyl, hydroxy, amino, (C 1 -C 6 ) lower alkylamino, (C 1 -C 6 ) lower alkoxy, —OCF 3 , (C 1 -C 6 ) lower alkoxy carbonyl, —NHCO[(C 1 -C 6 )lower alkyl], carboxy, —CONH 2 , —CONH[(C 1 -C 6 ) lower alkyl], or —CON[(C 1 -C 6 ) lower alkyl] 2 ;
[0020] R 3 is a substituent selected from hydrogen, (C 1 -C 6 ) lower alkyl, (C 1 -C 6 ) lower alkoxy, hydroxy, amino, (C 1 -C 6 ) lower alkylamino, CO lower alkyl (C 1 -C 6 ), or halogen;
[0021] R 4 is the moiety B-C; wherein:
[0022] B is selected from the group of:
[0023] and C is selected from the group of:
[0024] wherein:
[0025] A is CH or N;
[0026] R 5 , R 6 , R 7 , R 8 , R 9 , R 10 are, independently, selected from hydrogen, (C 1 -C 6 ) lower alkyl, (C 1 -C 6 ) lower alkoxy, (C 1 -C 6 ) lower alkylcarbonyl, (C 3 -C 6 ) lower alkenyl, (C 3 -C 6 ) lower alkynyl, (C 3 -C 8 ) cycloalkyl, formyl, cycloalkylcarbonyl, carboxy, alkoxycarbonyl, cycloalkyloxycarbonyl, aryl alkyloxycarbonyl, carbamoyl, —O—CH 2 —CH═CH 2 , halogen, halo lower alkyl, trifluoromethyl, OCF 3 , S(lower alkyl), —OC(O)N[lower alkyl] 2 , —CONH[lower alkyl], —CON[lower alkyl] 2 , lower alkylamino, di-lower alkylamino, lower alkyl di-lower alkylamino, hydroxy, cyano, trifluoromethylthio, nitro, amino, lower alkylsulfonyl, aminosulfonyl, lower alkylaminosulfonyl,
[0027] phenyl or naphthyl;
[0028] R 11 and R 12 are, independently, selected from the group of hydrogen, (C 1 -C 6 ) lower alkyl, (C 1 -C 6 ) lower alkenyl, (C 3 -C 6 ) lower alkynyl, hydroxy (C 1 -C 6 ) lower alkyl, alkoxy (C 1 -C 6 ) lower alkyl, acyloxy (C 1 -C 6 ) lower alkyl, cyclo lower alkyl, or aryl, optionally substituted by hydroxy, (C 1 -C 6 ) lower alkoxy, halogen, cyano, —SO 2 [(C 1 -C 6 ) lower alkyl, or —S[(C 1 -C 6 ) lower alkyl];
[0029] and R is selected from any of the following groups:
[0030] wherein:
[0031] R 13 is selected from hydrogen, (C 1 -C 6 ) lower alkyl, cyanoethyl or
[0032] R 14 is selected from hydrogen or (C 1 -C 6 ) lower alkyl;
[0033] R 15 is one or two substituents selected from the group of hydrogen, (C 1 -C 6 ) lower alkyl, halogen, trifluoromethyl, (C 1 -C 6 ) lower alkoxy, (C 1 -C 6 ) lower alkoxycarbonyl, or
[0034] R 16 represents one to two substituents selected from hydrogen, or (C 1 -C 6 ) lower alkyl;
[0035] m is an integer from 0 to 2;
[0036] n is an integer from 1 to 2;
[0037] and p is an integer from 0 to 1;
[0038] and the pharmaceutically acceptable salts, or pro-drug forms thereof.
[0039] Among the more preferred compounds of this invention are those of the formula:
[0040] wherein:
[0041] R 1 and R 2 are, independently, selected from hydrogen, (C 1 -C 6 )lower alkyl, halogen, cyano, trifluoromethyl, hydroxy, amino, (C 1 -C 6 ) lower alkylamino, (C 1 -C 6 ) lower alkoxy, —OCF 3 , (C 1 -C 6 ) lower alkoxycarbonyl, —NHCO[(C 1 -C 6 )lower alkyl], carboxy, —CONH 2 , —CONH (C 1 -C 6 ) lower alkyl, or —CON[(C 1 -C 6 ) lower alkyl] 2 ;
[0042] R 3 is a substituent selected from hydrogen, (C 1 -C 6 ) lower alkyl, (C 1 -C 6 ) lower alkoxy, hydroxy, amino, (C 1 -C 6 ) lower alkylamino, —CO lower alkyl (C 1 -C 6 ), or halogen;
[0043] R 4 is the moiety B-C; wherein:
[0044] B is selected from the group of:
[0045] and C is selected from the group of:
[0046] R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are independently, selected from H, (C 1 -C 6 ) lower alkyl, (C 1 -C 6 ) lower alkoxy, hydroxy (C 1 -C 6 ) lower alkyl, alkoxy (C 1 -C 6 ) lower alkyl, acyloxy (C 1 -C 6 ) lower alkyl, (C 1 -C 6 ) lower alkylcarbonyl, (C 3 -C 6 ) lower alkenyl, (C 3 -C 6 ) lower alkynyl, (C 3 -C 8 ) cycloalkyl, formyl, cycloalkylcarbonyl, carboxy, alkoxycarbonyl, cycloalkyloxycarbonyl, carbamoyl, —O—CH 2 —CH═CH 2 , halogen, halo lower alkyl, trifluoromethyl, —OCF 3 , —S(lower alkyl), —OC(O)N[lower alkyl] 2 , —CONH(lower alkyl), —CON[lower alkyl] 2 , lower alkylamino, di-lower alkylamino, lower alkyl di-lower alkylamino, hydroxy, cyano, trifluoromethylthio, nitro, amino, lower alkylsulfonyl, aminosulfonyl, or lower alkylaminosulfonyl;
[0047] R 11 and R 12 are, independently, selected from the group of hydrogen, (C 1 -C 6 ) lower alkyl, (C 1 -C 6 ) lower alkenyl, (C 3 -C 6 ) lower alkynyl, hydroxy (C 1 -C 6 ) lower alkyl, alkoxy (C 1 -C 6 ) lower alkyl, acyloxy (C 1 -C 6 ) lower alkyl, cyclo lower alkyl, or aryl, optionally substituted by hydroxy, (C 1 -C 6 ) lower alkoxy, halogen, cyano;
[0048] R is selected from any of the following groups:
[0049] wherein:
[0050] R 13 is selected from the group of hydrogen, (C 1 -C 6 ) lower alkyl, or cyanoethyl;
[0051] R 14 is selected from hydrogen or (C 1 -C 6 ) lower alkyl;
[0052] R 15 is one or two substituents selected, independently, from the group of hydrogen, (C 1 -C 6 ) lower alkyl, halogen, trifluoromethyl, (C 1 -C 6 ) lower alkoxy, (C 1 -C 6 ) lower alkoxycarbonyl;
[0053] R 16 and R 16′ are selected independently from H, or (C 1 -C 6 ) lower alkyl;
[0054] m is an integer from 0 to 2;
[0055] n is an integer from 1 to 2;
[0056] and p is an integer from 0 to 1;
[0057] or a pharmaceutically acceptable salt or pro-drug form thereof.
[0058] As used herein the term “lower” in relation to alkoxy or alkyl is understood to refer to those groups having from 1 to 6 carbon atoms. Halogen refers to fluorine, chlorine, bromine or iodine.
[0059] It is understood by those practicing the art that some of the compounds of this invention depending on the definition of R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , and R 12 may contain one or more asymmetric centers and may thus give rise to enantiomers and diastereomers. The present invention includes all stereoisomers including individual diastereomers and resolved, enantiomerically pure R and S stereoisomers, as well as racemates, and all other mixtures of the R and S stereoisomers and pharmaceutically acceptable salts thereof, which possess the indicated activity. Optical isomers may be obtained in pure form by standard procedures known to those skilled in the art. It is also understood that this invention encompasses all possible regioisomers, E-Z isomers, endo-exo isomers, and mixtures thereof which possess the indicated activity. Such isomers may be obtained in pure form by standard separation procedures known to those skilled in the art. It is understood also by those practicing the art that some of the compounds of this invention depending on the definition of R 4 , R 5 , R 6 , R 8 , R 9 , R 10 , R 11 and R 12 may be chiral due to hindered rotation, and give rise to atropisomers which can be resolved and obtained in pure form by standard procedures known to those skilled in the art. Also included in the present invention are all polymorphs and hydrates of the compounds of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0060] The present invention comprises the compounds described above, as well as pharmaceutical compositions containing the compounds of this invention in combination or association with one or more pharmaceutically acceptable carrier or excipient. In particular, the present invention provides a pharmaceutical composition which comprises a therapeutically effective amount of one or more compounds of this invention in a pharmaceutically acceptable carrier or excipient.
[0061] This invention also comprises methods for treating conditions in a mammal, preferably a human, which are remedied or alleviated by oxytocin antagonist activity including, but not limited to, treatment or prevention of preterm labor, dysmenorrhea and suppressing labor prior to caesarian delivery whenever desirable in a mammal, preferably in a human. The methods comprise administering to a mammal in need thereof a therapeutically effective but non-toxic amount of one or more of the compounds of this invention.
[0062] The present invention also comprises combinations of the compounds of the present invention with one or more agents useful in the treatment of disorders such as preterm labor, dysmenorrhea, and stopping labor prior to caesarian delivery. More specifically, the compounds of the present invention may be effectively administered in combination with effective amounts of other tocolytic agents used in the treatment or prevention of preterm labor, dysmenorrhea or suppressing labor prior to caesarean delivery including β-adrenergic agonists, calcium channel blockers, prostaglandin synthesis inhibitors, other oxytocin antagonists (e.g. atosiban), magnesium sulfate, ethanol, and other agents useful in the treatment of said disorders. The present invention is to be understood as embracing all simultaneous or alternating treatments of any combination of the compounds of the present invention with other tocolytic agents with any pharmaceutical composition useful for the treatment of preterm labor, dysmenorrhea, and suppressing labor prior to caesarean delivery in mammals.
[0063] The compositions are preferably adapted for intravenous (both bolus and infusion) and oral administration. However, they may be adapted for other modes of administration including subcutaneous, intraperitoneal, or intramuscular administration to a human or a farm animal in need of a tocolytic agent.
[0064] The compounds of the present invention can be used in the form of salts derived from non toxic pharmaceutically acceptable acids or bases. These salts include, but are not limited to, the following: salts with inorganic acids such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid and, as the case may be, such organic acids as acetic acid, oxalic acid, citric acid, tartaric acid, succinic acid, maleic acid, benzoic acid, benzene sulfonic acid, fumaric acid, malic acid, methane sulfonic acid, pamoic acid, and para-toluene sulfonic acid . Other salts include salts with alkali metals or alkaline earth metals, such as sodium, potassium, calcium or magnesium, or with organic bases including quaternary ammonium salts. The compounds can also be used in the form of esters, carbamates and other conventional prodrug forms, which in general, will be functional derivatives of the compounds of this invention which are readily converted to the active moiety in vivo. This is meant to include the treatment of the various conditions described hereinbefore with a compound of this invention or with a compound which is not specifically disclosed but which converts to a compound of this invention in vivo upon administration. Also included are metabolites of the compounds of the present invention defined as active species produced upon introduction of these compounds into a biological system.
[0065] When the compounds of this invention are employed for the above utilities, they may be combined with one or more pharmaceutically acceptable excipients or carriers, for example, solvents, diluents and the like, and may be administered orally in such forms as tablets, capsules (including time release and sustained release formulations), pills, dispersible powders, granules, or suspensions containing, for example, from 0.05 to 5% of suspending agent, syrups containing, for example, from about 10 to 50% of sugar, and elixirs and the like, or parenterally in the form of sterile injectable solutions, suspensions or emulsions containing from about 0.05 to 5% suspending agent in an isotonic medium. Such pharmaceutical preparations may contain, for example, from about 25 to about 90% of the active ingredient in combination with the carrier, more usually between about 5% and 60% by weight.
[0066] The effective dosage of active ingredients employed may vary depending on the particular compound or salt employed, the mode of administration, age, weight, sex and medical condition of the patient, and the severity of the condition being treated. An ordinarily skilled physician, veterinarian or clinician can readily determine and prescribe the effective amount of the agent required to prevent, counter or arrest the progress of the condition. However, in general, satisfactory results are obtained when the compounds of the invention are administered at a daily dose of from about 0.5 to about 500 mg/Kg of mammal body weight, preferably given in divided doses two to four times a day, or in a sustained release form. For most large mammals the total daily dosage is from about 0.5 to 100 mg, preferably from 0.5 to 80 mg/Kg. Dosage forms suitable for internal use comprise from about 0.05 to 500 mg of the active compound in intimate admixture with a solid or liquid pharmaceutically acceptable carrier. This dosage regimen may be adjusted to provide the optimal therapeutic response. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation.
[0067] These active compounds may be administered orally as well as by intravenous, intramuscular, or subcutaneous routes. Solid carriers include starch, lactose, dicalcium phosphate, microcrystalline cellulose, sucrose and kaolin, while liquid carriers include sterile water, polyethylene glycols, glycerol, non-ionic surfactants and edible oils such as corn, peanut and sesame oils, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of pharmaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, preserving agents, and antioxidants, for example vitamin E, ascorbic acid, BHT and BHA.
[0068] These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxypropylcellulose. Dispersions can also be prepared in glycerol, liquid polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
[0069] The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy injectability exists. It must be stable under conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol (e.g. glycerol, propylene glycol, and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oil.
[0070] Furthermore, active compounds of the present invention can be administered intranasally using vehicles suitable for intranasal delivery, or transdermally using transdermal skin patches known to those ordinarily skilled in the art. When using a transdermal delivery system, the dosage administration will be continuous rather than in a single or divided daily doses. The compounds of the present invention can also be administered in the form of liposome delivery system wherein the liposomal lipid bilayers are formed from a variety of phospholipids.
[0071] Compounds of the present invention may also be delivered by the use of carriers such as monoclonal antibodies to which the active compounds are coupled. The compounds of the present invention may also be coupled to soluble polymers as drug carriers or to biodegradable polymers useful in achieving controlled release of the active agent.
[0072] Also according to the present invention there are provided processes for producing the compounds of the present invention.
[0073] Process of the Invention
[0074] The compounds of the present invention may be prepared according to one of the general processes outlined below.
[0075] The compounds of general formula (I) wherein R 4 consists of the moiety B-C, where B is selected from the group (a) or (b) and C is selected from the group of (c), (d), (e) and (f) defined hereinbefore, can be conveniently prepared as shown in Scheme I.
[0076] According to the above preferred process, a tricyclic azepine of formula (1) wherein
[0077] R 3 and R 4 are defined hereinbefore, is reacted with perhaloalkanoyl halide preferable trichloroacetyl chloride in the presence of an organic base such as N,N-diisopropylethyl amine (Hünig's base) in an aprotic organic solvent such as dichloromethane at temperatures ranging from −10° C. to ambient, to provide the desired trichloroacetyl intermediate of formula (2). Subsequent hydrolysis of (2) with aqueous base such as sodium hydroxide, in an organic solvent such as tetrahydrofuran or acetone at temperatures ranging from −10° C. to ambient, yields the intermediate acid of formula (3). The required activation of the carboxylic acid (3) for the subsequent coupling with a primary or secondary amine of formula (5) can be accomplished in several ways. Thus, (3) can be converted to an acyl halide preferable a chloride or bromide of formula (4, J=COCl or COBr) by reaction with thionyl chloride(bromide) or oxalyl chloride(bromide) or similar reagents known in the art, either neat or in the presence of an inorganic base such as potassium carbonate, or in the presence of an organic base such as pyridine, 4-(dimethylamino)pyridine, or a tertiary amine such as triethylamine in an aprotic solvent such as dichloromethane, N,N-dimethylformamide or tetrahydrofuran at temperatures ranging from −5° C. to 50° C. to yield the intermediate acylated derivative (4). Subsequent coupling of the acyl chloride(bromide) (4, J=COCl or COBr) with an appropriately substituted primary or secondary amine of formula (5) in the presence of a stoichiometric amount of Hünig's base, in an aprotic solvent such as dichloromethane, N,N-dimethylformamide or tetrahydrofuran, at temperatures ranging from ambient to the reflux temperature of the solvent, provides the desired compounds of formula (I) wherein
[0078] R, R 3 and R 4 are as defined hereinbefore.
[0079] Alternatively, the acylating species can be a mixed anhydride of the corresponding carboxylic acid, such as that prepared by treating said acid of formula (3) with 2,4,6-trichlorobenzoyl chloride in an aprotic organic solvent such as dichloromethane according to the procedure of Inanaga et al., Bull. Chem. Soc. Jpn. 52, 1989 (1979). Treatment of said mixed anhydride of formula (4) with an appropriately substituted primary or secondary amine of formula (5) in an aprotic solvent such as dichloromethane at temperatures ranging from ambient to the reflux temperature of the solvent, provides the desired compounds of formula (I) wherein
[0080] R, R 3 and R 4 are as defined hereinbefore.
[0081] Alternatively, amidation of the carboxylic acids of formula (3) can be effectively carried out by treatment of said acid with triphosgene in an aprotic solvent such as dichloromethane, followed by reaction of the activated intermediate with an appropriately substituted primary or secondary amine of formula (5) in the presence of an organic base such as Hünig's base at temperatures ranging from −10° C. to ambient.
[0082] Another preferred process for the preparation of the compounds of the present invention of formula (I) wherein
[0083] R, R 3 and R 4 are as defined hereinbefore, consists of treating the acid of formula (3) with an activating reagent such as N,N-dicyclohexylcarbodiimide or 1-ethyl-3-(3-dimethylamino-propyl)carbodiimide hydrochloride in the presence of 1-hydroxybenzotriazole, followed by reaction of the activated intermediate with an appropriately substituted primary or secondary amine of formula (5), preferably in the presence of an organic base such as Hünig's base and a catalytic amount of 4-(dimethylamino)pyridine in an aprotic solvent such as dichloromethane, N,N-dimethylformamide or tetrahydrofuran at temperatures ranging from −10° C. to ambient.
[0084] In another preferred process, said acid (3) can be activated by treatment with other activating agents such as N,N′-carbonyldiimidazole in an aprotic solvent such as dichloromethane or tetrahydrofuran, at temperatures ranging from −10° C. to the reflux temperature of the solvent. Subsequent reaction of the intermediate activated imidazolide with an appropriately substituted primary or secondary amine of formula (5) provides the desired compounds of formula (I) wherein
[0085] R, R 3 and R 4 are as defined hereinbefore.
[0086] Alternatively, the coupling of the appropriately substituted primary or secondary amine of formula (5) with said acid of formula (3) can be effectively carried out by using hydroxybenzotriazole tetramethyluronium hexafluorophosphate as the coupling reagent in the presence of an organic base such as Hünig's base and in a solvent such as N,N-dimethylformamide at temperatures ranging from −10° C. to ambient, to provide in good isolated yield and purity the desired compounds of formula (I) wherein
[0087] R, R 3 and R 4 are as defined hereinbefore.
[0088] Related coupling reagents such as diphenylphosphoryl azide, diethyl cyano phosphonate, benzotriazol-1-yl-oxy-tris-(dimethylamino) phosphonium hexafluorophosphate and all other known in the literature that have been used in the formation of amide bonds in peptide synthesis can also be used for the preparation of compounds of formula (I) wherein
[0089] R, R 3 and R 4 are as defined hereinbefore.
[0090] As an alternative, reaction of the intermediate 3-trihalomethylketone of formula (2) directly with an appropriately substituted primary or secondary amine of formula (5) also provides the desired compounds of formula (I) wherein
[0091] R, R 3 and R 4 are as defined hereinbefore.
[0092] The method of choice for the preparation of compounds of formula (I) from the intermediate carboxylic acid (3) is ultimately chosen on the basis of its compatibility with the R, R 3 and R 4 groups, and its reactivity with the tricyclic diazepine of formula (1).
[0093] Another preferred process for the preparation of (I) of Scheme I is shown in Scheme II. A tricyclic diazepine of formula (1) is reacted with diphosgene in an aprotic solvent such as dichloromethane, preferably in the presence of an organic base such as triethylamine, followed by reaction of the resulting acylated intermediate with an appropriately substituted primary or secondary amine of formula (5), to provide the desired compounds of formula (I) wherein
[0094] R, R 3 and R 4 are as defined hereinbefore.
[0095] The tricyclic diazepines of formula (1) of Scheme I wherein R 4 is defined hereinbefore, can be conveniently prepared as shown in Scheme III.
[0096] Thus, a tricyclic diazepine of formula (6) is treated with an appropriately substituted acylating agent such as a haloaroyl halide, preferably an appropriately substituted acyl chloride(bromide) of formula (7, J=COCl or COBr) wherein R 4 is ultimately chosen on the basis of its compatibility with the present reaction scheme, in the presence of an inorganic base such as potassium carbonate, or in the presence of an organic base such as pyridine, 4-(dimethylamino)pyridine, or a tertiary amine such as triethylamine or N,N-diisopropylethyl amine, in an aprotic solvent such as dichloromethane, N,N-dimethylformamide or tetrahydrofuran, at temperatures ranging from −5° C. to 50° C. to provide intermediates of general formula (1) wherein R 4 is defined hereinbefore.
[0097] Alternatively, the acylating species of formula (7) can be a mixed anhydride of the corresponding carboxylic acid, such as that prepared by treating said acid with 2,4,6-trichlorobenzoyl chloride in an aprotic organic solvent such as dichloromethane according to the procedure of Inanaga et al., Bull. Chem. Soc. Jpn., 52, 1989 (1979). Treatment of said mixed anhydride of general formula (7) with a tricyclic diazepine of formula (6) in a solvent such as dichloromethane, and in the presence of an organic base such as 4-(dimethylaminopyridine), at temperatures ranging from 0° C. to the reflux temperature of the solvent, yields the intermediate acylated derivative (1) of Scheme III.
[0098] The acylating intermediate of formula (7) is ultimately chosen on the basis of its compatibility with the R 4 groups, and its reactivity with the tricyclic diazepine of formula (6).
[0099] The desired intermediates of formula (7) of Scheme III wherein R 4 consists of the moiety B-C wherein B is (a) and C is (c) can be conveniently prepared by a process shown in Scheme IV. Thus, an appropriately substituted aryl(heteroaryl) iodide (bromide, chloride, or trifluoromethane sulfonate) of formula (8, wherein P is a carboxylic acid protecting group, preferably P=alkyl or benzyl, M=I, Br, Cl, OTf)), and A, R 5 , R 6 and R 7 are defined hereinbefore, is reacted with an aryl(heteroaryl) tri(alkyl)tin(IV) derivative of formula (9, W=Sn(trialkyl) 3 , preferably Sn(n-Bu) 3 ) wherein A, R 8 , R 9 and R 10 are defined hereinbefore, in the presence of a Pd(0) catalyst, in the presence or absence of inorganic salts (e.g. LiCl), to provide the intermediate ester (10). Subsequent unmasking of the carboxylic function by hydrolysis, hydrogenolysis or similar methods known in the art, followed by activation of the intermediate acid (11) provides the desired compounds of formula (19) wherein A, R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are hereinbefore defined, suitable for coupling with the tricyclic diazepine of formula (6).
[0100] The desired intermediates of formula (7) of Scheme III wherein R 4 consists of the moiety B-C where B is (a) and C is (d), (e) or (f), or B is (b) and C is either (c), (d), (e) or (f), can be prepared by a process analogous to that exemplified in Scheme IV by replacing intermediates of formula (8 and 9) with appropriately substituted naphthyl, quinolyl, pyrimidinyl or pyrazinyl intermediates.
[0101] Alternatively, the desired intermediates of formula (10) of Scheme IV wherein R 4 consists of the moiety B-C where B is (a) and C is (c), can be prepared by coupling of the iodide(bromide, chloride, trifluoromethane sulfonate) (8, M=I, Br, Cl or OTf) and an appropriately substituted aryl(heteroaryl)boron derivative of formula (9, preferably W=B(OH) 2 ) in the presence of a palladium catalyst such as palladium(II) acetate or tetrakis(triphenylphosphine)palladium(0) and an organic base such as triethylamine or an inorganic base such as sodium(potassium or cesium) carbonate with or without added tetrabutylammonium bromide(iodide), in a mixture of solvents such as toluene-ethanol-water, acetone-water, water or water-acetonitrile, at temperatures ranging from ambient to the reflux temperature of the solvent (Suzuki, Pure & Appl. Chem. 66, 213-222 (1994), Badone et al., J. Org. Chem. 62, 7170-7173 (1997), Wolfe et al. J. Am. Chem. Soc. 121, 9559 (1999), Shen, Tetr. Letters 38, 5575 (1997)). The exact conditions for the Suzuki coupling of the halide and the boronic acid intermediates are chosen on the basis of the nature of the substrate and the substituents. Alternatively, the coupling of (8, M=I or Br) with (9, A=N) can be carried out by using a dialkylborane, preferably a diethylpyridoborane in the presence of an inorganic base such as potassium hydroxide and tetrabutylammonium bromide(iodide), in an aprotic solvent such as tetrahydrofuran, according to the method of Ishikura et al., Synthesis 936-938 (1984). The desired intermediates of formula (10) of Scheme IV can be similarly prepared from the bromide (8, M=Br) and the boronic acid (9) in a solvent such as dioxane in the presence of potassium phosphate and a Pd(0) catalyst.
[0102] Alternatively, a cross-coupling reaction of an iodide (bromide, or trifluoromethane sulfonate) of formula (9, W=Br, I or OTF) with a bis(pinacolato)diboron [boronic acid, or trialkyltin(IV)] derivative of formula (8, M=
[0103] B(OH) 2 , or SnBu 3 ) yields the desired intermediate of formula (10) which is converted to (I) in the manner of Scheme IV.
[0104] The desired intermediates of formula (10) of Scheme IV wherein R 4 consists of the moiety B-C wherein B is (a) and C is (d), (e) or (f), or B is (b) and C is either (c), (d), (e) or (f), can be prepared in analogous fashion by replacing intermediates of formulas (8 and 9) with appropriately substituted naphthyl, quinolyl, pyrimidinyl or pyrazinyl intermediates.
[0105] The required appropriately substituted aryl(heteroaryl) halides of formula (8, M=Br or I) of Scheme IV are either available commercially, or are known in the art, or can be readily accessed in quantitative yields and high purity by diazotization of the corresponding substituted anilines (8, P=H, alkyl or benzyl, M=NH 2 ) followed by reaction of the intermediate diazonium salt with iodine and potassium iodide in aqueous acidic medium essentially according to the procedures of Street et al,. J. Med. Chem. 36, 1529 (1993) and Coffen et al., J. Org. Chem. 49, 296 (1984) or with copper(I) bromide, respectively (March, Advanced Organic Chemistry, 3 rd Edn., p.647-648, John Wiley & Sons, New York (1985)).
[0106] Alternatively, the desired intermediates of formula (11, A=CH) of Scheme IV wherein R 4 consists of the moiety B-C wherein B is (a, A=CH) and C is (c, A=CH) can be conveniently prepared as shown in Scheme V by cross-coupling reaction of an appropriately substituted pinacolato borane of formula (13, A=CH) wherein R 8 , R 9 and R 10 are hereinbefore defined, with an aryl triflate of formula (14, Y=OTf) or an aryl halide (14, Y=Br, I) wherein R 5 , R 6 and R 7 are defined hereinbefore, according to the general procedures of Ishiyama et al., Tetr. Lett. 38, 3447-3450 (1997) and Giroux et al. Tetr. Lett. 38, 3841-3844 (1997), followed by basic or acidic hydrolysis of the intermediate nitrile of formula (15) (cf. March, Advanced Organic Chemistry, 3 rd Edn., John Wiley & Sons, New York, p. 788 (1985)).
[0107] Alternatively, reaction of an iodide (bromide, or trifluoromethane sulfonate) of formula (12, X=Br, I, or OTf) with a bis(pinacolato)diboron [boronic acid or trialkyl tin(IV)] derivative of formula (14, Y=
[0108] B(OH) 2 , or SnBu 3 ) yields the desired intermediate of formula (15) which is converted to (6) in the manner of Scheme V.
[0109] The desired intermediates of formula (11) of Scheme IV can be prepared in analogous fashion by replacing intermediates of formulas (13 and 14) with appropriately substituted naphthyl intermediates.
[0110] The desired phenyl boronic esters of formula (13) of Scheme V can be conveniently prepared by the palladium-catalyzed cross-coupling reaction of the pinacol ester of diboronic acid (16) with an appropriately substituted aryl halide preferably a bromide or iodide (12, X=Br, I) or aryl triflate (12, X=OTf) according to the described procedures of Ishiyama et al., J. Org. Chem. 60, 7508-7510 (1995) and Giroux et al., Tetr. Left. 38, 3841-3844 (1997).
[0111] The desired compounds of formula (1) of Scheme IV wherein R 4 consists of the moiety B-C wherein B is (a) and C is (c) can be alternatively prepared by a process shown in Scheme VI.
[0112] Thus, a tricyclic diazepine of formula (6) is treated with an appropriately substituted acylating agent such as a halo aroyl(heteroaroyl)halide, preferably an iodo(bromo)aroyl(heteroaroyl)chloride(bromide) of formula (17, J=COCl or COBr; X=I, Br) wherein R 5 , R 6 and R 7 are hereinbefore defined, using any of the procedures hereinbefore described, to provide the acylated intermediate of general formula (18) of Scheme VI.
[0113] Alternatively, the acylating species of formula (17) can be a mixed anhydride of the corresponding carboxylic acid. Treatment of said mixed anhydride of general formula (17) with a tricyclic diazepine of formula (6) according to the procedure described hereinbefore yields the intermediate acylated derivative (18).
[0114] The acylating intermediate of formula (17) is ultimately chosen on the basis of its compatibility with A and the R 5 , R 6 and R 7 groups, and its reactivity with the tricyclic diazepine of formula (6).
[0115] A Stille coupling reaction of (18, X=I) with an appropriately substituted organotin reagent such as a trialkyltin(IV) derivative, preferably a tri-n-butyltin(IV) derivative of formula (9, W=SnBu 3 ) where A, R 8 , R 9 and R 10 are hereinbefore defined, in the presence of a catalyst such as tetrakis(triphenylphosphine)palladium(0), in an aprotic organic solvent such as toluene and N,N-dimethylformamide, at temperatures ranging from ambient to 150° C. (cf. Farina et al., J. Org. Chem, 59, 5905 (1994) and references cited therein, affords the desired compounds of formula (1) wherein
[0116] A, R 3 , R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are as defined hereinbefore.
[0117] Alternatively, reaction of a compound of formula (18, X=Cl, Br or I) with an appropriately substituted aryl(heteroaryl)boronic acid of formula (9, W=B(OH) 2 ) wherein A, R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are hereinbefore defined, in a mixture of solvents such as toluene-ethanol-water, and in the presence of a Pd(0) catalyst and a base such as sodium carbonate, at temperatures ranging from ambient to the reflux temperature of the solvent, yields the desired compounds of formula (1) wherein
[0118] A, R 3 , R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are as defined hereinbefore.
[0119] The preferred substituted aroyl(heteroaroyl) chlorides(bromides) of formula (17) of Scheme VI (X=I, Br; J=COCl or COBr) wherein A, R 5 , R 6 and R 7 are as defined hereinbefore, are either available commercially, or are known in the art, or can be readily prepared by procedures analogous to those in the literature for the known compounds.
[0120] The intermediates of formula (9, W=Sn(alkyl) 3 , alkyl=n-butyl) of Scheme VI are either commercially available, or can be conveniently prepared as shown in Scheme VII from the corresponding bromo starting materials of formula (20) wherein A, R 8 , R 9 , and R 10 are hereinbefore defined, by first reacting them with n-butyl lithium followed by reaction of the intermediate lithiated species with a trialkyl (preferably trimethyl or tri-n-butyl)tin(IV) chloride.
[0121] The preferred substituted aryl(heteroaryl)boronic acids of formula (9, W=B(OH) 2 ) are either available commercially, or are known in the art, or can be readily prepared by procedures analogous to those in the literature for the known compounds.
[0122] The desired compounds of formula (1) of Scheme VI wherein R 4 consists of the moiety B-C wherein B is (a) and C is (d), (e) or (f), or B is (b) and C is either (c), (d), (e) or (f) can be prepared in analogous fashion by replacing intermediates of formulas (17 and 9) with appropriately substituted naphthyl, quinolyl, pyrimidinyl or pyrazinyl intermediates.
[0123] Alternatively, as shown in Scheme VIII, the appropriately substituted aroyl(heteroaroyl) halides, preferably aroyl(heteroaroyl)chlorides of formula (21, J=COCl) where A, R 5 , R 6 and R 7 are hereinbefore defined, are reacted with a tricyclic diazepine of formula (6) to provide the intermediate bromides of formula (22). Subsequent reaction of (22) with an hexa alkyl-di-tin (preferably hexa-n-butyl-di-tin(IV)) in the presence of a Pd(0) catalyst such as tetrakis(tri-phenylphosphine)palladium(0) and lithium chloride, provides the stannane intermediate of formula (23). Further reaction of the tri-n-butyl tin(IV) derivative (23) with the appropriately substituted aryl(heteroaryl)halide of formula (24, M=bromo or iodo) wherein A, R 8 , R 9 , and R 10 are hereinbefore defined, in the presence of a Pd(0) catalyst such as tetrakis(triphenylphosphine)palladium(0), yields the desired compounds of formula (1) wherein R 4 consists of the moiety B-C wherein B is (a) and C is (c), and
[0124] A, R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are defined hereinbefore.
[0125] The desired compounds of formula (1) of Scheme VIII wherein R 4 consists of the moiety B-C wherein B is (a) or (b) and C is (d), (e) or (f) can be prepared in analogous fashion by replacing intermediates of formulas (21 and 24) with appropriately substituted naphthyl, quinolyl, pyrimidinyl or pyrazinyl intermediates.
[0126] Alternatively, the desired compounds of formula (1) of Scheme VIII wherein R 4 consists of the moiety B-C wherein B is (a, A=CH), and C is (c, A=CH) can be prepared as shown in Scheme IX.
[0127] Thus, an appropriately substituted biphenyl of formula (43) wherein R 5 , R 6 , and R 7 are defined hereinbefore, is treated with carbon monoxide in the presence of a tricyclic diazepine of formula (6), a palladium(0) catalyst preferably PdBr 2 (Ph 3 P) 2 and a tertiary amine preferably n-tributylamine, in a solvent such as anisole or dioxane, at temperatures ranging from ambient to the reflux temperature of the solvent (cf. Schoenberg et al. J. Org. Chem. 39, 3327 (1974)) to provide the desired compounds of formula (1) wherein A is CH, and
[0128] R 3 , R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are defined hereinbefore.
[0129] In analogous fashion one can prepare compounds of formula (1) of Scheme IX wherein R 4 consists of the moiety B-C wherein B is (b) and C is (c, A=CH) or (d, A=CH) provided that the intermediates of formula (43) are replaced by the appropriately substituted phenyl or naphthyl intermediates.
[0130] A preferred process for the preparation of the compounds of formula (1) of Scheme I wherein
[0131] A, R 3 , R 5 , R 6 and R 7 are defined hereinbefore, and R 4 consists of the moiety B-C wherein B is (a) and C is (g) defined hereinbefore, is shown in Scheme X.
[0132] Thus, an appropriately substituted aroyl(heteroaroyl)halide preferably an aroyl(heteroaroyl)chloride of formula (25, J=COCl) is reacted with a tricyclic diazepine of formula (6) in the presence of a base such as pyridine, or a tertiary amine such as triethylamine or N,N-diisopropylethyl amine, in an aprotic organic solvent such as dichloromethane or tetrahydrofuran, at temperatures from −40° C. to 50° C. to provide the acylated intermediate of formula (26). Alternatively, the acylating species can be a mixed anhydride under the reaction conditions described hereinbefore. Subsequent reduction of (26) is preferably effected under conditions of catalytic reduction (i.e. hydrogen, Pd on charcoal), transfer hydrogenation (i.e. hydrazine/ethanol/Pd on charcoal) or under chemical reduction conditions (i.e. with tin(II)chloride dihydrate in a protic organic solvent such as ethanol, zinc in acetic acid) or related reduction conditions known in the art, to yield the desired aniline of formula (27). The exact conditions for the conversion of the nitro to amino group are chosen on the basis of compatibility with the preservation of other functional groups in the molecule. Condensation of (27) with a 1,4-diketone of formula (28) in an aprotic organic solvent such as benzene or toluene, in the presence of acetic acid or a catalytic amount of p-toluenesulfonic acid with concomitant removal of water, at temperatures ranging from ambient to reflux temperature of the solvent according to the general procedure of Bruekelman et al., J. Chem. Soc. Perkin Trans. I, 2801-2807 (1984) provides the desired compounds of formula (1) wherein R 4 consists of the moiety B-C wherein B is (a) and C is (g), and
[0133] A, R 3 , R 5 , R 6 , R 7 , R 11 and R 12 are defined hereinbefore.
[0134] The desired compounds of formula (1) of Scheme X wherein R 4 consists of the moiety B-C wherein B is (b) and C is (g) can be prepared in analogous fashion by replacing the intermediate of formula (25) with an appropriately substituted naphthyl.
[0135] Alternatively, the desired compounds of formula (1) of Scheme X can be prepared as shown in Scheme XI.
[0136] According to this process an aryl(heteroaryl)nitrile of formula (29) is condensed with a 1,4-diketone of formula (28) in an aprotic organic solvent such as benzene or toluene, in the presence of acetic acid or a catalytic amount of p-toluene sulfonic acid with concomitant removal of water, at temperatures ranging from ambient to reflux temperature of the solvent according to the general procedure of Bruekelman et al., J. Chem. Soc. Perkin Trans. I, 2801-2807 (1984) to yield the intermediate pyrrole of formula (30). Subsequent hydrolysis of the nitrile (30) to the carboxylic acid of formula (31) is efficiently accomplished by treatment of (30) with aqueous base (cf. March, Advanced Organic Chemistry, 3 rd Edn., John Wiley & Sons, New York, p. 788 (1985)). Subsequent conversion of the acid (31) into an acylating species, preferably an acid chloride(bromide) of formula (32, J=COCl or COBr) or a mixed anhydride is accomplished by procedures analogous to those described hereinbefore. The acylating agent (32) is used to acylate a tricyclic diazepine of formula (6) to provide the desired compounds of formula (1) wherein
[0137] A and R 3 are defined hereinbefore, and R 4 consists of the moiety B-C wherein B is (a) and C is the moiety (g) defined hereinbefore.
[0138] The compounds of formula (1) of Scheme Xl wherein R 4 consists of the moiety B-C wherein B is (b) and C is (g) defined hereinbefore can be prepared in analogous fashion by replacing the intermediates of formula (29) with an appropriately substituted naphthyl.
[0139] A preferred process for the preparation of the desired compounds of general formula (I) of Scheme I wherein R 4 consists of the moiety B-C, where B is selected from the group (a) and C is selected from the group (g) defined hereinbefore is shown in Scheme XII.
[0140] Thus, a tricyclic diazepine of formula (33) wherein
[0141] and R 3 are defined hereinbefore, carrying a protecting group such a fluorenylalkoxycarbonyl group, preferably a fluorenylmethyloxycarbonyl (P=Fmoc) group, or an alkoxycarbonyl protecting group preferably a tert-butyloxycarbonyl (P=Boc) group is reacted with a perhaloalkanoyl halide preferably trichloroacetyl chloride, in the presence of an organic base such as N,N-diisopropylethyl amine (Hünig's base) or a tertiary amine such as triethylamine, optionally in the presence of catalytic amounts of 4-(dimethylamino)pyridine, in an aprotic organic solvent such as dichloromethane, at temperatures ranging from −10° C. to ambient to provide the desired trichloroacetyl intermediate of formula (34). Subsequent hydrolysis of the trichloroacetyl group with aqueous base such as sodium hydroxide in an organic solvent such as acetone, at temperatures ranging from −10° C. to ambient, is accompanied by simultaneous removal of the protecting group and yields the intermediate acid of formula (35). The required amidation of the carboxylic acid (35) can be effectively accomplished by treating (35) with an activating reagent such as N,N-dicyclohexylcarbodiimide or 1-ethyl-3-(3-dimethylamino-propyl)carbodiimide hydrochloride in the presence of 1-hydroxybenzotriazole, followed by reaction of the activated intermediate with an appropriately substituted primary or secondary amine of formula (5) preferably in the presence of Hünig's base or a catalytic amount of 4-(dimethylamino)pyridine, in an aprotic solvent such as dichloromethane, N,N-dimethylformamide or tetrahydrofuran, at temperatures ranging from −10° C. to ambient.
[0142] Other coupling reagents known in the literature that have been used in the formation of amide bonds in peptide synthesis can also be used for the preparation of compounds of formula (36) wherein
[0143] R and R 3 are as defined hereinbefore. The method of choice for the preparation of compounds of formula (36) from the intermediate carboxylic acid (35) is ultimately chosen on the basis of its compatibility with the
[0144] and R 3 groups, and its reactivity with the tricyclic diazepine of formula (6). Subsequent reaction of a tricyclic diazepine amide (36) with an acylating agent of formula (32) of Scheme XI provides the desired compounds of formula (I) wherein
[0145] A and R 3 are defined hereinbefore, R 4 consists of the moiety B-C wherein B is (a) and C is the moiety (g) defined hereinbefore.
[0146] The preferred compounds of formula (I) of Scheme I wherein R 4 consists of the moiety B-C wherein B is (b) and C is the moiety (g) defined hereinbefore, can be prepared in analogous fashion by replacing the intermediate of formula (32) of Scheme XII with an appropriately substituted naphthyl intermediate.
[0147] Preferred processes for the preparation of compounds of formula (I) of Scheme I wherein R 4 consists of the moiety B-C wherein B is (a) or (b) and C is (d), (e) or (f) and
[0148] A, R, R 3 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are defined hereinbefore, also utilize acylation of the amide intermediate (36) of Scheme XII with an acylating agent of formula (19) of Scheme IV.
[0149] An alternate preferred process for the preparation of the compounds of formula (I) of Scheme I wherein R 4 consists of the moiety B-C wherein B is (a) and C is (g) defined hereinbefore, is shown in Scheme XIII.
[0150] According to the above process a substituted tricyclic diazepine of formula (37) wherein
[0151] A, R 3 , R 5 , R 6 and R 7 are defined hereinbefore, carrying a protecting group such a fluorenylalkoxycarbonyl group, preferably a fluorenylmethyloxycarbonyl (P=Fmoc) group is reacted with a perhaloalkanoyl halide preferably trichloroacetyl chloride in the presence of an organic base such as N,N-diisopropylethyl amine (Hünig's base) or a tertiary amine such as triethylamine, in an aprotic organic solvent such as dichloromethane, at temperatures ranging from −10° C. to ambient, to provide the desired trichloroacetyl intermediate of formula (38). Subsequent deprotection of (38) is carried out by treatment with a solution of an organic base preferably piperidine, in an organic solvent such as N,N-dimethylformamide, at ambient temperature to provide the desired aniline (44). Condensation of (44) with a 1,4-diketone of formula (28) either neat or in an aprotic organic solvent such as benzene or toluene, in the presence of a catalytic amount of a carboxylic acid preferably p-toluene sulfonic acid or acetic acid with concomitant removal of water, at temperatures ranging from ambient to 100° C. or to the reflux temperature of the solvent according to the general procedure of Bruekelman et al., J. Chem. Soc. Perkin Trans. I, 2801-2807 (1984), provides the desired intermediate of formula (45). Subsequent hydrolysis of the trichloroacetyl group with aqueous base such as sodium hydroxide, in an organic solvent such as acetone or tetrahydrofuran, at temperatures ranging from −10° C. to the reflux temperature of the solvent, yields the intermediate carboxylic acid of formula (46). Subsequent amidation provides the desired compounds of formula (I) wherein R 4 consists of the moiety B-C wherein B is (a) and C is (g), and
[0152] A, R 3 , R 5 , R 6 , R 7 , R 11 and R 12 are defined hereinbefore,
[0153] The required amidation of (46) can be effectively accomplished by treating said carboxylic acid with an activating reagent such as N,N-dicyclohexylcarbodiimide or 1-ethyl-3-(3-dimethylamino-propyl)carbodiimide hydrochloride in the presence of 1-hydroxybenzotriazole, followed by reaction of the activated intermediate with an appropriately substituted primary or secondary amine of formula (5), preferably in the presence of Hünig's base or a catalytic amount of 4-(dimethylamino)pyridine, in an aprotic solvent such as dichloromethane, N,N-dimethylformamide or tetrahydrofuran, at temperatures ranging from −10° C. to ambient. Other coupling reagents known in the literature that have been used in the formation of amide bonds in peptide synthesis can also be used for the preparation of compounds of formula (I) wherein R 4 consists of the moiety B-C wherein B is (a) and C is (g), and
[0154] A, R 3 , R 5 , R 6 , R 7 , R 11 and R 12 are defined hereinbefore. The method of choice for the preparation of compounds of formula (I) from the intermediate carboxylic acid (46) is ultimately chosen on the basis of its compatibility with the
[0155] and R 3 groups, and its reactivity with the tricyclic diazepine of formula (6).
[0156] The desired compounds of formula (I) of Scheme XIII wherein R 4 consists of the moiety B-C wherein B is (b) and C is (g) can be prepared in analogous fashion by replacing the intermediate of formula (27) with an appropriately substituted naphthyl intermediate.
[0157] Alternatively, the intermediate acids of formula (35) of Scheme XII wherein and R 3 are defined hereinbefore, can be obtained by reacting a tricyclic diazepine of formula (6) with an excess of acylating agent preferably trifluoroacetic anhydride or trichloroacetyl chloride in the presence of an inorganic base such as potassium carbonate or an organic base such as N,N-diisopropylethylamine, in an aprotic solvent such as N,N-dimethylformamide, followed by basic hydrolysis of the intermediate bis-trifluoroacetyl(trichloroacetyl) intermediate of formula (39 X=F or Cl) preferably with aqueous sodium hydroxide in a protic organic solvent such as ethano, at temperatures ranging from ambient to the reflux temperature of the solvent as exemplified in Scheme XIV.
[0158] Preferred processes for the preparation of compounds of formula (I) of Scheme I wherein R 4 consists of the moiety B-C wherein B is (a) or (b) and C is (d), (e) or (f) and
[0159] A, R, R 3 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are defined hereinbefore, also utilize acylation of the amide intermediate (36) of Scheme XII with an acylating agent of formula (17) of Scheme IV, as shown in Scheme XV.
[0160] Alternatively, the preferred compounds of formula (I) of Scheme I wherein R 4 consists of the moiety B-C wherein B is (a) and C is (c) and
[0161] A, R, R 3 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are defined hereinbefore, can be prepared by acylation of the amide intermediate (36) of Scheme XII with an acylating agent of formula (21) of Scheme VIII, as shown in Scheme XVI.
[0162] Alternatively, the preferred compounds of formula (I) of Scheme (I) wherein R 4 consists of the moiety B-C wherein B is (a) and C is (c) and
[0163] A, R, R 3 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are defined hereinbefore, can be prepared by acylation of the amide intermediate (36) of Scheme XII with an acylating agent of formula (19) of Scheme IV, wherein J is hereinbefore defined, as shown in Scheme XVII.
[0164] The subject compounds of the present invention were tested for biological activity according to the following procedures.
[0165] Vasopressin Binding in Chinese Hamster Ovary Cell Membranes Expressing Human Vasopressin V 1a Subtype Receptors
[0166] Receptor Source:
[0167] Chinese hamster ovary cells (CHO cells) stably transfected with the human vasopressin V 1a subtype receptors were either obtained from BioSignal Inc., 1744 rue Williams, Montreal, Quebec, Canada or obtained from M. Thibonnier, Case Western Reserve University School of Medicine, Cleveland, Ohio.
[0168] A. Passaging and Amplification of Cells:
[0169] CHO cells transfected with the human vasopressin V 1a subtype receptors obtained from M. Thibonnier (pZeoSV vector) are allowed to grow to confluency (approx. >90%) in T-150 flasks under sterile conditions, in a cell culture medium of F-12 Nutrient Mixture (HAM) with L-glutamine (Gibco Cat. # 11765-054) containing 15 mM HEPES (Gibco Cat. # 15630-080), 1% antibiotic/antimycotic (add 5 mL 100×, Gibco Cat. # 15240-062 per 500 mL F-12), 250 μg/mL Zeocin (add 1.25 mL of 100 mg/mL Invitrogen R-250-01 per 500 mL F-12) and 10% Fetal Bovine Serum (Qualified, heat inactivated, Gibco Cat. # 16140-063). The medium is removed by aspiration and the cells are washed with 10 mL of Hank's Balanced Salt solution (Gibco Cat. # 14175-095). The salt solution is removed by aspiration and the cells are trypsinized with 5 mL of trypsin-EDTA (0.05% trypsin, 0.53 mM EDTA-4Na, Gibco Cat. # 25300-070) for 1 min. The trypsin is removed by aspiration and the cells dislodged by tapping. Cell Culture medium (e.g. 30 mL for 1:30 split) is immediately added and mixed well to inactivate trypsin. 1 mL of detached cells is added to new culture flasks containing fresh cell culture medium (e.g., into 25 mL per T-150 flask), and mixed gently. The cells are incubated at 37° C. in 5% CO 2 . The medium is changed at 3 to 4 days interval (or as appropriate). The cells grow to confluency (approx. >75%-95%) within 7-8 days. All steps are done under sterile conditions.
[0170] B. Membrane Preparation:
[0171] The cells are washed twice gently with Hank's Balanced Salt solution (e.g,. use 10 mL per T-150 flask). The excess is removed and the cells are bathed for 15-30 min. in an enzyme-free Cell Dissociation Buffer (e.g. use 8 mL Hank's Based, Gibco Cat. # 13150-016 per T-150 flask) until the cells are loosened. The contents are transferred to centrifuge tubes (50 mL) kept in an ice bath. All subsequent steps are done at 4° C. The tubes are centrifuged at 300×g for 15 min (1380 rpm on SORVAL, Model RT6000D, using the rotor for 50 mL tubes). The supernatant is discarded and the cells suspended in homogenizing buffer(10 mM Tris-HCl containing 0.25 M sucrose and 1 mM EDTA, pH 7.4) ensuring that the volume of the buffer is about ten times the volume of the cell pellet. The cells are pooled into a centrifuge tube (50 mL) and homogenized with Polytron at setting 6 for 10 sec. The homogenate is transferred into a Potter-Elvjehm homogenizer and homogenized with 3 strokes. The homogenate is centrifuged at 1500×g for 10 min at 4° C. (3100 rpm using SORVAL, model RT6000D, using the rotor for 50 mL tubes). The pellet is discarded. The supernatant is centrifuged at 100,000×g for 60 min. at 4° C. (Beckman L8-80M ultracentrifuge; spin at 37,500 rpm with rotor type 70 Ti for 50 mL tubes; 38,000 rpm with type 80Ti for 15 mL tubes; or 35,800 rpm with rotor type 45Ti). The supernantant is discarded and the pellet suspended in 3 to 4 mL of Tris buffer (50 mM TRIS-HCl, pH 7.4). The protein content is estimated by the Bradford or Lowry method. The volume of the membrane suspension is adjusted with the membrane buffer (50 mM Tris-HCl containing 0.1% BSA and 0.1 mM PMSF) to give 3.0 mg/mL (or as appropriate) of protein. The membranes are aliquoted and stored at −70° C.
[0172] C. Radioligand Binding Assay:
[0173] In wells of a 96-well format microtiter plate, is added 90, 110 or 130 μL (to make up a final volume of 200 μL) of assay buffer containing 50 mM of Tris-HCl (pH 7.4), BSA (heat inactivated, protease-free), 0.1% of 5 mM MgCl 2 , 1 mg % aprotinin, 1 mg % leupeptin, 2 mg % 1,10-phenanthroline, 10 mg % trypsin inhibitor, and 0.1 mM PMSF. The inhibitors are added on the day of the experiment. The components are mixed at room temperature, and then kept in ice bath following adjustment of the pH to 7.4. To each well is added 20 μL of unlabeled Manning ligand (to give a final concentration of 0.1 to 10 nM for standard curve and 1000 nM for non specific binding) or test compounds in 50% DMSO (e.g. for final concentrations of 0.1 to 1000 nM or as appropriate) or 50% DMSO as vehicle control. 20 μL of 50% DMSO is added for Manning and other peptide ligands and the assay buffer volume is adjusted accordingly. To each well is added 50 μL of frozen membrane suspension thawed immediately prior to use and diluted in the assay buffer to the required concentration (equivalent to 25 to 50 μg of protein/well as needed). 20 μL of 8 nM [ 3 H]Manning ligand in the assay buffer, prepared just before use, is added, and incubated at room temperature for 60 min. shaking the plate on a mechanical shaker for the first 15 min. The incubation is stopped by rapid filtration of the the plate contents followed by wash with ice-cold buffer (50 mM Tris-HCl, pH 7.4) using a cell harvester (Tomtek and Printed filtermat-B filter paper). The filter paper is thoroughly dried (7-12 min. in a microwave oven) and impregnated with MeltiLex B/H melt-on scintillation wax sheets and the radioactivity counted in a betaplate scintillation counter.
[0174] Vasopressin Binding in Chinese Hamster Ovary Cell Membranes Expressing Human Vasopressin V 2 Subtype Receptors
[0175] Receptor Source:
[0176] Chinese Hamster Ovary (CHO) cells stably transfected with the human V 2 subtype receptors were obtained from M. Thibonnier, Case Western Reserve University School of Medicine, Cleveland, Ohio.
[0177] A. Passaging and Amplification of Cells:
[0178] CHO cells transfected with the human vasopressin V 2 subtype receptors obtained from M. Thibonnier (pZeoSV vector) are allowed to grow to confluency (approx. >90%) in T-150 flasks under sterile conditions, in a cell culture medium of F-12 Nutrient Mixture (HAM) with L-glutamine (Gibco Cat. # 11765-054) containing 15 mM HEPES (Gibco Cat. # 15630-080), 1% antibiotic/antimycotic (add 5 mL 100×, Gibco Cat. # 15240-062 per 500 mL F-12), 250 μg/mL Zeocin (add 1.25 mL of 100 mg/mL Invitrogen R-250-01 per 500 mL F-12) and 10% Fetal Bovine Serum (Qualified, heat inactivated, Gibco Cat. # 16140-063). The medium is removed by aspiration and the cells washed with 10 mL of Hank's Balanced Salt solution (Gibco Cat. # 14175-095). The salt solution is removed by aspiration and the cells trypsinized with 5 mL of trypsin-EDTA (0.05% trypsin, 0.53 mM EDTA-4Na, Gibco Cat. # 25300-070) for 1 min. The trypsin is removed by aspiration and the cells dislodged by tapping. Cell Culture medium (e.g. 30 mL for 1:30 split) is immediately added and mixed well to inactivate trypsin. 1 mL of detached cells is added to new culture flasks containing fresh Cell Culture medium (e.g. into 25 mL per T-150 flask), and mixed gently. The cells are incubated at 37° C. in 5% CO 2 . The medium is changed at 3 to 4 day interval (or as appropriate). The cells grow to confluency (approx. >75%-95%) within 7-8 days. All steps are done under sterile conditions.
[0179] B. Membrane Preparation:
[0180] The cells are washed twice gently with Hank's Balanced Salt solution (e.g. use 10 mL per T-150 flask). The excess solution is removed and the cells bathed for 15-30 min. in an enzyme-free Cell Dissociation Buffer (e.g. use 8 mL Hank's Based, Gibco Cat. # 13150-016 per T-150 flask) until cells are loosened. The contents are transferred to centrifuge tubes (50 mL) kept in ice bath. All subsequent steps are done at 4° C. The tubes are centrifuged at 300×g for 15 min (1380 rpm on SORVAL, Model RT6000D, using the rotor for 50 mL tubes). The supernatant is discarded and the cells suspended in homogenizing buffer(10 mM Tris-HCl containing 0.25 M sucrose and 1 mM EDTA, pH 7.4) ensuring that the volume of the buffer is about ten times the volume of the cell pellet. The cells are pooled into a centrifuge tube (50 mL) and homogenized with Polytron at setting 6 for 10 sec. The homogenate is transferred into a Potter-Elvjehm homogenizer and homogenized with 3 strokes. The homogenate is centrifuged at 1500×g for 60 min at 4° C. (3100 rpm using SORVAL, model RT6000D, using the rotor for 50 mL tubes). The pellet is discarded. The supernatant is centrifuged at 100,000×g for 60 min. at 4° C. (Beckman L8-80M ultracentrifuge; spin at 37,500 rpm with rotor type 70 Ti for 50 mL tubes; 38,000 rpm with type 80Ti for 15 mL tubes; or 35,800 rpm with rotor type 45Ti). The supernantant is discarded and the pellet suspended in 3 to 4 mL of Tris buffer (50 mM TRIS-HCl, pH 7.4). The protein content is estimated by the Bradford or Lowry method. The volume of the membrane suspension is adjusted with the membrane buffer (50 mM Tris-HCl containing 0.1% BSA and 0.1 mM PMSF) to give 3.0 mg/mL (or as appropriate) of protein. The membranes are aliquoted and stored at −70° C.
[0181] C. Radioligand Binding Assay:
[0182] In wells of a 96-well format microtiter plate, is added 90, 110 or 130 μL (to make up a final volume of 200 μL) of assay buffer containing 50 mM of Tris-HCl (pH 7.4), BSA (heat inactivated, protease-free), 5 mM of 0.1% MgCl 2 , 1 mg % aprotinin, 1 mg % leupeptin, 2 mg % 1,10-phenanthroline, 10 mg % trypsin inhibitor, and 0.1 mM PMSF. The inhibitors are added on the day of the experiment. The components are mixed at room temperature, and then kept in ice bath following adjustment of the pH to 7.4. To each well is added 20 μL of unlabeled arginine vasopressin (AVP) (to give a final concentration of 0.1 to 10 nM for standard curve and 1000 nM for non specific binding) or test compounds in 50% DMSO (e.g. for final concentrations of 0.1 to 1000 nM or as appropriate) or 50% DMSO as vehicle control. For vasopressin and other peptide ligands 20 μL of 50% DMSO is added and the assay buffer volume is adjusted accordingly. To each well is added 50 μL of frozen membrane suspension thawed immediately prior to use and diluted in assay buffer to the required concentration (equivalent to 25 to 50 μg of protein/well as needed). 20 μL of 8 nM [ 3 H]arginine vasopressin ligand in the assay buffer, prepared just before use is added and incubated at room temperature for 60 min. shaking the plate on a mechanical shaker for the first 15 min. The incubation is stopped by rapid filtration of the plate contents followed by wash with ice-cold buffer (50 mM Tris-HCl, pH 7.4) using a cell harvester (Tomtek and Printed filtermat-B filter paper). The filter paper is thoroughly dried (7-12 min. in a microwave oven) and impregnated with MeltiLex B/H melt-on scintillation wax sheets and the radioactivity counted in a betaplate scintillation counter.
[0183] Oxytocin Binding in Chinese Hamster Ovary Cell Membranes Expressing Human Oxytocin Receptors
[0184] Receptor Source:
[0185] Chinese Hamster Ovary (CHO) cells stably transfected with the human oxytocin receptor (cf. Tanizawa et al., U.S. Pat. No. 5,466,584 (1995) to Rohto Pharmaceutical Co. Ltd., Osaka, Japan) were obtained from M. Thibonnier, Case Western Reserve University School of Medicine, Cleveland, Ohio.
[0186] A. Passaging and Amplification of Cells:
[0187] CHO cells transfected with the human oxytocin receptors obtained from M. Thibonnier (pcDNA3.1 vector) are allowed to grow to confluency (approx. >90%) in T-150 flasks under sterile conditions, in a cell culture medium of F-12 Nutrient Mixture (HAM) with L-glutamine (Gibco Cat. # 11765-054) containing 15 mM HEPES (Gibco Cat. # 15630-080), 1% antibiotic/antimycotic (add 5 mL 100×, Gibco Cat. # 15240-062 per 500 mL F-12), 400 μg/mL of Geneticin (add 4 mL of 50 mg/mL per 500 mL F-12) and 10% Fetal Bovine Serum (Qualified, heat inactivated, Gibco Cat. # 16140-063). The medium is removed by aspiration and the cells are washed with 10 mL of Hank's Balanced Salt solution (Gibco Cat. # 14175-095). The salt solution is removed by aspiration and the cells trypsinized with 5 mL of trypsin-EDTA (0.05% trypsin, 0.53 mM EDTA-4Na, Gibco Cat. # 25300-070) for 1 min The trypsin is removed by aspiration and the cells dislodged by tapping. Cell Culture medium (e.g. 30 mL for 1:30 split) is immediately added and mixed well to inactivate trypsin. 1 mL of detached cells is added to new culture flasks containing fresh Cell Culture medium (e.g. into 25 mL per T-150 flask), and mixed gently. The cells are incubated at 37° C. in 5% CO 2 . The medium is changed at 3 to 4 days interval (or as appropriate). The cells grow to confluency (approx. >75%-95%) within 7-8 days. All steps are done under sterile conditions.
[0188] B. Membrane Preparation:
[0189] The cells are washed twice gently with Hank's Balanced Salt solution (e.g., use 10 mL per T-150 flask). The excess solution is removed and the cells bathed for 15-30 min. in an enzyme-free Cell Dissociation Buffer (e.g., use 8 mL Hank's Based, Gibco Cat. # 13150-016 per T-1 50 flask) until cells are loosened. The contents are transferred to centrifuge tubes (50 mL size) kept in ice bath. All subsequent steps are done at 4° C. The tubes are centrifuged at 300×g for 15 min (1380 rpm on SORVAL, Model RT6000D, using rotor for 50 mL tubes). The supernatant is discarded and the cells suspended in homogenizing buffer (10 mM Tris-HCl containing 0.25 M sucrose and 1 mM EDTA, pH 7.4) ensuring that the volume of the buffer is about ten times the volume of the cell pellet. The cells are pooled into a centrifuge tube (50 mL) and homogenized with a Polytron at setting 6 for 10 sec. The homogenate is transferred into a Potter-Elvjehm homogenizer and homogenized with 3 strokes. The homogenate is centrifuged at 1500×g for 10 min at 4° C. (3100 rpm using SORVAL, model RT6000D, using a rotor for 50 mL tubes). The pellet is discarded. The supernatant is centrifuged at 100,000×g for 60 min. at 4° C. (Beckman L8-80M ultracentrifuge; spin at 37,500 rpm with rotor type 70 Ti for 50 mL tubes; 38,000 rpm with rotor type 8OTi for 15 mL tubes; or 35,800 rpm with rotor type 45Ti). The supernantant is discarded and the pellet suspended in 3 to 4 mL of Tris buffer (50 mM TRIS-HCl, pH 7.4). The protein content is estimated by the Bradford or Lowry method. The volume of the membrane suspension is adjusted with the membrane buffer (50 mM Tris-HCl containing 0.1% BSA and 0.1 mM PMSF) to give 3.0 mg/mL (or as appropriate) of protein. The membranes are aliquoted and stored at −70° C.
[0190] C. Radioligand Binding Assay:
[0191] In wells of a 96-well format microtiter plate, is added 90, 110 or 130 μL (to make up a final volume of 200 μL) of assay buffer containing 50 mM of Tris-HCl (pH 7.4), BSA (heat inactivated, protease-free), 5 mM of 0.1% MgCl 2 , 1 mg % aprotinin, 1 mg % leupeptin, 2 mg % 1,10-phenanthroline, 10 mg % trypsin inhibitor, and 0.1 mM PMSF. The inhibitors are added on the day of the experiment. The components are mixed at room temperature, and then kept in ice bath following adjustment of the pH to 7.4. To each well is added 20 μL of unlabeled oxytocin (to give a final concentration of 0.1 to 10 nM for standard curve and 1000 nM for non specific binding) or test compounds in 50% DMSO (e.g. for final concentrations of 0.1 to 1000 nM or as appropriate) or 50% DMSO as vehicle control. For oxytocin and other peptide ligands, 20 μL of 50% DMSO is added and the assay buffer volume is adjusted accordingly.
[0192] To each well is added 50 μL of frozen membrane suspension thawed immediately prior to use and diluted in assay buffer to the required concentration (equivalent to 25 to 50 μg of protein/well as needed). 20 μL of 8 nM [ 3 H]oxytocin in the assay buffer, prepared just before use is added and incubated at room temperature for 60 min. shaking the plate on a mechanical shaker for the first 15 min. The incubation is stopped by rapid filtration of the plate contents followed by washing with ice-cold buffer (50 mM Tris-HCl, pH 7.4) using a cell harvester (Tomtek and Printed filtermat-B filter paper). The filter paper is thoroughly dried (7-12 min. in a microwave oven) and impregnated with MeltiLex B/H melt-on scintillation wax sheets and the radioactivity counted in a betaplate scintillation counter.
[0193] Binding data is either reported as percent inhibition at a certain concentration or if an IC 50 was calculated, as a nanomolar concentration. The results of these tests on representative compounds of this invention are shown in Table I.
TABLE 1 Binding to membranes of Chinese Hamster Ovary (CHO) cell line stably transfected with human vasopressin V 1a receptor subtype, human vasopressin V 2 receptor subtype and human oxytocin receptor V 2 OT V 1a % inhibition % inhibition @ 100 % inhibition @ 100 (IC 50 , nM)*n @ Example nM (IC 50 , nM)* nM (IC 50 , nM)* 100 nM 1 (11.2) 9 18 2 (16.8) (3180) (1418) 3 (45) (>3000) (>3000) 4 (2.44) (791.78) (463.73) 5 (10.2) (>3000) (433) 6 (7.51) (927.96) (308.77) 7 (3.34) (803) (407) 8 (4.65) (801) (237) 24 50 7 26 25 50 21 33 26 47 17 23 27 22 20 16 28 50 28 20 29 42 0 12 30 25 −7 14 31 18 6 31 32 47 13 21 33 42 23 21 34 5 5 5 35 27 4 14 36 46 −3 24 37 60 12 7 38 26 0 21 39 35 10 11 40 17 15 11 41 41 20 16 42 33 −11 8 43 18 −6 7 44 22 11 31 45 37 5 19 46 31 7 8 47 1 −1 6 48 15 0 9 49 58 1 26 50 67 26 17 51 31 2 16 52 51 16 8 53 6 11 13 54 55 30 18 55 50 −7 5 56 31 −11 11 57 32 2 33 58 37 9 22 59 40 12 4 60 11 4 15 61 26 6 14 62 (10.68) (177) (1491) 63 (5.08) (273.45) (714.49) 64 91 21 13 65 95 25 16 66 92 58 24 67 91 40 24 68 93 81 13 69 94 72 15 70 77 8 10 71 81 20 24 72 89 54 11 73 32 6 16 74 91 63 1 75 62 −1 9 76 62 11 21 77 21 5 10 78 59 6 8 79 49 18 10 80 50 6 8 81 50 −6 5 82 27 −1 8 83 30 9 22 84 46 3 14 85 32 −5 5 86 21 1 11 87 52 1 4 88 44 8 13 89 67 29 15 90 44 14 11 91 44 11 10 92 30 21 0 93 69 50 27 94 37 0 5 95 7 1 −1 96 28 7 22 97 36 4 16 98 39 24 10 99 13 −7 12 100 24 10 0 101 (2.23) (355) (270) 102 (4.14) (275) (534) 103 (6.25) (448.88) (318.40) 104 99 32 23 205 −9 0 6 106 98 68 −10 107 92 12 30 108 83 4 24 109 70 7 0 110 94 49 32 111 36 4 23 112 (3.87) (1597) (1126) 113 (10.77) (365) (545) 114 94 56 18 115 66 22 8 116 101 77 63 117 13 1 4 118 83 62 −10 119 83 9 17 120 67 6 16 121 57 17 −4 122 61 9 −10 123 95 71 30 124 24 11 18 125 94 17 −10 126 93 38 5 127 102 66 15 128 88 31 10 129 98 54 28 130 0 5 12 131 99 83 −5 132 99 26 25 133 87 19 15 134 88 30 1 135 96 68 35 136 44 7 19 137 95 −1 11 138 97 8 42 139 96 21 34 140 95 −3 29 141 96 9 40 142 93 −5 16 144 57 11 2 145 22 −1 2 146 38 11 15 147 64 15 21
[0194] The following examples are presented to illustrate rather than limit the scope of this invention.
EXAMPLE 1
[10-(2-Methyl-2′-trifluoromethyl-biphenyl-4-carbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl]-(4-pyridin-4-yl)-piperazin-1-yl)-methanone
Step A. 4-Bromo-3-methylbenzoic acid methyl ester
[0195] To a suspension of 4-bromo-3-methylbenzoic acid (10.0 g, 46.5 mmol) in methanol (125 mL) was added concentrated sulfuric acid (1 mL). The reaction was heated at reflux overnight with a homogeneous solution obtained after several minutes of heating. After cooling, the methanol was removed in vacuo and the residue was dissolved in dichloromethane and washed with saturated aqueous sodium bicarbonate. The organic phase was dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give 10.2 g of title compound as a brown solid, m.p. 41-43° C.
[0196] [0196] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.39 (s, 3H), 3.85 (s, 3H), 7.64-7.72 (m, 2H), 7.88-7.89 (m, 1H).
[0197] MS [EI, m/z]: 228 [M] + .
[0198] Anal. Calcd. for C 9 H 9 BrO 2 : C, 47.19; H 3.90. Found: C, 47.22; H, 3.80.
Step B. (2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-carboxylic acid methyl ester
[0199] A mixture of 4-bromo-3-methylbenzoic acid methyl ester of Step A (2.0 g, 8.7 mmol), 2-trifluoromethyl-phenyl boronic acid (1.65 g, 8.7 mmol) and sodium carbonate (4.1 g, 38.7 mmol) in toluene:ethanol:water (50 mL:25 mL: 25 mL) was purged with nitrogen for 1 hour. After addition of the tetrakis(triphenylphosphine) palladium(0) catalyst (0.50 g, 0.43 mmol) the reaction was heated at 100° C. overnight. The cooled reaction mixture was filtered through Celite and the cake washed with ethyl acetate. The organic layer was washed with water, dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a brown oil. Purification by flash chromatography with a solvent gradient of 25% to 50% dichloromethane in hexane provided 2.0 g of the title compound as a colorless oil.
[0200] [0200] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.03 (s, 3H), 3.88 (s, 3H), 7.26 (d, 1H), 7.34 (d, 1H), 7.66 (t, 1H), 7.75 (t, 1H), 7.81-7.83 (m, 1H), 7.86-7.88 (m, 1H), 7.90-7.91 (m, 1H)
[0201] MS [ESI, m/z]: 312 [M+NH 4 ] + .
[0202] Anal. Calcd. for C 16 H 13 F 3 O 2 : C, 65.31; H, 4.45. Found: C, 64.92; H, 4.54.
Step C. (2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-carboxylic acid
[0203] To a solution of (2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-carboxylic acid methyl ester of Step B (1.9 g, 6.5 mmol) in tetrahydrofuran (30 mL) was added 1 N sodium hydroxide (13 mL, 13 mmol). The reaction mixture was heated at reflux overnight, then cooled and acidified with 2 N hydrochloric acid. The aqueous layer was extracted with ethyl acetate and the combined extracts were dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give 1.65 g of the title compound as a white solid, m.p. 171-174° C.
[0204] [0204] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.02 (s, 3H), 7.23 (d, 1H), 7.34 (d, 1H), 7.65 (t, 1H), 7.75 (t, 1H), 7.79-7.81 (m, 1H), 7.86-7.89 (m, 2H), 13.00 (br, 1H).
[0205] MS [(−)ESI, m/z]: 279 [M−H] − .
[0206] Anal. Calcd. for C 15 H 11 F 3 O 2 : C, 64.29; H, 3.96. Found: C, 64.26; H, 3.80.
Step D. (10,11-Dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-10-yl)-[(2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]methanone
[0207] A suspension of (2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-carboxylic acid of Step C (0.50 g, 1.78 mmol) in thionyl chloride (3 mL) was heated at reflux for 90 minutes. After cooling, the thionyl chloride was removed in vacuo and the residue dissolved in toluene. The solution was concentrated in vacuo to yield the crude acid chloride as a brown oil. The acid chloride was dissolved in dichloromethane (5 mL) and slowly added to a solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (0.49 g, 2.66 mmol) and N,N-diisopropylethyl amine (0.68 mL, 3.90 mmol) in dichloromethane (15 mL). After stirring for 2 hours, the reaction was quenched with water. The organic layer was sequentially washed with 1 N hydrochloric acid, 1 N sodium hydroxide and brine, dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a yellow foam. Purification by flash chromatography using a solvent gradient of 15 to 25% ethyl acetate in hexane gave a white foam which was crystallized by sonication from ethanol/hexane to provide the title compound (0.55 g) as a white solid, m.p. 127-130° C.
[0208] [0208] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.86 (s, 3H), 4.80-5.40 (br, 4H), 5.93-5.98 (m, 2H), 6.85 (t, 1H), 6.91-6.96 (m, 2H), 7.03-7.05 (m, 1H), 7.10-7.14 (m, 1H), 7.19-7.24 (m, 2H), 7.29 (s, 1H), 7.47-7.49 (m, 1H), 7.61 (t, 1H), 7.70 (t, 1H), 7.81 (d, 1H).
[0209] MS [EI, m/z]: 446 [M] + .
[0210] Anal. Calcd. for C 27 H 21 F 3 N 2 O: C, 72.64; H, 4.74; N, 6.27. Found: C, 72.48; H, 4.57; N, 6.16.
Step E. 2,2,2-Trichloro-1-(10-{[2-methyl-2′-trifluoromethyl-[1-1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl)ethanone
[0211] To a solution of (10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-10-yl)-[(2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]methanone of Step D (1.87 g, 4.19 mmol) in dichloromethane (20 mL) was added N,N-diisopropylethyl amine (1.46 mL, 8.38 mmol) followed by the slow addition of trichloroacetyl chloride (1.45 mL, 13.0 mmol). The reaction mixture was stirred overnight at room temperature, and then quenched with water. The organic phase was washed with 0.1 N hydrochloric acid followed by water, then dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a green oil. Purification by flash chromatography using a solvent system of 20% ethyl acetate in hexane provided 2.2 g of title product as a pale, yellow foam.
[0212] [0212] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.84 (s, 3H), 5.25 (br, 2H), 5.97 (br, 2H), 6.37 (d, 1H), 6.89-6.92 (m, 2H), 7.02-7.04 (m, 1H), 7.06-7.10 (m, 1H), 7.15-7.22 (m, 2H), 7.28 (s, 1H), 7.41-7.46 (m, 2H), 7.58 (t, 1H), 7.67 (t, 1H), 7.79 (d, 1H).
[0213] MS [(+)APCI, m/z]: 591 [M+H] + .
[0214] Anal. Calcd. for C 29 H 20 Cl 3 F 3 N 2 O 2 +0.20 C 4 H 8 O 2 +0.80 H 2 O: C, 57.37; H, 3.75; N, 4.49. Found: C, 57.06; H, 3.39; N, 4.50.
Step F. 10-(2-Methyl-2′-trifluoromethyl-biphenyl-4-carbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0215] To a solution of 2,2,2-trichloro-1-(10-{[2-methyl-2′-(trifluoromethyl)[1-1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl)ethanone of Step E (2.3 g, 3.9 mmol) in acetone (20 mL) was added 2.5 N sodium hydroxide (3.1 mL, 7.8 mmol). After stirring overnight, the reaction mixture was acidified with 2 N hydrochloric acid (4.3 mL, 8.6 mmol) and then concentrated in vacuo. The residue was partitioned between ethyl acetate and water. The organic layer was dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a brown solid. Trituration with diethyl ether/hexane provided the title compound (1.32 g) as a white solid, m.p. 233-235° C.
[0216] [0216] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.84 (s, 3H), 5.17 (br, 2H), 5.94 (br, 2H), 6.10-6.11 (m, 1H), 6.76 (d, 1H), 6.85-6.91 (m, 2H), 7.00-7.06 (m, 2H), 7.12-7.16 (m, 1H), 7.21 (d, 1H), 7.25 (s, 1H), 7.32-7.34 (m, 1H), 7.59 (t, 1H), 7.68 (t, 1H), 7.79 (d, 1H), 12.33 (br, 1H).
[0217] MS [ESI, m/z]: 491 [M+H] + .
[0218] Anal. Calcd. for C 28 H 21 F 3 N 2 O 3 : C, 68.57; H, 4.32; N, 5.71. Found: C, 68.39; H, 4.25; N, 5.64.
Step G. [10-(2-Methyl-2′-trifluoromethyl-biphenyl-4-carbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl]-(4-pyridin-4-yl-piperazin-1-yl)-methanone
[0219] To a solution of 10-(2-methyl-2′-trifluoromethyl-biphenyl-4-carbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step F (0.50 g, 1.02 mmol), 1-(4-pyridinyl)-piperazine (0.20 g, 1.23 mmol) and 1-hydroxybenzotriazole monohydrate (0.15 g, 1.11 mmol) in N,N-dimethylformamide (4 mL) was added 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (0.22 g, 1.15 mmol) followed by N,N-diisopropylethyl amine (0.27 mL, 1.55 mmol). The reaction mixture was stirred overnight, diluted with ethyl acetate and washed with water and saturated aqueous sodium bicarbonate. The organic phase was then dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a yellow oil. Purification by flash chromatography using a solvent system of 10% methanol in chloroform provided 0.39 g of the title product which was dissolved in dichloromethane and concentrated in vacuo to a white foam.
[0220] [0220] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.83 (s, 3H), 3.40-3.43 (m, 4H), 3.74-3.76 (m, 4H), 5.15 (broad s, 2H), 5.44 (s, 2H), 6.09 (d, 1H), 6.32 (d, 1H), 6.82-6.90 (m, 4H), 6.99-7.06 (m, 2H), 7.13 (t, 1H), 7.22 (d, 1H), 7.26 (s, 1H), 7.40-7.42 (m, 1H), 7.58 (t, 1H), 7.67 (t, 1H), 7.79 (d, 1H), 8.17-8.19 (m, 2H).
[0221] MS [(+)APCI, m/z]: 636 [M+H] + .
[0222] Anal. Calcd. for C 37 H 32 F 3 N 5 O 2 +0.14 CH 2 Cl 2 +0.04 C 3 H 7 NO: C, 68.80; H, 5.05; N, 10.85. Found: C, 66.63; H, 4.97; N, 10.41.
EXAMPLE 2
10-{[2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-3-({4-[(1-oxidopyridin-3-yl)methyl]piperazin-1-yl}carbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
Step A. 3-Chloromethyl-pyridine-1-oxide
[0223] To a solution of 3-hydroxymethyl-pyridine N-oxide (1.0 g, 8.0 mmol) in dichloromethane (40 mL) was added thionyl chloride (10 mL, 137 mmol). After stirring for 2 hours, the reaction mixture was concentrated in vacuo. The residue was partitioned between dichloromethane and saturated aqueous sodium bicarbonate. The aqueous layer was repeatedly extracted with dichloromethane. The combined organic layers were dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give 0.60 g of the title product as a white solid, m.p. 133-137° C.
[0224] [0224] 1 H NMR (DMSO-d 6 , 400 MHz): δ4.74 (s, 2H), 7.40-7.45 (m, 2H), 8.17-8.20 (m, 1H), 8.35 (s, 1H).
[0225] MS [(+)APCI, m/z]: 144 [M+H] + .
[0226] Anal. Calcd. for C 6 H 6 ClNO: C, 50.19; H, 4.21; N, 9.76. Found: C, 49.56; H, 4.21; N, 9.58.
Step B. 4-[[10,11-Dihydro-10-[[2-methyl-2-trifluoromethyl-[1,1-biphenyl]-4-yl]carbonyl]-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl]carbonyl]-1-piperazinecarboxylic acid, tert-butyl ester
[0227] 10-(2-Methyl-2-trifluoromethyl-biphenyl-4-carbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Example 1, Step F (1.0 g, 2.04 mmol), 1-(tert-butoxycarbonyl)piperazine (0.46 g, 2.47 mmol) and 1-hydroxybenzotriazole monohydrate (0.30 g, 2.22 mmol) were dissolved in N,N-dimethylformamide (8 mL). 1-[3-(dimethylamino)propyl]-3-ethyl carbodiimide hydrochloride (0.43 g, 2.24 mmol) was then added followed by N,N-diisopropylethyl amine (0.55 mL, 3.09 mmol). The reaction mixture was stirred overnight, diluted with ethyl acetate and washed with water and saturated aqueous sodium bicarbonate. The organic phase was then dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a brown oil. Purification by flash chromatography using a solvent gradient from 30% to 50% of ethyl acetate in hexane provided 1.1 g of the desired title compound as a white foam, m.p. 104-121° C. This material was redissolved in dichloromethane and concentrated in vacuo to a white foam.
[0228] [0228] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.41 (s, 9H), 1.83 (s, 3H), 3.38 (br, 4H), 3.59-3.61 (m, 4H), 5.15 (br, 2H), 5.41 (s, 2H), 6.07 (d, 1H), 6.28 (d, 1H), 6.85-6.90 (m, 2H), 6.99-7.06 (m, 2H), 7.12-7.16 (m, 1H), 7.21 (d, 1H), 7.25 (s, 1H), 7.40-7.42 (m, 1H), 7.58 (t, 1H), 7.67 (t, 1H), 7.79 (d, 1H).
[0229] MS [(+)APCI, m/z]: 659 [M+H] + .
[0230] Anal. Calcd. for C 37 H 37 F 3 N 4 O 4 +0.09 CH 2 Cl 2 +0.18 C 4 H 8 O 2 C, 66.56; H, 5.71; N, 8.21. Found: C, 66.27; H 5.40; N, 8.00.
Step C. 10,11-Dihydro-10-[[2-methyl-2-(trifluoromethyl)[1,1-biphenyl]-4-yl]carbonyl]-3-(1-piperazinylcarbonyl)-5H-pyrrolo[2,1-c][1,4]benzodiazepine hydrochloride salt
[0231] The 4-[[10,11-dihydro-10-[[2-methyl-2-(trifluoromethyl)[1,1-biphenyl]-4-yl]carbonyl]-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl]carbonyl]-1-piperazinecarboxylic acid, tert-butyl ester of Step B (0.85 g, 1.29 mmol) was then added in one portion to stirred ethyl acetate (10 mL) saturated with hydrogen chloride gas at 0° C. The reaction mixture was stirred for 90 minutes under anhydrous conditions. A precipitate formed after several minutes. The reaction was then warmed to room temperature and diluted with diethyl ether. The precipitated product was collected by filtration and dried under high vacuum to provide 0.65 g of the desired title compound hydrochloride salt as an off-white foam.
[0232] [0232] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.84 (s, 3H), 3.16 (br, 4H), 3.83-3.85 (m, 4H), 5.15 (br, 2H), 5.43 (s, 2H), 6.09 (d, 1H), 6.38 (d, 1H), 6.87-6.91 (m, 2H), 6.99-7.01 (m, 1H), 7.06 (t, 1H), 7.13-7.17 (m, 1H), 7.21 (d, 1H), 7.26 (s, 1H), 7.44-7.46 (m, 1H), 7.59 (t, 1H), 7.68 (t, 1H), 7.79 (d, 1H), 9.28 (br, 2H).
[0233] MS [(+)APCI, m/z]: 559 [M+H] + .
[0234] Anal. Calcd. for C 32 H 29 F 3 N 4 O 2 +1.0 HCl+1.00 H 2 O+0.06 C 4 H 10 O: C, 62.70; H, 5.32; N, 9.07. Found: C, 62.42; H, 5.22; N, 8.94.
Step D. 10-{[2-methyl-2′-(trifluoromethyl)[1,1′-biphenyl]-4-yl]carbonyl}-3-({4-[(1-oxidopyridin-3-yl)methyl]piperazin-1-yl}carbonyl)-10,11-dihydro-5H-pyrrolo[2,1c][1,4]benzodiazepine
[0235] A mixture of the 10,11-dihydro-10-[[2-methyl-2-(trifluoromethyl)[1,1-biphenyl]-4-yl]carbonyl]-3-(1-piperazinylcarbonyl)-5H-pyrrolo[2,1-c][1,4]benzodiazepine hydrochloride salt of Step C (0.50 g, 0.84 mmol), 3-chloromethyl-pyridine-1-oxide of Step A (0.11 g, 0.77 mmol) and N,N-diisopropylethyl amine (0.30 mL, 1.70 mmol) in N,N-dimethylformamide (10 mL) was heated at 50° C. The reaction was then cooled, quenched with saturated aqueous sodium bicarbonate and extracted with chloroform. The combined organic layers were dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a yellow oil. Purification by flash chromatography using a solvent system of 5% methanol in dichloromethane provided 0.47 g of the title compound as a yellow foam.
[0236] [0236] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.84 (s, 3H), 2.42 (br, 4H), 3.52 (m, 2H), 3.64 (br, 4H), 5.15 (br, 2H), 5.40 (s, 2H), 6.06 (d, 1H), 6.24 (d, 1H), 6.84-6.90 (m, 2H), 6.99-7.06 (m, 2H), 7.15 (t, 1H), 7.21 (d, 1H), 7.25 (s, 1H), 7.29 (d, 1H), 7.35-7.42 (m, 2H), 7.58 (t, 1H), 7.68 (t, 1H), 7.79 (d, 1H), 8.11 (d, 1H), 8.17 (s, 1H).
[0237] MS [(+)APCI, m/z]: 666 [M+H] + .
[0238] Anal. Calcd. for C 38 H 34 F 3 N 5 O 3 +1.00 H 2 O+0.11 CH 2 Cl 2 : C, 66.04; H, 5.27; N, 10. Found: C, 65.88; H, 5.03; N, 10.03.
EXAMPLE 3
3-({4-[(2-Methyl-1-oxidopyridin-3-yl)methyl]piperazin-1-yl}carbonyl)-10-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
Step A. 3-Hydroxymethyl-2-methyl-pyridine
[0239] Prepared according to a slightly modified procedure of I. M. Bell et al., J. Med. Chem. 41, 2146-2163 (1998). To a stirred solution of ethyl 2-methylnicotinate (2.0 g, 12.1 mmol) in tetrahydrofuran (40 mL) cooled to 0° C. was slowly added a 1 M solution of diisobutyl aluminum hydride in tetrahydrofuran (30 mL, 30 mmol). After 5 minutes, the reaction was quenched with saturated aqueous sodium bicarbonate and saturated aqueous sodium potassium tartrate. The aqueous phase was repeatedly extracted with chloroform. The combined organic layers were dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give 2.5 g of the crude title compound as a yellow oil. The crude material was used as such in the next step.
[0240] [0240] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.40 (s, 3H), 4.49 (d, 2H), 5.23 (t, 1H), 7.16-7.19 (m, 1H), 7.67-7.69 (m, 1H), 8.28-8.31 (m, 1H).
[0241] MS [(+)APCI, m/z]: 124 [M+H] + .
Step B. 3-Chloromethyl-2-methyl-pyridine
[0242] Prepared essentially according to the procedure of I. M. Bell et al., J. Med. Chem. 41, 2146-2163 (1998). To a stirred solution of the 3-hydroxymethyl-2-methyl-pyridine of Step A (2.5 g, 20.3 mmol) in dichloromethane (100 mL) was added thionyl chloride (15 mL, 206 mmol). After stirring for 2 hours, the reaction mixture was concentrated in vacuo. The residue was partitioned between dichloromethane and saturated aqueous sodium bicarbonate. The aqueous layer was repeatedly extracted with dichloromethane. The combined organic layers were dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give 1.35 g of the title compound as an orange oil which was immediately used in the next step.
[0243] [0243] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.54 (s, 3H), 4.82 (s, 2H), 7.21-7.24 (m, 1H), 7.75-7.78 (m, 1H), 8.39-8.41 (m, 1H).
[0244] MS [(+)APCI, m/z]: 142 [M+H] + .
Step C. 3-Chloromethyl-2-methyl-pyridine 1-oxide
[0245] Prepared essentially according to the procedure of I. M. Bell et al., J. Med. Chem. 41, 2146-2163 (1998). To a stirred solution of the crude 3-hydroxymethyl-2-methyl-pyridine of Step B (1.35 g, 9.53 mmol) in chloroform (50 mL) was added 90% m-chloroperbenzoic acid (2.0 g, 10.4 mmol). After stirring overnight at room temperature, an additional quantity of 90% m-chloroperbenzoic acid (1.0 g, 5.2 mmol) was added. The reaction mixture was stirred for an additional 3 hours and then quenched with saturated aqueous sodium bicarbonate. The organic layer was washed with water, dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a yellow solid. Purification by flash chromatography using a solvent system of 3% methanol in chloroform provided 0.85 g of the title compound as a brown-orange amorphous solid.
[0246] [0246] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.41 (s, 3H), 4.84 (s, 2H), 7.26-7.29 (m, 1H), 7.38-7.40 (m, 1H), 8.25-8.27 (m, 1H).
[0247] MS [(+)APCI, m/z]: 158 [M+H] + .
[0248] Anal. Calcd. for C 7 H 8 ClNO: C, 53.35; H, 5.12; N, 8.89. Found: C, 52.69; H, 4.64; N, 8.06.
Step D. 3-({4-[(2-Methyl-1-oxidopyridin-3-yl)methyl]piperazin-1-yl}carbonyl)-10-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
[0249] A stirred mixture of the 10,11-dihydro-10-[[2-methyl-2-(trifluoromethyl)[1,1-biphenyl]-4-yl]carbonyl]-3-(1-piperazinylcarbonyl)-5H-pyrrolo[2,1-c][1,4]benzodiazepine hydrochloride salt of Example 2, Step C (0.50 g, 0.84 mmol), 3-chloromethyl-2-methyl-pyridine 1-oxide of Step B (0.13 g, 0.82 mmol) and N,N-diisopropylethyl amine (0.30 mL, 1.70 mmol) in N,N-dimethylformamide (10 mL) was heated at 50° C. overnight. The reaction mixture was then cooled, quenched with saturated aqueous sodium bicarbonate and extracted with chloroform. The combined organic layers were dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a yellow oil. Purification by flash chromatography using a solvent system of 5% methanol in dichloromethane provided 0.41 g of the title product as a white foam.
[0250] [0250] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.84 (s, 3H), 2.40 (s, 3H), 2.43 (br, 4H), 3.53 (s, 2H), 3.62 (br, 4H), 5.15 (br, 2H), 5.41 (s, 2H), 6.06 (d, 1H), 6.23 (d, 1H), 6.85-6.90 (m, 2H), 6.99-7.06 (m, 2H), 7.13-7.17 (m, 1H), 7.20-7.26 (m, 4H), 7.38-7.40 (m, 1H), 7.58 (t, 1H), 7.68 (t, 1H), 7.79 (d, 1H), 8.19-8.20 (m, 1H).
[0251] MS [ESI, m/z]: 680 [M+H] + .
[0252] Anal. Calcd. for C 39 H 36 F 3 N 5 O 3 +0.50 H 2 O+0.40 CH 2 Cl 2 : C, 65.48; H, 5.27; N, 9.69. Found: C, 65.08; H, 5.04; N, 9.62.
EXAMPLE 4
N-Methyl-10-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-[(1-oxidopyridin-3-yl)methyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. tert-Butyl methyl(pyridin-3-ylmethyl)carbamate
[0253] To a stirred solution of 3-(methylaminomethyl) pyridine (1.0 g, 8.2 mmol) in dichloromethane (20 mL) was added di-tert-butyl dicarbonate (1.8 g, 8.2 mmol). After 10 minutes, the reaction was quenched with water. The organic layer was washed with 5% aqueous sodium bicarbonate, dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give 1.8 g of crude product as a pale yellow oil, which was used as such in the next step.
[0254] [0254] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.10 (s, 9H), 2.77 (s, 3H), 4.38 (s, 2H), 7.35-7.38 (m, 1H), 7.60-7.62 (d, 1H), 8.44-8.48 (m, 2H).
[0255] MS [ESI, m/z]: 223 [M+H] + .
Step B. tert-Butyl methyl[(1-oxidopyridin-3-yl)methyl]carbamate
[0256] To a stirred solution of tert-butyl methyl(pyridin-3-ylmethyl)carbamate of Step A (0.50 g, 2.25 mmol) in dichloromethane (15 mL) was added 90% m-chloroperbenzoic acid (1.3 g, 6.8 mmol). After stirring overnight, the reaction was quenched with saturated aqueous sodium bicarbonate. The organic layer was dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give 0.38 g of product as a colorless oil.
[0257] [0257] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.40 (br, 9H), 2.80 (s, 3H), 4.32 (s, 2H), 7.16 (d, 1H), 7.39 (t, 1H), 8.07 (s, 1H), 8.12 (d, 1H).
[0258] MS [ESI, m/z]: 239 [M+H] + .
Step C. Methyl-(1-oxy-pyridin-3-ylmethyl)-amine dihydrochloride
[0259] Hydrogen chloride gas was bubbled for 15 minutes into a solution of tert-butyl methyl[(1-oxidopyridin-3-yl)methyl]carbamate of Step B (0.38 g, 1.60 mmol) in ethyl acetate (10 mL) kept at 0° C. A drying tube was attached, and the reaction warmed to room temperature while stirring for 1 hour. The reaction was then concentrated in vacuo to give 0.31 g of the title product as an amorphous white solid, which is used as such in the nest step.
[0260] [0260] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.52 (t, 3H), 4.16 (t, 2H), 7.64-7.67 (m, 1H), 7.86(d, 1H), 8.46-8.48 (m, 1H), 8.60 (br, 1H), 8.68 (s, 1H), 9.75 (br, 2H).
[0261] MS [(+)APCI, m/z]: 139 [M+H] + .
[0262] Anal. Calcd. for C 7 H 10 N 2 O+2 HCl: C, 39.83; H, 5.73; N, 13.27. Found: 40.01; H, 5.77; N, 13.19.
Step D. N-methyl-10-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-[(1-oxidopyridin-3-yl)methyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0263] To a stirred solution of the 10-(2-methyl-2′-trifluoromethyl-biphenyl-4-carbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Example 1, Step F (0.50 g, 1.02 mmol), methyl-(1-oxy-pyridin-3-ylmethyl)-amine dihydrochloride of Step C (0.26 g, 1.23 mmol) and 1-hydroxybenzotriazole (0.16 g, 1.18 mmol) in N,N-dimethylformamide (4 mL) was added 1-[3-(dimethylamino)propyl]-3-ethyl carbodiimide hydrochloride (0.21 g, 1.10 mmol) followed by N,N-diisopropylethyl amine (0.73 mL, 4.10 mmol). The reaction mixture was stirred overnight, diluted with ethyl acetate and washed with water and saturated aqueous sodium bicarbonate. The organic phase was then dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a yellow foam. Purification by flash chromatography eluting with 2% methanol in chloroform provided 0.52 g of the title compound, which was redissolved in dichloromethane and concentrated in vacuo to give a white foam.
[0264] [0264] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.84 (s, 3H), 3.07 (s, 3H), 4.67 (s, 2H), 5.15 (br, 2H), 5.49 (s, 2H), 6.08 (d, 1H), 6.40 (br, 1H), 6.86-6.91 (m, 2H), 7.00-7.07 (m, 2H), 7.13-7.17 (m, 1H), 7.22 (d, 1H), 7.26-7.29 (m, 2H), 7.39-7.45 (m, 2H), 7.59 (t, 1H), 7.68 (t, 1H), 7.80 (d, 1H), 8.15-8.19 (m, 2H).
[0265] MS [ESI, m/z]: 611 [M+H] + .
[0266] Anal. Calcd. for C 35 H 29 F 3 N 4 O 3 +0.14 CH 2 Cl 2 +0.14 CHCl 3 : C, 66.29; H, 4.64; N, 8.76. Found: C, 64.26; H, 3.98; N, 8.39.
EXAMPLE 5
10-{[6-Chloro-3-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. 4-Iodo-5-chloro-2-methoxy benzoic acid
[0267] A stirred solution of 4-amino-5-chloro-2-methoxy benzoic acid (12.25 g , 60.8 mmol) in water (136 mL) and concentrated sulfuric acid (34 mL) was cooled to 0° C. in a flask fitted with an overhead stirrer. A solution of sodium nitrite (4.62 g , 66.9 mmol) in water (26 mL) was added dropwise while keeping the internal temperature around 0° C. Potassium iodide (11.11 g , 66.9 mmol) and iodine (4.24g , 33.5 mmol) were dissolved in water (130 mL) and added dropwise to the stirred reaction mixture. After 2 hours the reaction was extracted with ethyl acetate. The organic extracts were then washed with 10% sodium thiosulfate and brine, then dried over magnesium sulfate, filtered and evaporated to dryness to yield 11.32 g of the title compound, m.p. 150-151° C. This material was used without further purification.
[0268] [0268] 1 H NMR (DMSO-d 6 , 400 MHz): δ13.03 (br, 1H), 7.70 (s, 1H), 7.63 (s, 1H), 3.82 (s, 3H).
[0269] MS [(−)-APCI, m/z]: 311 [M−H] −
[0270] Anal. Calcd. for C 8 H 6 ClIO 3 : C, 30.75; H, 1.94. Found: C, 31.28; H, 1.78.
Step B. 2-Chloro-2′-trifluoromethyl-5-methoxy-[1,1′-biphenyl]-4-carboxylic acid
[0271] To a stirred solution of 4-iodo-5-chloro-2-methoxy benzoic acid of Step A (3.12 g, 10 mmol) in N,N-dimethylformamide(100 mL) was added 2-trifluoromethyl phenyl boronic acid (5.70 g, 30 mmol) and potassium carbonate (12.73 g, 92 mmol). This mixture was purged with nitrogen and then treated with a catalytic amount of tetrakis(triphenylphosphine) palladium(0) (0.58 g, 0.5 mmol). The reaction was heated to reflux overnight, cooled, acidified with 2N hydrochloric acid and extracted with ethyl acetate. The organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and evaporated to provide a nearly quantitative amount of the title acid which was used in the next step without further purification.
Step C. 10-{[6-Chloro-3-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
[0272] A stirred solution of the 2-chloro-2′-trifluoromethyl-5-methoxy-[1,1′-biphenyl]-4-carboxylic acid of Step B (3.46 g, 10.46 mmol) in tetrahydrofuran (20 mL) containing a catalytic amount of N,N-dimethylformamide was treated dropwise with thionyl chloride (1.36 g, 11.51 mmol). The reaction mixture was stirred for 2 hours, and then added dropwise to a solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (1.92 g 10.46 mmol) in tetrahydrofuran (20 mL) containing triethylamine (2.32 g, 23 mmol). The reaction mixture was stirred for 2 hours, diluted with dichloromethane and washed with saturated aqueous sodium bicarbonate and brine. The organic layer was dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness. Trituration of the residue with acetone gave 3.14 g of the title compound. Recrystallization from acetone/hexane provided white crystals, m.p. 208-210° C.;
[0273] [0273] 1 H NMR (DMSO-d 6 , 400 MHz) δ3.46 (s, 3H), 5.16-5.20 (br, d, 3H), 5.89 (t, 1H), 5.97 (s, 1H), 6.70 (s, 1H), 6.80 (t, 1H), 7.80-7.00 (m, 10H).
[0274] MS [(+) ESI, m/z]: 497 [M+H] + .
[0275] Anal. Calcd. for C 27 H 20 ClF 3 N 2 O 2 +0.5 H 2 O: C, 64.10; H, 4.18; N, 5.54. Found: C, 64.40; H, 3.97; N, 5.54.
Step D. 10-{[6-Chloro-3-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0276] A solution of the 10-{[6-chloro-3-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine of Step C (2.29 g, 4.6 mmol) in dichloromethane (30 mL) was treated with N,N-diisopropylethylamine (0.62 g, 4.84 mmol) and stirred for 10 minutes. Trichloroacetylchloride (0.92 g, 5.07 mmol) was then added dropwise. The reaction mixture was stirred overnight, diluted with dichloromethane, washed with 0.1N hydrochloric acid, saturated aqueous sodium bicarbonate, and brine. The organic phase was dried over anhydrous magnesium sulfate, filtered, and evaporated to yield the crude trichloroketone intermediate which without further purification, was dissolved in acetone and treated with an excess of 1N sodium hydroxide The mixture was stirred overnight, and then diluted with isopropyl acetate and acidified with 1 N hydrochloric acid. The organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness. The solid residue was triturated with methanol to provide the title compound (1.23 g ) as a white solid, m.p. 220-222° C. (dec).
[0277] [0277] 1 H NMR (DMSO-d 6 , 400 MHz) δ3.40 (s, 3H), 6.12 (d, 1H), 6.68 (s, 1H), 6.72 (d, 1H), 6.94 (s, 2H), 7.07 (t, 1H), 7.25 (d, 2H), 7.62 (t, 2H), 7.70 (t, 1H), 7.78 (d, 1H), 12.31 (br, 1H).
[0278] MS [(+)APCI, m/z]: 541 [M+H] + .
[0279] Anal. Calcd. for C 28 H 20 ClF 3 N 2 O 4 +0.25 H 2 O: C, 61.66; H, 3.79; N, 5.14. Found: C, 61.47; H, 3.64; N, 5.06.
Step E. 10-{[6-Chloro-3-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepine-3-carboxamide
[0280] To a stirred solution of the 10-{[6-chloro-3-methoxy-2′-(trifluoromethyl)[1,1′-biphenyl]-4-yl]carbonyl-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step D (0.250 g, 0.46 mmol) in N,N-dimethylformamide (2 mL) was added 3-(methylaminomethyl)pyridine (0.068 g, 0.55 mmol), 1-hydroxybenzotriazole (0.069 g, 0.51 mmol), 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (0.087 g, 0.51 mmol), and N,N-diisopropylethyl amine (0.090 g, 0.69 mmol). After stirring overnight, the reaction mixture was taken up in chloroform, washed with saturated aqueous sodium bicarbonate and brine, dried over magnesium sulfate, filtered and evaporated to yield the title compound (0.153 g) as a solid which was recrystallized from ethyl acetate, m.p. 124-126° C. The sample was shown to be 93% pure by analytical HPLC [Primesphere C-18 column (2.0×150 mm); mobile phase: 45/55 acetonitrile/water containing 0.1% phosphoric acid].
[0281] [0281] 1 H NMR (DMSO-d 6 , 400 MHz) δ3.02 (s, 3H), 3.41 (br, 3H), 4.74 (s, 2H), 5.36 (br, 1H), 5.40 (br, 1H), 6.08 (d, 1H), 6.33 (s, 1H), 6.68 (s, 1H), 6.95 (s, 2H), 7.09 (t, 1H), 7.25-7.90 (m, 8H), 8.51 (t, 2H).
[0282] MS [(+)APCI, m/z]: 645 [M+H] + .
[0283] Anal. Calcd. for C 35 H 28 ClF 3 N 4 O 3 : C, 65.17; H, 4.38; N, 8.69. Found: C, 63.84; H, 4.47; N, 9.00.
EXAMPLE 6
10-[(2′,6-Dichloro-3-methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. 2-Chloro-2′-chloro-5-methoxy-[1,1′-biphenyl]-4-carboxylic acid
[0284] To a stirred solution of 4-iodo-5-chloro-2-methoxy benzoic acid of Example 5, Step A (3.38 g, 10.8 mmol) in N,N-dimethylformamide (80 mL) was added 2-chloro phenyl boronic acid (5.07 g, 32.4 mmol) and potassium carbonate (3.44 g, 32.4 mmol). This mixture was purged with nitrogen and then treated with tetrakis(triphenylphosphine) palladium(0) (0.625 g, 0.54 mmol). The reaction was heated to reflux overnight, cooled, acidified with 2 N hydrochloric acid and extracted with ethyl acetate. The organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and evaporated to provide 2.4 g of the title acid which was used in the next step without further purification.
Step B. 10-{[2′,6-Dichloro-3-methoxy-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
[0285] A stirred solution of the 2-chloro-2′-chloro-5-methoxy-[1,1′-biphenyl]-4-carboxylic acid of Step A (2.29 g, 7.71 mmol) in tetrahydrofuran (20 mL) containing a catalytic amount of N,N-dimethylformamide was treated dropwise with thionyl chloride (1.00 g, 8.48 mmol). The reaction mixture was stirred for 2 hours, and then added dropwise to a solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (1.42 g, 7.71 mmol) in tetrahydrofuran (20 mL) containing triethylamine (1.72 g, 16.96 mmol). The reaction mixture was stirred for 2 hours, diluted with dichloromethane and washed with saturated aqueous sodium bicarbonate and brine. The organic layer was dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness. Trituration of the residue with ethyl acetate provided 1.93 g of the title compound which was recrystallized from ethyl acetate/hexanes as white crystals, m.p. 209-211° C.
[0286] [0286] 1 H NMR (DMSO-d 6 , 400 MHz) δ3.55 (s, 3H), 5.16-5.20 (br, m, 3H), 5.89 (t, 1H), 5.97 (s, 1H), 6.71 (s, 1H), 6.80 (s, 1H), 7.04-7.60 (m, 10H).
[0287] MS [(+)APCI, m/z]: 463 [M+H] + .
[0288] Anal. Calcd. for C 26 H 20 Cl 2 N 2 O 2 +0.25 C 4 H 8 O 2 : C, 66.81; H, 4.57; N, 5.77. Found: C, 66.76; H, 4.24; N, 5.93.
Step C. 10-[(2′,6-Dichloro-3-methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid.
[0289] A solution of the 10-[(2′,6-dichloro-3-methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine of Step B (1.36 g, 2.94 mmol) in dichloromethane (25 mL) was treated with N,N-diisopropylethyl amine (0.398 g, 3.08 mmol) and stirred for 10 minutes. Trichloroacetylchloride (0.587 g, 3.23 mmol) was then added dropwise. The reaction mixture was stirred overnight, diluted with dichloromethane, washed with 0.1 N hydrochloric acid, saturated aqueous sodium bicarbonate, and brine. The organic phase was dried over anhydrous magnesium sulfate, filtered, and evaporated to yield the crude trichloroketone intermediate which without further purification, was dissolved in acetone and treated with an excess of 1 N sodium hydroxide. The mixture was stirred overnight, and then diluted with isopropyl acetate and acidified with 1 N hydrochloric acid. The organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness. The solid residue was triturated with methanol to provide the title compound (1.02 g) as a white powder which was used as such in the next step.
Step D. 10-[(2′,6-Dichloro-3-methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0290] To a stirred solution of the 10-[(2′,6-dichloro-3-methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine carboxylic acid of Step C (0.250 g, 0.49 mmol) in N,N-dimethylformamide (2 mL) was added 3-(methylaminomethyl) pyridine (0,073 g, 0.59 mmol), 1-hydroxybenzotriazole (0.074 g, 0.54 mmol), 1-[3-(dimethylamino)propyl]-3-ethyl carbodiimide hydrochloride (0.093 g, 0.54 mmol), and N,N-diisopropylethyl amine (0.096 g, 0.74 mmol). After stirring overnight, the reaction mixture was taken up in chloroform, washed with saturated aqueous sodium bicarbonate and brine, dried over magnesium sulfate, filtered and evaporated to dryness. Trituration of the residue with ethyl acetate provided the title compound (0.225 g) as a white solid, m.p. 196-198° C., found to be 93.88% pure by analytical HPLC [Primesphere C-18 column (2.0×150 mm); mobile phase: 45/55 acetonitrile/water containing 0.1% phosphoric acid].
[0291] [0291] 1 H NMR (DMSO-d 6 , 400 MHz) δ3.02 (s, 3H), 3.46 (br, s, 3H), 4.74 (s, 2H), 5.38 (s, 2H), 6.08 (d, 1H), 6.33 (s, 1H), 6.69 (s, 1H), 6.98-7.72 (m, 12H), 8.49-8.53 (m, 2H).
[0292] MS [(+)APCI, m/z]: 611 [M+H] + .
[0293] Anal. Calcd. for C 34 H 28 Cl 2 N 4 O 3 : C, 66.78; H, 4.62; N, 9.16. Found: C, 64.98; H, 4.63, N, 9.45.
EXAMPLE 7
10-{[2-Methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. Trifluoromethanesulfonic acid 4-formyl-2-methoxy-phenyl ester
[0294] To a solution of vanillin (6.08 g, 40.0 mmol) and triethylamine (6.70 mL, 48.0 mmol) in dichloromethane (300 mL) was added dropwise a solution of trifluoromethanesulfonic anhydride (12.4 g, 44.0 mmol) in dichloromethane (100 mL) at 0° C. After stirring for 2 hours, the solution was concentrated, and the residue washed with water and extracted twice with ethyl acetate. Upon drying and concentrating, the residual dark oil was subjected to flash chromatography on silica gel eluting with 20% ethyl acetate in hexane providing the title product (8.91 g) as a light yellow oil, which was used in the next step without further purification.
Step B. 2-Methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-carboxaldehyde
[0295] A stirred solution of trifluoromethanesulfonic acid 4-formyl-2-methoxy-phenyl ester of Step A (6.9 g, 22.1 mmol), 2-trifluoromethyl phenyl boronic acid (5.4 g, 28.6 mmol) and potassium phosphate (13.2 g, 62.2 mmol) in N,N-dimethylformamide (120 mL) was degassed with nitrogen, whereupon a catalytic amount (0.285 g) of [1,4-bis-(diphenylphosphine)butane]palladium (II) dichloride was added. The solution was heated to 120° C. for 5 hours, poured into water and extracted with ethyl acetate. The combined extracts were washed with water, dried over anhydrous magnesium sulfate and filtered through a plug of silica gel. Removal of the solvent provided the crude title compound (4.54 g) as an oil, which was used as such in the next step.
[0296] [0296] 1 H NMR (200 MHz, CDCl 3 ): δ10.03 (s, 1H), 8.14 (d,1H), 7.31-7.56 (m, 6H), 3.91 (s, 3H).
Step C. 2-Methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-carboxylic acid
[0297] The 2-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-carboxaldehyde of Step B (0.95 g, 3.41 mmol) and sulfamic acid (0.43 g, 4.43 mmol) were dissolved in a mixture of tetrahydrofuran and water (1:1, v/v, 30 mL). Sodium chlorite (0.31 g, 4.43 mmol) was added under stirring, and the solution turned yellow. After 30 minutes, additional sodium chlorite (0.1 g) and sulfamic acid were added, and the solution stirred an additional hour. The solution was then concentrated, and the residue partitioned between ethyl acetate and water. The ethyl acetate layer was dried and concentrated to yield an oil, which solidified upon trituration with hexane to provide the title compound (0.84 g) as a yellow solid, which was used in the next step.
Step D. (10,11-Dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl)-(2-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-methanone
[0298] The 2-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-carboxylic acid of Step C (1.6 g, 5.40 mmol) was added to a flask containing toluene (30 mL), thionyl chloride (1.4 mL) and one drop of N,N-dimethylformamide. The solution was stirred at 70° C. for 1 hour and then concentrated in vacuo. The residue was diluted with dichloromethane (40 mL) and to this solution was added 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (0.94 g, 5.16 mmol). After the solution became homogeneous, N,N-diisopropylethyl amine (1.07 mL, 6.19 mmol) was added in one portion at 0° C. After 30 minutes the solution was concentrated, and the residue partitioned between water and ethyl acetate. The ethyl acetate was dried and concentrated to give a crude oil, which was chromatographed on silica gel eluting with 30% ethyl acetate in hexane to yield 1.2 g of product. The solid was recrystallized from ethyl acetate/hexane to provide the desired title product (0.87 g) as colorless crystals, m.p. 146-148° C.
[0299] [0299] 1 H NMR (400 MHz, DMSO-d 6 ) δ7.72 (d,1H), 7.62 (t,1H ), 7.53 (t,1H), 7.46 (d, 1H), 7.19 (m, 2H), 7.11 (t,1H), 6.92-7.01 (m, 4H), 6.83 (s, 1H), 5.95 (br, 1H), 5.91 (s, 1H), 5.31 (br, 4H), 3.45 (s, 3H).
[0300] MS [(+)ESI, m/z]: 463 [M+H] + .
[0301] Anal. Calcd. for C 27 H 21 F 3 N 2 O 2 : C, 70.12; H, 4.58; N, 6.06. Found: C, 70.53; H, 4.72, N, 5.89.
Step E. 10-{[2-Methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0302] To a stirred solution of the (10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl)-(2-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-methanone of Step D (2.34 g, 5.0 mmol) and N,N-diisopropylethyl amine (1.04 mL, 6.0 mmol) in dichloromethane (100 mL) was added dropwise a solution of trichloroacetyl chloride (1.09 g, 6.0 mmol) in dichloromethane (20 mL) kept at 0° C. After the addition was complete, the solution was stirred overnight at room temperature, then washed with 10% aqueous potassium carbonate. The organic phase was dried and concentrated to yield a black residue. The residue was purified by filtration through a plug of silica gel, eluting with 20% ethyl acetate in hexane. The resulting tan colored product was dissolved in acetone and 1 N NaOH (2:1, v/v) and the mixture was stirred for 30 minutes. The solution was then concentrated and extracted with ethyl acetate. The combined organic phases were dried and concentrated to yield a yellow oil. The oil was triturated with hexane, and the resulting solid was removed by filtration to yield the title compound (1.86 g) as an off white solid, which was used without further purification.
Step F. 10-{[2-Methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0303] To a stirred solution of the 10-{[2-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step E (0.17 g, 0.37 mmol) in N,N-dimethylformamide (15 mL), was added 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (0.092 g, 0.48 mmol) and 1-hydroxybenzotriazole monohydrate (0.065 g, 0.48 mmol). After the solution became homogeneous 3-(methylaminomethyl) pyridine (0.045 g, 0.37 mmol) was added, and the solution was stirred at room temperature overnight. The solution was then poured into water and extracted with ethyl acetate. The combined ethyl acetate layers were washed with water, dried and concentrated to dryness. The residue was subjected to silica chromatography eluting with 10% methanol in chloroform. The pure fractions were concentrated and the residue azeotroped and triturated several times with hexane to provide the title product (0.150 g) as an amorphous white solid, 150-153° C. (dec.)
[0304] [0304] 1 H NMR (400 MHz, DMSO-d 6 ): δ3.14 (s, 3H), 3.46 (s, 3H), 4.82(s, 2H), 5.52 (br, 2H), 6.06 (s, 1H), 6.43 (s, 1H), 6.85-6.97 (m, 4H), 7.04 (t, 1H), 7.18 (t, 1H), 7.21 (d, 1H), 7.42 (d, 1H), 7.56 (t, 1H), 7.62 (t, 1H), 7.74 (d, 1H), 7.86 (t, 1H), 8.29(m, 1H), 8.89 (m, 2H).
[0305] MS [El, m/z]: 610 [M] + .
[0306] Anal. Calcd. for C 35 H 29 F 3 N 4 O 3 : C, 64.96; H, 4.67; N, 8.66. Found: C, 63.28; H, 4.85, N, 8.22.
EXAMPLE 8
10-{[2-Methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-methyl-N-(1-oxo-pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0307] The title compound [white solid, 0.112 g, m.p. 165-170° C. (dec.)] was prepared from 10-{[2-methoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo.[2,1-c][1,4].benzodiazepine-3-carboxylic acid of Example 7, Step E (0.225 g, 0.48 mmol) and methyl-(1-oxy-pyridin-3-ylmethyl)-amine dihydrochloride of Example 4, Step C (0.140 g, 0.70 mmol) in the manner of Example 4, Step D.
[0308] [0308] 1 H NMR (400 MHz, DMSO-d 6 ): δ3.14 (s, 3H), 3.46(s, 3H), 4.62(s, 2H), 5.52 (br, 2H), 6.06 (s, 1H), 6.41 (s, 1H), 6.85-6.973 (m, 4H), 7.04 (t, 1H), 7.18 (t, 1H), 7.20(d, 1H), 7.23 (d, 1H), 7.42 (m, 2H), 7.56 (t, 1H), 7.62 (t, 1H ), 7.74 (d, 1H), 8.18(m, 2H).
[0309] MS [El, m/z]: 626 [M] +
[0310] Anal. Calcd. for C 35 H 29 F 3 N 4 O 4 : C, 67.09; H, 4.66; N, 8.94. Found: C, 65.28; H, 4.49, N, 8.00.
EXAMPLE 9
10-[4-(Naphthalen-1-yl)-benzoyl]-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo [2,1-c] [1,4]benzodiazepine-3-carboxamide
Step A. 4-Naphthalen-1-yl-benzoic acid methyl ester
[0311] Methyl 4-bromobenzoate (0.96 g, 4.46 mmol) was added to a mixture of 1-naphthaleneboronic acid (0.73 g, 4.25 mmol) and sodium carbonate (0.075 g, 7.08 mmol) in toluene (30 mL), ethanol (6 mL) and water (12 mL). The resultant solution was purged with nitrogen for 10 minutes before tetrakis(triphenylphosphine)palladium(0) (0.10 g, 0.09 mmol) was added. The reaction mixture was heated to reflux for 65 hours. The solution was cooled to ambient temperature, then filtered through a pad of Celite, which was subsequently rinsed with ethyl acetate. The combined filtrate was diluted to 100 mL with water/ethyl acetate (1:1). The aqueous layer was extracted with ethyl acetate, and the combined extracts were dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness to yield the title compound as a gold oil (1.09 g). This material was used without further purification in the next step.
[0312] [0312] 1 H NMR (300 MHz, DMSO-d 6 ) δ8.10 (d, 2H), 8.02 (t, 2H), 7.75 (d, 1H), 7.57 (m, 6H), 3.92 (s,3H).
Step B. 4-Naphthalen-1-yl-benzoic acid
[0313] To a stirred solution of the 4-naphthalen-1-yl-benzoic acid methyl ester of Step A (1.09 g, 4.15 mmol), in methanol (18 mL) and water (6 mL), cooled to 5° C., was added lithium hydroxide monohydrate (0.42 g, 10.0 mmol). The solution was allowed to warm to ambient temperature as stirring was continued for 20 hours. The reaction mixture was poured into water, acidified to pH 4 with acetic acid, and the resultant precipitate was isolated by vacuum filtration to afford the title compound as an off-white solid (0.92 g), m.p. 221-224° C.
[0314] [0314] 1 H NMR (400 MHz, DMSO-d 6 ): δ6.40-7.60 (m, 7H), 7.56 (d, 1H), 7.98 (d, 1H), 8.01 (d, 1H), 8.07 (d, 2H).
[0315] MS [El, m/z]: 248 [M] + .
[0316] Anal. Calc'd. for C 17 H 12 O 2 : C, 82.24; H, 4.87. Found: C, 81.90; H, 4.63.
Step C. [4-(Naphthalen-1-yl)phenyl][10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl]methanone
[0317] N,N-Dimethylformamide (2 drops) was added to a solution of the 4-naphthalen-1-yl-benzoic acid of Step B (0.60 g, 2.40 mmol) in anhydrous tetrahydrofuran (15 mL). Oxalyl chloride (0.34 g, 2.64 mmol) was added and the mixture was warmed to reflux. The resultant solution was cooled to ambient temperature before being evaporated to dryness to give the crude acid chloride as a golden solid, which was used without further purification. To a mixture of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (0.37 g, 2.00 mmol) and triethylamine (0.24 g, 2.40 mmol) in dichloromethane (5 mL), cooled in an ice bath, was added dropwise a solution of the crude acid chloride in dichloromethane (5 mL). The cooling bath was removed and after stirring for 48 hours, the reaction mixture was washed sequentially with water, saturated aqueous sodium bicarbonate, saturated aqueous sodium chloride and 1 N sodium hydroxide. The dichloromethane solution was dried with anhydrous magnesium sulfate, filtered, then evaporated to dryness to yield a brown foam. Purification by flash chromatography on silica gel eluting with hexane-ethyl acetate (4:1) resulted in a white foam (0.47 g). Treatment of the white foam with diethyl ether and sonication resulted in a white solid (0.37g), m.p. 169.5-171° C.
[0318] [0318] 1 H NMR (400 MHz, DMSO-d 6 ): δ5.32 (br, 4H), 5.93 (m, 1H), 5.97 (s, 1H), 6.83 (m, 1H), 7.01 (d, 1H), 7.18 (m, 2H), 7.32, (t, 2H), 7.41, (d, 1H), 6.45-7.60 (m, 5H), 7.93 (d,1H), 7.97 (d, 1H)
[0319] MS [El, m/z]: 414 [M] + .
[0320] Anal. Calcd. for C 17 H 12 O 2 +0.4H 2 O: C, 82.60; H, 5.45; N, 6.64. Found: C, 82.71; H, 5.44; N, 6.54.
Step D. 10-[(4-Naphthalen-1-yl)benzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0321] The title compound was prepared by treatment of [4-(naphthalen-1-yl)phenyl][10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl]methanone of Step C with trichloroacetyl chloride, followed by basic hydrolysis of the intermediate trichloroacetate ester in the manner of Example 7, Step E.
Step E. 10-[4-(Naphthalen-1-yl)-benzoyl]-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c] [1,4]benzodiazepine-3-carboxamide
[0322] The title compound was prepared by the coupling the 10-[4-(naphthalen-1-yl)benzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step D, with 3-(methylaminomethyl)pyridine (1.25 equiv) in the manner of Example 7.
EXAMPLE 10
10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-N-(pyridin-4-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-carboxamide
Step A. (4-Bromo-2-chloro-benzoyl)-(10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepine
[0323] N,N-Dimethylformamide (1 drop) was added to a solution of 4-bromo-2-chlorobenzoic acid (2.20 g, 9.35 mmol) in anhydrous tetrahydrofuran (20 mL). Oxalyl chloride (1.46 g, 11.46 mmol) was added and the mixture was warmed to reflux. The resultant solution was cooled to ambient temperature before being evaporated to dryness to give the crude acid chloride as a gold viscous liquid, which was used without further purification. To a mixture of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (1.44 g, 7.79 mmol) and triethylamine (0.95 g, 9.35 mmol) in methylene chloride (40 mL), cooled in an ice bath, was added dropwise a solution of the acid chloride in dichloromethane (20 mL). The cooling bath was removed and after stirring for 22 hours, the reaction mixture was washed sequentially with water, saturated aqueous sodium bicarbonate, 0.5 N hydrochloric acid and water. The dichloromethane solution was dried over anhydrous sodium sulfate, filtered, then evaporated to dryness to yield an off-white foam. Purification by flash chromatography on silica gel eluting with hexane-ethyl acetate (2:1) resulted in a white foam (3.02 g), m.p. 77-80° C. This material was used as is in the next step.
[0324] [0324] 1 H NMR (400 MHz, DMSO-d 6 ): δ5.45 (br, 4H), 7.02 (t, 1H), 7.07 (td,1H), 7.14 (td), 7.32 (br, 1H), 7.38 (d, 2H), 7.60 (br, 1H).
[0325] MS [El, m/z]: 400 [M] + .
Step B. (2-Chloro-4-naphthalen-1-yl-phenyl)-(10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl)-methanone
[0326] 1-Naphthaleneboronic acid (0.52 g, 3.00 mmol) was added to a mixture of (4-bromo-2-chlorophenyl)-(5H,11H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl)-methanone of Step A (1.27 g, 3.15 mmol) and sodium carbonate (0.53 g, 4.98 mmol) in toluene (22.5 mL), ethanol (4.5 mL) and water (9 mL). The resultant solution was purged with nitrogen for 10 minutes, then tetrakis(triphenylphosphine)palladium (0.18 g, 0.06 mmol) was added. The reaction mixture was heated to reflux for 76 hours. The solution was cooled to ambient temperature, then filtered through a pad of Celite, which was subsequently rinsed with ethyl acetate. The combined filtrate was diluted to 100 mL water/ethyl acetate (1:1). The aqueous layer was extracted with ethyl acetate, and the combined organic layer was dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness to yield a brown oil. Purification by flash chromatography on silica gel eluting with hexane-ethyl acetate (5:1) resulted in a white solid which was dried under vacuum (0.62 g), m.p. 115-117.5° C.
[0327] [0327] 1 H NMR (400 MHz, DMSO-d 6 ): δ5.91 (t, 1H), 6.02 (br, 1H), 6.84 (br,1H), 7.14 (m, 2H), 7.24 (d, 1H), 7.34, (d, 1H), 7.95 (d, 1H), 7.98 (d, 1H).
[0328] MS [(+)ESI, m/z]: 449 [M+H] + .
[0329] Anal. Calcd. for C 29 H 21 CIN 2 O+0.25 H 2 O: C, 76.72; H, 4.79; N, 6.17. Found C, 76.72; H, 4.53; N, 5.95.
Step C. 10-{[2-Chloro-4-(naphthalen-1-yl)phenyl]carbonyl}-10,11-dihydro-5H-pyrrolo [2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0330] Prepared by treatment of [2-chloro-4-(naphthalen-1-yl)-phenyl]-(10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl)-methanone of Step B with trichloroacetyl chloride, followed by basic hydrolysis of the intermediate trichloroacetate ester in the manner of Example 5, Step D.
Step D. 10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-N-(pyridin-4-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-carboxamide
[0331] The title compound was prepared by the coupling the 10-[2-chloro-4-(naphthalen-1-yl)phenyl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step C, with 4-(aminomethyl)pyridine (1.25 equiv) in the manner of Example 1, Step G.
EXAMPLE 11
{[10-(4-Methyl-napthalen-1-yl)benzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl} [4-(pyridin-4-yl)-1-piperazinyl]methanone
Step A. 4-(4-Methyl)-napthalen-1-yl-benzoic acid
[0332] To a mixture of 1-bromo-4-methyl napthalene (1.11 g, 5.00 mmol) and 4-carboxyphenyl boronic acid (1.00 g, 6.00 mmol) in ethylene glycol dimethyl ether (20 mL) was added a solution of sodium carbonate (2.37 g, 22.38 mmol) in water (18.75 mL). The resultant mixture was purged with nitrogen for 20 minutes before tetrakis(triphenylphosphine)palladium(0) (0.03 g, 0.02 mmol) was added. The reaction mixture was heated to reflux for 68 hours. After the solution cooled to ambient temperature, the solvent was removed in vacuo and the residue was acidified with 5 N hydrochloric acid to produce an orange-brown solid that was isolated by vacuum filtration. This material was used without further purification in the next step.
[0333] [0333] 1 H NMR (300 MHz, DMSO-d 6 ): δ2.70 (s, 3H), 7.57 (d, 2H), 8.07 (d, 2H).
Step B. [4-(4-Methyl-naphthalen-1-yl)phenyl][10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl]methanone
[0334] N,N-Dimethylformamide (2 drops) was added to a solution of 4-(4-methyl)-napthalen-1-yl-benzoic acid of Step A (0.90 g, 3.43 mmol), in anhydrous tetrahydrofuran (10 mL). Oxalyl chloride (0.52 g, 4.12 mmol) was added and the mixture was warmed to reflux. The resultant solution was cooled to ambient temperature before being evaporated to dryness to give the crude acid chloride as a brown residue, which was used without further purification. To a mixture of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepine (0.53 g, 2.86 mmol) and triethylamine (0.35 g, 3.43 mmol) in dichloromethane (10 mL), cooled in an ice bath, was added dropwise a solution of the crude acid chloride in dichloromethane (10 mL). The cooling bath was removed and after stirring for 137 hours, the reaction mixture was washed sequentially with water, saturated aqueous sodium bicarbonate, and saturated aqueous sodium chloride. The dichloromethane solution was dried over anhydrous magnesium sulfate, filtered, then evaporated to dryness to yield an amber oil. Purification by flash chromatography on silica gel eluting with hexane-ethyl acetate (4:1) resulted in a tan foam (0.49 g). Treatment of this material with diethyl ether and sonication resulted in an off-white solid (0.37 g), m.p. 160-162° C.
[0335] [0335] 1 H NMR (400 MHz, DMSO-d 6 ): δ2.66 (s, 3H), 5.32 (br, 4H), 5.93 (t,1H), 5.97(br, 1H), 6.83 (t, 1H), 7.01 (d, 1H), 7.22 (d, 2H), 7.28 (d, 2H), 7.39 (t, 3H), 7.45 (m, 2H), 7.57 (m, 2H), 8.06 (d, 1H).
[0336] MS [(+)ESI, m/z]: 429 [M+H] + .
[0337] Anal. Calcd. for C 30 H 24 N 2 O+0.13 H 2 O: C, 83.63; H,5.67; N, 6.50. Found: C, 83.63; H, 5.64; N, 6.43.
Step C. 10-{[4-(4-Methyl-naphthalen-1-yl)phenyl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0338] Prepared from [4-(4-methyl-naphthalen-1-yl)-phenyl]-[10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-10-yl]methanone of Step B by treatment with trichloroacetyl chloride, followed by basic hydrolysis of the intermediate trichloroacetate ester in the manner of Example 1, Steps E and F.
Step D. {[10-(4-Methyl-napthalen-1-yl)benzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl} [4-(pyridin-4-yl)-1-piperazinyl]methanone
[0339] Prepared by the coupling of 10-{[4-(4-methyl-naphthalen-1-yl)phenyl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step C, with 1-(4-pyridinyl)-piperazine (1.2 equiv.) in the manner of Example 1.
EXAMPLE 12
10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)-carbonyl]-N-methyl-N-[2-(pyridin-4-yl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. (2-Methyl-2′-methoxy-[1,1′-biphenyl]-4-yl)carboxylic acid methyl ester
[0340] A mixture of 3-methyl-4-bromobenzoic acid methyl ester (2.0 g, 8.7 mmol), 2-methoxyphenyl boronic acid (1.32 g, 8.7 mmol) and sodium carbonate (4.1 g, 38.7 mmol) in toluene:ethanol:water (50 mL:25 mL: 25 mL), was purged with nitrogen for 1 hour. After addition of the tetrakis(triphenylphosphine) palladium(0) catalyst (0.50 g, 0.43 mmol), the reaction mixture was heated at 100° C. overnight. After cooling, the reaction was filtered through Celite and the cake washed with ethyl acetate. The organic layer was washed with water, dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a brown oil. Purification by flash chromatography on silica gel with a solvent gradient from 20% to 50% dichloromethane in hexane gave 2.0 g of product as a colorless oil.
[0341] [0341] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.09 (s, 3H), 3.70 (s, 3H), 3.85 (s, 3H), 7.00-7.04 (m, 1H), 7.08-7.11 (m, 2H), 7.23 (d, 1H), 7.37-7.41 (m, 1H), 7.77-7.79 (m, 1H), 7.83-7.84 (m, 1H).
[0342] MS [(+)APCI, m/z]: 257 [M+H] + .
[0343] Anal. Calcd. for C 16 H 16 O 3 : C, 74.98; H, 6.29. Found: C, 74.06; H, 6.17.
Step B. (2-Methyl-2′-methoxy-[1,1′-biphenyl]-4-yl)carboxylic acid
[0344] The (2-methyl-2′-methoxy-[1,1′-biphenyl]-4yl)carboxylic acid methyl ester of Step A (1.9 g, 7.4 mmol) was dissolved in tetrahydrofuran (30 mL) and 1 N sodium hydroxide (15 mL, 15 mmol) was added. The reaction mixture was heated at reflux overnight, then cooled and acidified with 2 N hydrochloric acid. The aqueous layer was extracted with ethyl acetate. The combined organic layers were dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give 1.6 g of product as a white solid, m.p. 160-162° C.
[0345] [0345] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.09 (s, 3H), 3.70 (s, 3H), 7.00-7.03 (m, 1H), 7.08-7.10 (m, 2H), 7.20 (d, 1H), 7.36-7.40 (m, 1H), 7.75-7.78 (m, 1H), 7.82 (s, 1H), 12.85 (br, 1H).
[0346] MS [(−)APCI, m/z]: 241 [M−H] − .
[0347] Anal. Calcd. for C 15 H 14 O 3 : C, 74.36; H, 5.82. Found: C, 73.93; H, 5.71.
Step C. (10,11-Dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-10-yl)-(2′-methoxy-2-methyl-[1,1′-biphenyl]-4-yl)-methanone
[0348] The (2-methyl-2′-methoxy-[1,1′-biphenyl]-4-yl)carboxylic acid of Step B (0.50 g, 2.06 mmol) was suspended in thionyl chloride (3 mL) and the mixture heated at reflux for 30 minutes. After cooling, the thionyl chloride was removed in vacuo. The residue was dissolved in toluene and concentrated in vacuo to give the crude acid chloride as a brown oil. The acid chloride was then dissolved in dichloromethane (5 mL) and slowly added to a solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (0.57 g, 3.10 mmol) and N,N-diisopropylethyl amine (0.79 mL, 4.53 mmol) in dichloromethane (15 mL). After stirring for 1 hour, the reaction was quenched with water. The organic layer was washed with 1 N hydrochloric acid, 1 N sodium hydroxide and brine, dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a yellow foam. Purification by flash chromatography using a solvent gradient of 5 to 15% ethyl acetate in hexane yielded a white foam which crystallized upon sonication in ethanol/hexane to give 0.42 g of the desired title product as a white solid, m.p. 133-135° C.
[0349] [0349] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.93 (s, 3H), 3.65 (s, 3H), 4.80-5.40 (br, 4H), 5.92-5.96 (m, 2H), 6.81-6.82 (m, 1H), 6.89-6.91 (m, 1H), 6.95-7.05 (m, 5H), 7.16-7.25 (m, 3H), 7.31-7.35 (m, 1H), 7.47-7.49 (m, 1H).
[0350] MS [(+)ESI, m/z]: 409 [M+H] + .
[0351] Anal. Calcd. for C 27 H 24 N 2 O 2 : C, 79.39; H, 5.92; N, 6.86. Found: C, 79.16; H, 5.87; N, 6.90.
Step D. 2,2,2-Trichloro-1-{10-[(2′-methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-3-yl} ethanone
[0352] To a solution of (10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl)-(2′-methoxy-2-methyl-[1,1′-biphenyl]-4-yl)-methanone of Step C (1.5 g, 3.67 mmol) in dichloromethane (20 mL) was added N,N-diisopropylethyl amine (1.28 mL, 7.35 mmol) followed by slow addition of trichloroacetyl chloride (1.23 mL, 11.0 mmol). The reaction mixture was stirred overnight at room temperature then quenched with water. The organic phase was washed with 0.1 N hydrochloric acid followed by water, then dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a green oil. Purification by flash chromatography on silica gel using a solvent system of 20% ethyl acetate in hexane provided 2.1 g of title compound. The material was redissolved in dichloromethane and evaporated to dryness to provide a yellow foam, which was used in the next step.
[0353] [0353] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.94 (s, 3H), 3.65 (s, 3H), 5.25 (br, 2H), 5.97 (br, 2H), 6.36-6.37 (m, 1H), 6.90-6.92 (m, 1H), 6.96-7.06 (m, 5H), 7.15-7.23 (m, 2H), 7.26 (s, 1H), 7.32-7.36 (m, 1H), 7.44-7.47 (m, 2H).
[0354] MS [(+)APCI, m/z]: 553 [M+H] + .
[0355] Anal. Calcd. for C 29 H 23 Cl 3 N 2 O 3 +0.13 C 4 H 8 O 2 +0.13 CH 2 Cl 2 : C, 61.79; H, 4.25; N, 4.86. Found: C, 60.43; H, 4.50; N, 4.80.
Step E. 10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0356] To a solution of 2,2,2-trichloro-1-{10-[(2′-methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-3-yl} ethanone of Step D (2.0 g, 3.6 mmol) in acetone (20 mL) was added 2.5 N sodium hydroxide (2.9 mL, 7.25 mmol). After stirring overnight, the reaction mixture was acidified with 2 N hydrochloric acid (4.0 mL, 8.0 mmol) then concentrated in vacuo. The residue was partitioned between ethyl acetate and water. The organic layer was dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a brown solid. Trituration with diethyl ether-hexane provided 1.4 g of the desired product as a white solid, m.p.174-184° C.
[0357] [0357] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.93 (s, 3H), 3.65 (s, 3H), 5.17 (br, 2H), 5.94 (br, 2H), 6.09-6.10 (m, 1H), 6.77 (d, 1H), 6.89-7.06 (m, 6H), 7.10-7.19 (m, 2H), 7.23 (s, 1H), 7.31-7.38 (m, 2H), 12.31 (br, 1H).
[0358] MS [(−)APCI, m/z]: 451 [M−H] − .
[0359] Anal. Calcd. for C 28 H 24 N 2 O 4 +0.10 C 4 H 10 O: C, 74.17; H, 5.48; N, 6.09. Found: C, 73.63; H, 5.68; N, 5.94.
Step F. 10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)-carbonyl]-N-methyl-N-[2-(pyridin-4-yl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0360] Prepared by treatment of 10-[(2′-methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step E, with 4-(2-methylaminoethyl)pyridine (1.2 equiv.) in the manner of Example 5, Step E.
EXAMPLE 13
N-Methyl-10-[(3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)-carbonyl]-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[1,2-c][1,4]benzodiazepine-3-carboxamide
Step A. 4-Iodo-2-methoxybenzoic acid methyl ester
[0361] 4-Amino-2-methoxybenzoic acid methyl ester (3.0 g, 16.6 mmol) was suspended in water (40 mL) and concentrated sulfuric acid (10 mL). The suspension was cooled in an ice/salt water bath, and an aqueous solution (10 mL) of sodium nitrite (1.26 g, 18.3 mmol) was added dropwise so that the temperature remained close to 0° C. After the addition, a homogeneous, yellow-green solution was obtained. An aqueous solution (60 mL) of potassium iodide (3.02 g, 18.2 mmol) and iodine (2.31 g, 9.1 mmol) was then added dropwise, and the reaction stirred for an additional 1 hour. The reaction mixture was then extracted with ethyl acetate, the organic extracts were combined and washed with 1 N sodium thiosulfate, 1 N sodium hydroxide and brine. After drying over anhydrous sodium sulfate the solution was filtered and concentrated in vacuo to give 2.7 g of the title product as an orange oil which was used in the next step.
[0362] [0362] 1 H NMR (DMSO-d 6, 400 MHz): δ2.76 (s, 3H), 3.82 (s, 3H), 7.39 (s, 2H), 7.48 (s, 1H).
[0363] MS [El, m/z]: 292 [M] + .
Step B. 4-Iodo-2-methoxybenzoic acid
[0364] The 4-iodo-2-methoxybenzoic acid methyl ester of Step A (2.7 g, 9.24 mmol) was dissolved in tetrahydrofuran (40 mL) and 1 N sodium hydroxide (20 mL, 20 mmol) was added. The reaction mixture was heated at reflux for 3 hours, then cooled and concentrated in vacuo to give an orange oil that was partitioned between ethyl acetate and 2 N hydrochloric acid. The organic layer was dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give 2.5 g of title product as a yellow-orange solid, m.p. 144-146° C.
[0365] [0365] 1 H NMR (DMSO-d 6 , 400 MHz): δ3.81 (s, 3H), 7.37 (s, 2H), 7.44 (s, 1H), 12.72 (br,1H).
[0366] MS [El, m/z]: 278 [M] + .
[0367] Anal. Calcd. for C 8 H 7 IO 3 +0.10 C 4 H 8 O 2 : C, 35.17; H, 2.74. Found: C, 35.37; H, 2.49.
Step C. 10-(4-Iodo-2-methoxybenzoyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepine
[0368] A suspension of 4-iodo-2-methoxybenzoic acid of Step B (2.5 g, 9.0 mmol) in thionyl chloride (10 mL) was heated at reflux for 1 hour. After cooling, the thionyl chloride was removed in vacuo. The residue was dissolved in toluene and concentrated in vacuo to give the crude acid chloride as a brown solid. The acid chloride was then dissolved in dichloromethane (10 mL) and slowly added to a solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (1.75 g, 9.5 mmol) and N,N-diisopropylethyl amine (3.4 mL, 19.5 mmol) in dichloromethane (20 mL). After stirring for 2 hours, the reaction was quenched with water. The organic layer was washed with 1 N hydrochloric acid, 1 N sodium hydroxide and brine, dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a yellow foam. Purification by flash chromatography on silica gel using a solvent gradient of 15 to 25% ethyl acetate in hexane provided 3.6 g of title product as a white foam, which was redissolved in dichloromethane and evaporated to dryness prior to use in the next step.
[0369] [0369] 1 H NMR (DMSO-d 6 , 400 MHz): δ3.55 (br, 3H), 4.80-5.32 (br, 4H), 5.88-5.90 (m, 1H), 5.94 (s, 1H), 6.79 (s, 1H), 6.94 (s, 1H), 7.03 (t, 1H), 7.09-7.13 (m, 3H), 7.20-7.22 (m, 1H), 7.36-7.38 (m, 1H).
[0370] MS [(+)ESI, m/z]: 445 [M+H] + .
[0371] Anal. Calcd. for C 20 H 17 IN 2 O 2 +0.10 C 4 H 8 O 2 +0.13 CH 2 Cl 2 : C, 53.13; H, 3.92; N, 6.04. Found: C, 53.03; H, 3.65; N, 6.03.
Step D. (10,11-Dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-10-yl)-[3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl]-methanone
[0372] A mixture of 10-(4-iodo-2-methoxybenzoyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepine of Step C (1.8 g, 4.1 mmol), 2-methylphenyl boronic acid (0.55 g, 4.1 mmol) and sodium carbonate (1.9 g, 17.9 mmol) in toluene:ethanol: water (20 mL:10 mL:10 mL) was purged with nitrogen for 1 hour. After addition of the tetrakis(triphenylphosphine) palladium(0) catalyst (0.24 g, 0.21 mmol), the reaction mixture was heated at 100° C. overnight. After cooling, the reaction was filtered through Celite and the cake washed with ethyl acetate. The organic layer was washed with water, dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a brown oil. Purification by flash chromatography on silica gel using a solvent system of 20% ethyl acetate in hexane provided 1.5 g of title product as a white foam, which was redissolved in dichloromethane and evaporated to dryness in vacuo prior to use in the next step.
[0373] [0373] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.08 (s, 3H), 3.54 (s, 3H), 4.80-5.30 (br, 4H), 5.89-5.91 (m, 1H), 5.97 (s, 1H), 6.66 (s, 1H), 6.77-6.80 (m, 2H), 6.93-7.01 (m, 2H), 7.09-7.10 (m, 2H), 7.19-7.24 (m, 3H), 7.36-7.38 (m, 2H).
[0374] MS [(+)ESI, m/z]: 409 [M+H] + .
[0375] Anal. Calcd. for C 27 H 24 N 2 O 2 +0.10 CH 2 Cl 2 : C, 78.05; H, 5.84; N, 6.72. Found: C, 78.12; H, 5.13; N, 6.69.
Step E. 2,2,2-Trichloro-1-{10-[(3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}ethanone
[0376] To a solution of (10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-10-yl)-[3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl]-methanone of Step D (1.36 g, 3.33 mmol) in dichloromethane (15 mL) was added N,N-diisopropylethyl amine (1.2 mL, 6.89 mmol) followed by slow addition of trichloroacetyl chloride (1.1 mL, 9.85 mmol). The reaction mixture was stirred overnight at room temperature then was quenched with water. The organic phase was washed with 0.1 N hydrochloric acid followed by water, then dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a green oil. Purification by flash chromatography on silica gel using a solvent system of 20% ethyl acetate in hexane gave 1.7 g of title product as a yellow foam.
[0377] [0377] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.09 (s, 3H), 3.50 (s, 3H), 5.30 (br, 2H), 5.87 (br, 2H), 6.37-6.38 (m, 1H), 6.64 (s, 1H), 6.82-6.83 (m, 1H), 6.90-6.92 (m, 1H), 6.97-6.99 (m, 1H), 7.10-7.12 (m, 2H), 7.20-7.25 (m, 4H), 7.35-7.37 (m, 1H), 7.44-7.46 (m, 1H).
[0378] MS [(+)APCI, m/z]: 553 [M+H] + .
[0379] Anal. Calcd. for C 29 H 23 Cl 3 N 2 O 3 +0.20 C 4 H 8 O 2 +0.40 H 2 O: C, 61.85; H, 4.42; N, 4.84. Found: C, 61.50; H, 4.07; N, 4.72.
Step F. 10-[(3-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2, 1-c][1,4]benzodiazepine-3-carboxylic acid
[0380] To a solution of 2,2,2-trichloro-1-{10-[(3-methoxy-2′-methyl[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}ethanone of Step E (1.6 g, 2.9 mmol) in acetone (20 mL) was added 2.5 N sodium hydroxide (2.3 mL, 5.8 mmol). After stirring overnight, the reaction was acidified with 2 N hydrochloric acid (3.2 mL, 6.4 mmol) then concentrated in vacuo. The residue was partitioned between ethyl acetate and water. The layers were separated, and the organic layer was dried over anhydrous sodium sulfate, filtered and concentrated in vacuo to give a brown solid. Trituration with diethyl ether/hexane provided 1.2 g of desired product as an off-white solid, m.p. 201-204° C.
[0381] [0381] 1 H NMR (DMSO-d 6 , 400 MHz): δ2.09 (s, 3H), 3.48 (s, 3H), 5.20 (br, 2H), 5.85 (br, 2H), 6.12 (s, 1H), 6.62 (s, 1H), 6.73 (d, 1H), 6.79-6.87 (m, 2H), 6.91-6.95 (m, 1H), 6.99-7.03 (m, 1H), 7.06-7.12 (m, 1H), 7.18-7.25 (m, 4H), 7.39 (br, 1H), 12.31 (br, 1H).
[0382] MS [(+) ESI, m/z]: 453 [M+Na] + .
[0383] Anal. Calcd. for C 28 H 24 N 2 O 4 +0.10 C 4 H 10 O+0.15 C 4 H 8 O 2 : C, 73.61; H, 5.58; N, 5.92. Found: C, 73.23; H, 5.49; N, 6.06.
Step G N-Methyl-10-[(3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)-carbonyl]-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[1,2-c][1,4]benzodiazepine-3-carboxamide
[0384] Prepared from the 10-[(3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step F and methyl-pyridin-3ylmethyl-amine (1.1 equiv.) in the manner of Example 5.
EXAMPLE 14
7,8-Dimethoxy-{10-[(2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[1,2-c][1,4]benzodiazepin-3-yl}[4-(pyridin-2-yl)-1-piperazinyl]methanone
Step A. 1-[(4,5-Dimethoxy-2-nitrophenyl)methyl]-1H-pyrrole-2-carboxaldehyde
[0385] To a suspension of sodium hydride (0.724 g, 60% suspension in oil) in N,N-dimethyl formamide (50 mL) was added pyrrole 2-carboxaldehyde (1.7 g, 18.1 mmol) and the reaction mixture was stirred for 30 minutes. It was then cooled to 0° C. and 4,5-dimethoxy-2-nitrobenzyl bromide (5.0 g, 1 equiv) was added dropwise over 20 minutes. After the addition, the reaction mixture was stirred at room temperature for 3 hours. It was then diluted with ethyl acetate (450 mL), washed with water, dried over anhydrous magnesium sulfate, filtered and evaporated to dryness. The crude product was triturated with water, filtered and washed with water. This material was dried over anhydrous potassium carbonate in vacuo to provide the title compound as a yellow crystalline solid (4.97 g), m.p. 109-112° C., which was used in the next step.
Step B. 7,8-Dimethoxy 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
[0386] A mixture of the 1-[(4,5-dimethoxy-2-nitrophenyl)methyl]-1H-pyrrole-2-carboxaldehyde of Step A (4.97 g), acetic acid (0.5 mL), magnesium sulfate (0.5 g) and 10% palladium on charcoal (0.5 g) in ethyl acetate (50 mL) was hydrogenated overnight at atmospheric pressure. The reaction was then filtered through Celite and the solvent removed in vacuo to give the crude title compound as an amber foam (3.2 g) which was used in the next step without further purification.
Step C. 7,8-Dimethoxy-(10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl)-(4-bromo-3-methyl-phenyl)-methanone
[0387] To a solution of 7,8-dimethoxy-10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepine of Step B (3.20 g) in dichloromethane (20 mL) was added 3-methylbenzoyl chloride (3.4 g, 1.1 equiv) and triethylamine (2.0 g, 1.5 equiv) and the mixture was stirred at room temperature overnight. The solvent was then removed in vacuo and the residue chromatographed on silica gel eluting with a solvent gradient from 5 to 50% of ethyl acetate in petroleum ether to provide the title compounds as a yellow crystalline solid (3.5 g), m.p. 165-168° C.
[0388] [0388] 1 H NMR (CDCl 3 , 200 MHz): δ2.30 (s, 3H), 3.55 (br, 3H), 3.85 (s, 3H), 5.1 (br, 4H), 6.05 (br, 1H), 6.1 (t, 1H), 6.3 (br, 1H), 6.65 (t, 1H), 6.8 (s, 2H), 7.3 (s, 2H).
[0389] MS [(+)ESI, m/z]: 442 [M +H] + .
Step D. 7,8-Dimethoxy-[10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl]-[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]methanone
[0390] The 7,8-dimethoxy-(10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl)-(4-bromo-3-methyl-phenyl)-methanone of Step C (1.0 g) was reacted with 2-trifluoromethylphenyl boronic acid (0.645 g, 1.5 equiv.), potassium phosphate (0.964 g, 2.0 equiv.) and a catalytic amount (0.050 g) of tetrakis(triphenylphosphine) palladium(0) in refluxing dioxane (10 mL) under nitrogen for 24 hours. The reaction was then cooled to room temperature, filtered through Celite, and the solvent removed in vacuo. The residue was dissolved in dichloromethane and the solution was washed with water, dried over anhydrous magnesium sulfate, filtered and evaporated to dryness. The crude product so obtained was purified by chromatography on silica gel eluting with 5% ethyl acetate/dichloromethane to provide the title product (1.0 g) as a white crystalline solid, m.p. 187-188° C.
[0391] [0391] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.85 (s, 3H), 3.40 (s, 3H), 3.70 (s, 3H), 6.20 (br, 4H), 5.92 (t, 1H), 5.96 (s, 1H), 6.56 (s, 1H), 6.77 (t, 1H), 6.90 (m, 1H), 7.05 (m, 2H), 7.20 (d, 1H), 7.30 (s, 1H), 7.58 (t, 1H), 7.68 (t, 1H), 7.80 (d, 1H).
[0392] MS [(+)APCI, m/z]: 507 [M+H] + .
[0393] Anal. Calcd. for C 29 H 25 F 3 N 2 O 3 : C, 68.77; H, 4.97; N, 5.53. Found: C, 68.85; H, 5.05; N, 5.43.
Step E. 7,8-Dimethoxy-{10-[(2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[1,2-c][1,4]benzodiazepin-3-yl}[4-(pyridin-2-yl)-1-piperazinyl]methanone dihydrochloride salt
[0394] A solution of 7,8-dimethoxy-[10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl][2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]methanone of Step D (0.31 mmol), diphosgene (1.1 equiv.) and triethylamine (1.5 equiv.) in dichloromethane (5 mL) was stirred at room temperature overnight. The solvent was removed in vacuo and the residue was dissolved in dichloromethane (5 mL). To the solution was added triethylamine (1.5 equiv.) and 1-(2-pyridinyl)piperazine (1.5 equiv.) The reaction mixture was washed with water, dried over anhydrous magnesium sulfate, filtered and evaporated to dryness. The residue was first chromatographed on silica gel eluting with a solvent gradient of methanol in ethyl acetate to provide the title compound as a foam.
[0395] Treatment of a solution of the free base in ethanol with anhydrous hydrogen chloride in dioxane followed by removal of the solvent provided the dihydrochloride salt.
EXAMPLE 15
10-[(6-Chloro-3-methoxy-2′-ethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(pyridin-2-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. 2-Chloro-2′-ethoxy-5-methoxy-[1,1′-biphenyl]-4-carboxylic acid
[0396] To a stirred solution of 4-iodo-5-chloro-2-methoxy benzoic acid of Example 15, Step A (0.500 g, 1.6 mmol) in N,N-dimethylformamide (30 mL) was added 2-ethoxy phenyl boronic acid (0.8 g, 4.8 mmol) and potassium carbonate (2.04 g, 14.7 mmol). This mixture was purged with nitrogen and then treated with a catalytic amount of tetrakis(triphenylphosphine) palladium(0) (0.093 g, 0.08 mmol). The reaction was heated to reflux overnight, cooled, acidified with 2 N hydrochloric acid and extracted with ethyl acetate. The organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and evaporated to yield the title acid which was used in the next step without further purification.
Step B. 10-{[6-Chloro-3-methoxy-2′-ethoxy-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
[0397] To a stirred solution of the 2-chloro-2′-ethoxy-5-methoxy [1,1′-biphenyl]-4-carboxylic acid of Step A (0.491 g) in tetrahydrofuran (5 mL) containing a catalytic amount of N,N-dimethyl formamide was added dropwise thionyl chloride (0.210 g, 1.76 mmol). The reaction mixture was stirred for 2 hours, and then added dropwise to a solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (0.294 g, 1.60 mmol) in tetrahydrofuran (5 mL) containing triethylamine (0.357 g, 3.52 mmol). The reaction mixture was stirred for 2 hours, diluted with dichloromethane and washed with saturated aqueous sodium bicarbonate and brine. The organic layer was dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness. Trituration of the residue with methanol provided the title compound as an off-white solid, 99.24% pure by analytical HPLC [Primesphere C-18 column (2.0×150 mm); mobile phase 70/30 acetonitrile/water containing 0.1% phosphoric acid], m.p. 213-215° C.
[0398] [0398] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.11, (t, 3H), 3.51 (s, 3H), 3.92 (q, 2H), 5.17-5.20 (br, m, 3H), 5.89 (t, 1H), 5.97 (s, 1H), 6.67-7.55 (m, 10H).
[0399] MS [(+)APCI, m/z]: 473 [M+H] + .
[0400] Anal. Calcd. for C 28 H 25 CIN 2 O 3 : C, 71.11; H, 5.33; N, 5.92. Found: C, 70.31; H, 5.27; N, 5.79.
Step C. 10-{[6-Chloro-3-methoxy-2′-ethoxy-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0401] Prepared by treatment of 10-{[6-chloro-3-methoxy-2′-ethoxy-1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine of Step B with trichloroacetyl chloride, followed by basic hydrolysis of the intermediate trichloroacetate ester in the manner of Example 1, Steps E and F.
Step D. 10-[(6-Chloro-3-methoxy-2′-ethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(pyridin-2-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0402] Prepared by coupling the 10-{[6-chloro-3-methoxy-2′-ethoxy-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step C with 2-(aminomethyl)pyridine (1.25 equiv.) in the manner of Example 1.
EXAMPLE 16
10-[(6-Chloro-3-methoxy-2′-fluoro-[1,1′-biphenyl]-yl)carbonyl]-N-methyl-N-[2-(pyridin-2-yl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. 2-Chloro-2′-fluoro-5-methoxy-[1,1′-biphenyl]-4-carboxylic acid
[0403] To a stirred solution of 4-iodo-5-chloro-2-methoxy benzoic acid of Example 15, Step A (3.72 g, 19.1 mmol) in N,N-dimethylformamide (20 mL) was added 2-fluorophenyl boronic acid (5.0 g, 35.7 mmol) and potassium carbonate (14.8 g, 107 mmol). This mixture was purged with nitrogen and then treated with a catalytic amount of tetrakis(triphenylphosphine) palladium(0) (0.688 g, 0.59 mmol). The reaction was heated to reflux overnight, cooled, acidified with 2 N hydrochloric acid and extracted with ethyl acetate. The organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness. The residue was flash chromatographed on acid washed silica using a 10 to 50% gradient of diethyl ether in hexane to provide the desired title compound (3.8 g) as a white solid.
[0404] [0404] 1 H NMR (DMSO-d 6 , 400 MHz) δ3.83 (s, 3H), 7.15 (s, 1H), 7.30-7.35 (m, 2H), 7.42 (m, 1H), 7.48-7.54 (m, 1H), 7.74 (s, 1H).
[0405] MS [(+)ESI, m/z]: 298 [M+NH 4 ] + .
[0406] Anal. Calcd. for C 14 H 10 ClFO 3 : C, 59.91; H, 3.59. Found: C, 59.79; H, 3.35.
Step B. 10-{[6-Chloro-3-methoxy-2′-fluoro-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
[0407] To a stirred solution of 2-chloro-2′-fluoro-5-methoxy-[1,1′-biphenyl]-4-carboxylic acid of Step A (3.80 g, 13.5 mmol) in tetrahydrofuran (20 mL) containing a catalytic amount of N,N-dimethylformamide was added dropwise thionyl chloride (1.77 g, 14.9 mmol). The reaction mixture was stirred for 2 hours, and then added dropwise to a solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (2.49 g, 13.5 mmol) in tetrahydrofuran (20 mL) containing triethylamine (3.0 g, 29.8 mmol). The reaction mixture was stirred for 2 hours, diluted with dichloromethane and washed with saturated aqueous sodium bicarbonate and brine. The organic layer was dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness. Recrystallization of the residue from ethyl acetate/heptane provided the title compound as a pale yellow solid, m.p. 192-194° C., found to be 99.99% pure by analytical HPLC [Primesphere C-18 column (2.0×150 mm); mobile phase: gradient from 10 to 100% of acetonitrile/water containing 0.1% phosphoric acid, 7 minute gradient].
[0408] [0408] 1 H NMR (DMSO-d 6 , 400 MHz): δ3.55 (s, 3H), 5.19 (br m, 2H), 5.90 (t, 1H), 5.96 (s, 1H), 6.80 (s, 2H), 7.07-7.63 (m, 10H).
[0409] MS [(+)ESI, m/z]: 447 [M+H] + .
[0410] Anal. Calcd. for C 26 H 20 ClFN 2 O 2 +H 2 O: C, 69.60; H, 4.54; N, 6.24. Found: C, 69.39; H, 4.41; N, 6.20.
Step C. 10-{[6-Chloro-3-methoxy-2′-fluoro-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0411] A solution of the 10-{[6-chloro-3-methoxy-2′-fluoro-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine of Step B (3.02 g, 6.76 mmol) in dichloromethane (35 mL) was treated with N,N-diisopropylethyl amine (0.960 g, 7.43 mmol) and stirred for 10 minutes. Trichloroacetyl chloride (1.47 g, 8.10 mmol) was then added dropwise. The reaction mixture was stirred overnight, diluted with dichloromethane, washed with 0.1 N hydrochloric acid, saturated aqueous sodium bicarbonate, and brine. The organic phase was dried over anhydrous magnesium sulfate, filtered, and evaporated to yield the crude trichloroketone intermediate which without further purification, was dissolved in acetone and treated with an excess of 1 N sodium hydroxide The mixture was stirred overnight, and then diluted with isopropyl acetate and acidified with 1 N hydrochloric acid. The organic layer was washed with brine, dried over anhydrous magnesium sulfate, filtered, and evaporated to dryness. The solid residue was triturated with methanol to provide the title compound (2.95 g) as a beige solid, m.p. 207-208° C.
[0412] [0412] 1 H NMR (DMSO-d 6 , 400 MHz): δ3.49 (br, 3H), 6.12 (d, 1H), 6.72 (d, 1H), 6.77 (s, 1H), 7.01 (d, 2H), 7.09 (m, 1H), 7.26 (m, 4H), 7.45 (m, 2H), 7.61 (br, 1H), 12.35 (br, 1H).
[0413] MS [(+)APCI, m/z]: 491 [M+H] + .
[0414] Anal. Calcd for C 27 H 20 ClFN 2 O 4 : C, 66.06; H, 4.11; N, 5.71. Found: C, 65.68; H, 4.24; N, 5.48.
Step D. 10-[(6-Chloro-3-methoxy-2′-fluoro-[1,1′-biphenyl]-yl)carbonyl]-N-methyl-N-[2-(pyridi-2-yl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0415] Prepared by the coupling of the [(6-chloro-3-methoxy-2′-fluoro-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step C with methyl-(2-pyridin-2-yl-ethyl)-amine (1.25 equiv.), in the manner of Example 1.
EXAMPLE 17
10-{[6-(Naphthalen-1-yl)-pyridin-3-yl]carbonyl}-N-(pyridin-4-ylmethyl)-10,11-dihydro-5H-pyrrolo[1,2-c][1,4]benzodiazepine-3-carboxamide
Step A. (6-Chloro-pyridin-3-yl)-[10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl]methanone
[0416] A solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (100 mmol) and N,N′-diisopropylethyl amine (130 mmol) in dichloromethane (500 mL) was cooled to 0° C. 6-Chloronicotinoyl chloride (130 mmol) was added dropwise under nitrogen. The solution was stirred for one hour as it returned to room temperature. The reaction mixture was filtered through a sica gel pad, washed with 0.5 N sodium hydroxide and water, dried over anhydrous magnesium sulfate. The solution was again filtered through a silica gel pad and evaporated to dryness in vacuo. The residual oil crystallized from diethyl ether to provide the title compound as a colorless crystalline solid, m.p. 165-167° C.
[0417] [0417] 1 HNMR 9400 Mhz, DMSO-d 6 ): δ5.35 (br, 4H), 5.91 (t, 1H), 5.97 (s, 1H), 6.83 (t, 1H), 7.0 (br d, 1H), 7.18 (t, 1H), 7.19 (t, 1H), 7.39 (d, 1H), 7.46 (dd, 1H), 7.71 (d, 1H), 8.26 (s, 1H).
[0418] MS [El, m/z]: 323 [M] + .
[0419] Anal. Calcd. for C 18 H 14 CIN 3 O: C, 66.77; H, 4.36; N, 12.98. Found: C, 65.91; H, 4.18; N, 12.69.
Step B. [6-(Naphthalen-1-yl)-pyridin-3-y]-[10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl]methanone
[0420] A suspension of (6-chloro-pyridin-3-yl)-[10,11-dihydro-5H-pyrrolo{2,1-c][1,4]benzodiazepin-10-yl]methanone of Step A (0.645 g, 1.9 mmol) and naphthalene boronic acid (0.372 g, 2.1 mmol) in a mixture of toluene (1.2 mL), ethanol (2 mL) and 1M aqueous sodium carbonate (0.4 mL) was sparged with nitrogen for 10 minutes. To this was added palladium(I) acetate (0.026 g, 0.1 mmol). The mixture was heated at reflux under a static pressure of nitrogen for 48 hrs. The reaction was diluted with ethyl acetate and water. The organic layer was washed with saturated aqueous sodium bicarbonate then water. The sample was dried over anhydrous magnesium sulfate, filtered and concentrated in vacuo to a brown oil. Flash chromatography of the residue on silica gel eluting with 20-50% ethyl acetate in hexane, yielded 0.180 g of a solid which was recrystallized from chloroform to provide the title compound as off white crystals, m.p. 155-158° C.
[0421] [0421] 1 H NMR (400 MHz, DMSO-d 6 ): δ5.40 (br, 4H), 5.93(m, 1H), 5.99 (s, 1H), 6.84 (s, 1H), 7.08(br d, 1H), 7.16 (t, 1H), 7.23 (t, 1H), 7.52 (m, 6H), 7.84(d, 2H), 7.98 (dd, 2H), 8.55 (s, 1H).
[0422] MS [(+)ESI, m/z]: 416 [M+H] + .
[0423] Anal. Calcd. for C 28 H 21 N 3 O+0.5 H 2 O: C, 79.22; H, 5.23; N, 9.90. Found: C, 79.08; H, 4.94; N, 9.73.
Step C. 10-{[6-(Naphthalen-1-yl)-pyridin-3-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[1,2-c][1.4]benzodiazepine-3-carboxylic acid
[0424] Prepared from [6-(naphthalen-1-yl)-pyridin-3-yl][10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-10-yl]methanone of Step B by treatment with trichloroacetyl chloride, followed by basic hydrolysis of the intermediate trichloroacetate ester in the manner of Example 1, Steps E and F.
Step D. 10-{[6-(Naphthalen-1-yl)-pyridin-3-yl]carbonyl}-N-(pyridin-4-ylmethyl)-10,11-dihydro-5H-pyrrolo[1,2-c][1,4]benzodiazepine-3-carboxamide
[0425] Prepared by the coupling of 10-{[6-(naphthalen-1-yl)-pyridin-3-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[1,2-c][1.4]benzodiazepine-3-carboxylic acid of Step C, and 4-(aminomethyl)pyridine (1.25 equiv) in the manner of Example 1.
EXAMPLE 18
10-[(6-Phenyl-pyridin-3-yl)carbonyl]-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. 10-(Methoxycarbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid
[0426] A solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (5 mmol) and N,N-diisopropylethyl amine (12 mmol) in dichloromethane (100 mL) was cooled to 0° C. and treated dropwise with trichloroacetylchloride (12 mmol) in dichloromethane (20 mL). The solution was maintained at 0° C. for two hours and then allowed to warm to room temperature overnight. The solution was then treated with methanol (25 mL) and stirring was continued for 2 hours. The solution was washed with 0.1N hydrochloric acid, water and brine, dried over anhydrous magnesium sulfate, filtered and concentrated to yield the title compound as a white solid, m.p. 153-154° C. (dec.).
[0427] Anal. Calcd. for C 15 H 14 N 2 O 4 +0.06 C 4 H 8 O 2 +0.07 C 3 H 6 O: C, 62.77; H, 5.08; N, 9.48. Found: C, 62.26; H, 5.22; N, 9.37.
Step B. 10-(Methoxycarbonyl)-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0428] The title compound was prepared by coupling the 10-(methoxycarbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid of Step A with 3-(aminomethyl) pyridine (1.2 equiv.), in the manner of Example 1, Step G.
Step C. N-(3-Pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0429] A solution of 10-(methoxycarbonyl)-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide (5 mmol) of Step B in methanol (50 mL) was treated with potassium carbonate and stirred at room temperature overnight. Water was then added to the solution and the pH adjusted to 6 with 6N hydrochloric acid. The solution was extracted with ethyl acetate, and the combined organic layers were dried over anhydrous magnesium sulfate, and evaporated to dryness. The residual oil was triturated with ethyl acetate and hexane to yield the title compound as a powder.
Step D. 10-[(6-Phenyl-pyridin-3-yl)carbonyl]-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0430] A solution of 6-phenyl-nicotinyl chloride (6 mmol) [prepared by the method of Ogawa (Ogawa et al WO 9534540)] in dichloromethane (20 mL) was added dropwise to a cold (0° C.) solution of N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepine-3-carboxamide of Step C (5 mmol) and N,N-diisopropylethyl amine (6 mmol) in dichloromethane (100 mL). The solution was stirred at 0° C. for 2 hours and then allowed to warm to room temperature overnight. The solution was washed with pH 6 buffer, and brine, dried over anhydrous sodium sulfate, filtered and concentrated. The residue was chromatographed on silica gel using 5% methanol in chloroform containing 0.5% ammonium hydroxide, to provide the title compound.
EXAMPLE 19
[3-Methyl-4-(pyridin-4-yl)-phenyl]-{3-[4-(pyridin-2-yl)-piperazin-1-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-10-yl-methanone
Step A. (4-Bromo-3-methylphenyl)-[10,11-dihydro-5H-pyrrolo[2,1 c][1,4] benzodiazepin-10-yl]methanone
[0431] A solution of 4-bromo-3-methyl benzoic acid (4.3 g, 2 mmol) in dry tetrahydrofuran (100 mL) was cooled to 0° C. under nitrogen. To this was added N,N-dimethylformamide (50 μL) followed by oxalyl chloride (2.2 mL, 25 mmol) dropwise to control the gas evolution. When the gas evolution ceased, the mixture was warmed to reflux for 5 minutes then cooled to room temperature and concentrated in vacuo. The sample was treated with tetrahydrofuran and evaporated to dryness (twice) to yield the crude acid chloride as an orange oil. A solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (3.60 g, 20 mmol) and Hünig's base (4.35 mL, 25 mmol) in dichloromethane was cooled to 0° C., and a solution of the crude acid chloride in dichloromethane (25 mL) was added dropwise. The mixture was stirred overnight at room temperature, washed with 1N hydrochloric acid, saturated aqueous sodium bicarbonate and brine. The solution was dried over anhydrous sodium sulfate, filtered and evaporated in vacuo to yield a solid (8.01 g) which was purified by flash chromatography on silica gel eluting with 20% ethyl acetate in hexane to provide the title compound (6.03 g) as a white solid.
[0432] [0432] 1 H NMR (300 MHz, CDCl 3 ): δ2.30 (s, 3H), 5.20 (br, 4H), 6.05 (d, 2H), 6.70 (s, 1H), 6.85 (br, 2H), 7.17 (m, 2H), 7.30 (m, 2H), 7.37 (d, 1H).
Step B. [3-Methyl-4-(pyridin-4-yl)phenyl]-[10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl]methanone
[0433] A suspension of (4-bromo-3-methylphenyl)[10,11-dihydro-5H-pyrrolo[2,1-c][1,4] benzodiazepin-10-yl]methanone of Step A (1.14 g, 2.9 mmol), pyridine-4-boronic acid (0.368 mg, 2.9 mmol) and sodium carbonate (0.760 g, 7.2 mmol) in a mixture of toluene (30 mL), water (10 mL), and ethanol (5 mL) was sparged with nitrogen for 15 minutes. To this was added tetrakis(triphenylphosphine)palladium(0) (0.027 g) and the mixture was heated to reflux under a static pressure of nitrogen. After 24 hours additional boronic acid (0.128 mg, 1 mmol) and sodium carbonate (0.116 g) were added and the heating was continued for 24 hours. Additional catalyst (0.012 g) was added and heating was continued for another 24 hours. The mixture was partitioned between ethyl acetate and hexane. The water layer was washed twice with ethyl acetate and the combined organic layers were dried over anhydrous magnesium sulfate and stripped to a solid. Flash chromatography of the residue on silica gel eluting with 30% ethyl acetate in hexane provided a solid which was recrystallized from ethyl acetate/hexane to provide the title compound (0.254 g) as tan plates m.p. 208-210° C.
[0434] [0434] 1 H NMR (400 MHz, DMSO-d 6 ): δ1.75 (s, 3H), 1.77 (s, 3H), 5.18 (br, 4H), 5.89 (s, 2H), 6.05 (br, 1H), 6.08 (t, 1H), 6.69 (t, 1H), 6.85 (br, 1H), 7.03 (br, 3H), 7.16 (t,1H), 7.35 (d, 1H).
[0435] MS [El, m/z]: 379 [M] + .
[0436] Anal. Calcd. for C 25 H 21 N 3 O+0.5 H 2 O: C, 77.30; H, 5.71; N, 10.82. Found: C, 77.01; H, 5.37; N, 10.68.
Step C. 10-[3-Methyl-4-(pyridin-4-yl)benzoyl]-10,11-dihydro-5H-pyrrolo[2,1 c][1,4]benzodiazepine-3-carboxylic acid
[0437] To a stirred solution of [3-methyl-4-(pyridin-4-yl)phenyl][10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-10-yl]methanone of Step B (5 mmol) and N,N-diisopropylethyl amine (12 mmol) in dichloromethane (200 mL) cooled to 0° C. was added dropwise a solution of trichloroacetyl chloride (12 mmol) in dichloromethane. The temperature was maintained at 0° C. until the addition was complete. The reaction was stirred overnight as it warmed to room temperature. The solution was then washed with 10% aqueous sodium bicarbonate and the organic layer was dried, concentrated and filtered through a pad of silica gel with 1:1 ethyl acetate/hexane containing 0.1% acetic acid. The filtrate was concentrated in vacuo and the residue was dissolved in acetone and 1N sodium hydroxide (2:1,v/v) and stirred at room temperature for 1 hour and then the pH was adjusted to pH 4 with glacial acetic acid. The solution was concentrated to one half the volume in vacuo and the residue extracted with ethyl acetate. The combined organic layers were dried and evaporated to an oil which was triturated with hexane to yield a solid (0.98 g).
Step D. [3-Methyl-4-(pyridin-4-yl)-phenyl]-{3-[4-(pyridin-2-yl)-piperazin-1-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-10-yl-methanone
[0438] The title compound was obtained from the 10-[3-methyl-4-(pyridin-4-yl)benzoyl]-10,11-dihydro-5H-pyrrolo[2,1c][1,4]benzodiazepine-3-carboxylic acid of Step C and 1-(pyridin-2-yl)piperazine ((1.2 equiv.), in the manner of Example 1.
EXAMPLE 20
10-[(2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)carbonyl]-8-[(piperidin-1-yl)carbonyl]-N-(pyridin-4-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. [4-(2-Formyl-1H-pyrrole-1-yl)methyl]-3-nitro]-benzoic acid methyl ester
[0439] To a suspension of sodium hydride (8.1 g, 60% suspension in oil) in N,N-dimethylformamide (25 mL) was added dropwise over 15 minutes a solution of pyrrole 2-carboxaldehyde (9.1 g, 1 equiv.) in N,N-dimethylformamide (25 mL). After the addition, the reaction mixture was stirred for 30 minutes and then cooled to 0° C. A solution of 4-bromomethyl-2-nitrobenzoic acid (25.0 g, 1 equiv.) in N,N-dimethylformamide (50 mL) was added dropwise over 20 minutes. After the addition, the reaction mixture was stirred at room temperature for 1 hour and then iodomethane (1.2 eq.) was added. The reaction mixture was stirred at room temperature overnight and diluted with water (200 mL). The solid was filtered, washed with water and dried over anhydrous potassium carbonate in vacuo at 50° C. to provide the crude title compound as a brown solid (26 g) which was used as such in the next step.
Step B. 10,11-Dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-8-carboxylicacid methyl ester
[0440] To a stirred solution of tin(II) chloride dihydrate (23 g, 3.5 eq) in 2 N hydrochloric acid (106 mL) was added the [4-(2-formyl-1H-pyrrole-1-yl)methyl]-3-nitro]-benzoic acid methyl ester of Step A (8 g). Methanol (200 mL) was then added to this solution and the reaction mixture was stirred at 40° C. for 2 hours. The reaction was then cooled to room temperature, quenched by the addition of saturated aqueous sodium carbonate (20 mL) and filtered through Celite. The filter pad was washed with methanol and hot ethyl acetate. The filtrate and washings were combined, concentrated in vacuo to a volume of 300 mL and extracted with ethyl acetate. The combined extracts were dried over anhydrous magnesium sulfate, filtered and concentrated in vacuo to a volume of 200 mL. Acetic acid (1 g) and 10% palladium on charcoal (1.5 g) were added and the mixture was hydrogenated overnight at atmospheric pressure. The reaction was then filtered through Celite and the solvent removed in vacuo to give a dark brown crystalline solid (16.4 g). This was dissolved in dichloromethane and filtered through a silica pad eluting with dichloromethane to provide the title compound as a yellow crystalline solid (11.7 g). Recrystallization from 1,2-dichloroethane yielded a yellow crystalline solid (5.7 g), m.p. 198-200° C.
[0441] [0441] 1 H NMR(CDCl 3 , 200 MHz): δ3.95 (s, 3H), 4.50 (s, 2H), 5.20 (s, 2H), 6.05 (t, 2H), 6.70 (t, 1H), 7.05 (d, 1H), 7.15 (s, 1H), 7.20 (d, 1H), 7.30 (s, 1H).
Step C. Methyl 10-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1.4]benzodiazepine-8-carboxylate
[0442] To a solution of 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-8-carboxylic acid methyl ester of Step B (1.64 g) in 1,2-dichloroethane (25 mL) was added 4-(2-trifluoromethylphenyl)-3-methylbenzoyl chloride (2.0 g, 1.1 eq) prepared in the manner of Example 1, Step D and triethylamine (1.0 g) and the mixture was stirred at room temperature overnight. The solvent was then removed in vacuo and the residue chromatographed on silica gel eluting with 10% ethyl acetate in petroleum ether to provide the title compound as a white crystalline solid, m.p. 180-182° C.
[0443] [0443] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.80 (s, 3H), 3.70 (s, 3H), 5.0-5.5 (br, 4H), 5.80 (t, 1H), 6.00 (s, 1H), 6.85 (t, 1H), 6.90 (s, 1H), 7.00 (br, 1H), 7.20 (d, 1H), 7.35 (s, 1H), 7.60 (t, 2H), 7.70 (t, 2H), 7.75 (d, 1H), 7.80 (d, 1H).
[0444] MS [(+)ESI, m/z]: 505 [M+H] + .
[0445] Anal. Calcd. for C 29 H 23 F 3 N 2 O 3 : C, 69.04; H, 4.60; N, 5.55. Found: C, 67.76; H, 4.30; N, 5.40.
Step D. 10-{[2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-8-carboxylic acid sodium salt
[0446] To a stirred solution of methyl 10-{[2-methyl-2′-(trifluoromethyl)-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1.4]benzodiazepine-8-carboxylate of Step C (0.200 g) in ethanol (5 mL) was added 2.5 N sodium hydroxide (4 mL). The reaction mixture was then stirred overnight at room temperature and the solvent removed in vacuo. The residue was acidified with 2 N hydrochloric acid and extracted with diethyl ether. The combined extracts were dried over anhydrous magnesium sulfate and filtered, and the the filtrate evaporated to dryness. The residue was dissolved in anhydrous ethanol and treated with 2.5 N sodium hydroxide (1.0 equiv.). After stirring for 30 minutes at room temperature, the solvent was removed in vacuo to provide the title compound sodium salt as a white solid, m.p. 210° C.
[0447] [0447] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.85 (s, 3H), 5.20 (br, 3H), 5.90 (s, 2H), 6,80 (t, 1H), 6.90-7.80 (m, 11H).
[0448] MS [(+)APCI, m/z]: 491 [M+H] + .
[0449] Anal. Calcd. for C 28 H 21 F 3 N 2 O 3 Na+H 2 O: C, 63.27; H, 4.36; N, 5.27. Found: C, 63.04; H, 4.21; N, 4.99.
Step E. 8-[(Piperidin-1-yl)carbonyl]-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
[0450] Prepared by coupling of 10-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-8-carboxylic acid of Step D with piperidine, in the manner of Example 1, Step G.
Step F. 10-[(2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)carbonyl]-8-[(piperidin-1-yl)carbonyl]-N-(pyridin-4-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0451] Prepared by treatment of 8-[(piperidin-1-yl)carbonyl]-{[2-methyl-2′-(trifluoromethyl)-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine of Step E with diphosgene (1.1 equiv.) and triethylamine (1.5 equiv.) followed by 4-(aminomethyl)pyridine (1.5 equiv.) in the manner of Example 14, Step E.
EXAMPLE 21
10-[(3,6-Dimethoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
Step A. 2,5-Dimethoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-carboxylic acid
[0452] A suspension of 4-bromo-2,5-dimethoxybenzoic acid [prepared in the manner of Bortnik et al., Zh. Org. Khim. 8, 340 (1972)] (2.43 g, 9 mmol), 2-trifluoromethylphenyl boronic acid (5.3 g, 28 mmol), and potassium carbonate (6.21 g, 60 mmol) in dioxane (40 mL) was sparged with nitrogen and treated with tetrakis(triphenylphosphine)palladium(0) (0.328 g, 0.2 mmol). The mixture was heated to reflux for 48 hours, cooled, acidified with 1N hydrochloric acid and extracted with ethyl acetate The extracts were dried over anhydrous magnesium sulfate, filtered and stripped to a solid which was used as such in the next step.
[0453] [0453] 1 H NMR (300 MHz,CDCl 3 ): δ3.90 (s, 3H), 4.05 (s,3H), 7.30 (d, 1H), 7.70 (s, 1H).
Step B. 10-{[3,6-Dimethoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-[10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine
[0454] The title compound was prepared in the manner of Example 19, Step A using 2,5-dimethoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-carboxylic acid of Step A (1.63 g, 5 mmol), oxalyl chloride (700 μL, 8 mmol), N,N-dimethylformamide (10 μL), 10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (0.93 g, 5 mmol) and Hünig's base (1.78 ml, 10 mmol). Flash chromatography over silica gel using a solvent gradient from 30% ethyl acetate in hexane to 100% ethyl acetate provided the title compound (0.900 g) as a solid. Recrystallization from acetone/hexane yielded white needles, m.p. 210-213° C.
[0455] [0455] 1 H NMR (400 MHz, DMSO-d 6 : δ3.41 (s, 3H), 3.56 (s, 3H), 5.21 (br, 4H), 5.90 (t, 1H), 5.96 (s, 1H), 6.50 (s, 1H), 6.80 (s, 1H), 7.00 (s, 2H), 7.07 (s, 1H), 7.10 (t, 1H), 7.18 (d, 1H), 7.37 (d, 1H), 7.53 (t, 1H), 7.62 (t, 1H), 7.73 (d, 1H).
[0456] MS [(+)ESI, m/z]: 493 [M+H] + .
[0457] Anal. Calcd. for C 28 H 23 F 3 N 2 O 3 : C, 68.29; H, 4.71; N, 5.69. Found: C, 67.98; H, 4.66; N, 5.61.
Step C. 10-{[3,6-Dimethoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]-carbonyl}-10,11-dihydro-5H-pyrrolo[1,2-c][1,4]benzodiazepine-3-carboxylic acid
[0458] Prepared from 10-{[3,6-dimethoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]-carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine of Step B and trichloroacetyl chloride, followed by basic hydrolysis of the intermediate trichloroacetate ester, in the manner of Example 1, Steps E and F.
Step D. 10-[(3,6-Dimethoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(pyridin-3-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0459] Prepared from 10-{[(3,6-dimethoxy-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]-carbonyl}-10,11-dihydro-5H-pyrrolo[1,2-c][1,4]benzodiazepine-3-carboxylic acid of Step C and methyl-pyridin-3-ylmethyl-amine (1 equiv.) in the manner of Example 5, Step E.
EXAMPLE 22
10-[(2′-Chloro-2-methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(pyridin-2-ylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-carboxamide
[0460] To a solution of 10-{[2-methoxy-2′-chloro[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxylic acid (0.230 g, 0.54 mmol) [prepared from trifluoromethanesulfonic acid 4-formyl-2-methoxy-phenyl ester of Example 7, Step A and 2-chlorophenyl boronic acid, in the manner of Example 7, Steps B-E], in N,N-dimethylformamide (15 mL) is added 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (0.120 g, 0.625 mmol) and 1-hydroxybenzotriazole (0.625 mmol). To the homogeneous solution was added methyl-pyridin-2-ylmethyl-amine (0.625 mmol) and the stirring was continued at room temperature overnight. At the end of this time the solution was poured into water and extracted with ethyl acetate. The combined extracts were washed with water, dried and concentrated and the residue was chromatographed on silica gel, eluting with 95:5 chloroform:methanol. The pure fractions were concentrated, and the residue azeotroped and triturated several times with hexane to yield the title product.
EXAMPLE 23
{[[3-(Pyridin-2-ylmethyl)amino]carbonyl]-4H-10H-3a,5,9-triaza-benzo[f]azulen-9-yl}-(2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-methanone
Step A. 2-Chloromethyl-pyridine-3-carboxylic acid methyl ester
[0461] A solution of methyl 2-methyinicotinate (20.0 g, 0.132 mol) and trichloroisocyanuric acid (46.0 g, 0.198 mol) in dichloromethane (100 mL) was stirred at room temperature overnight. The reaction mixture was then washed with saturated aqueous sodium carbonate and saturated aqueous sodium chloride, dried over anhydrous magnesium sulfate, filtered, and the solvent evaporated in vacuo to provide the title compound as a yellow liquid (11.2 g), which is used as such in the next step
Step B. 2-(2-Formyl-pyrrol-1-ylmethyl)-pyridine-3-carboxylic acid methyl ester
[0462] To a suspension of sodium hydride (5.8 g, 0.12 mol), was in dry N,N-dimethyl formamide (25 mL) was added slowly under nitrogen a solution of pyrrole 2-carboxaldehyde (10.5 g, 0.11 mol) in N,N-dimethylformamide (10 mL), and the reaction mixture was stirred at room temperature for 30 minutes. The reaction was then cooled to 5° C. and 2-chloromethyl-pyridine-3-carboxylic acid methyl ester of Step A was added slowly, the temperature being maintained at or below 20° C. After the addition was complete, the reaction was stirred at room temperature for 30 minutes. The mixture was evaporated to dryness, and the residue was dissolved in ethyl acetate (250 mL). This solution was washed with water and dried over anhydrous magnesium sulfate. The solvent was then removed in vacuo leaving a dark crystalline solid (23.4 g), which was purified by chromatography on silica gel eluting with a gradient of ethyl acetate/petroleum ether to provide the title compound as a tan crystalline solid (13.75 g), m.p. 91-93° C.
Step C. 1-(3-Phenylacetyl-pyridin-2-ylmethyl)-1H-pyrrole-2-carbaldehyde
[0463] To a stirred solution of 2-(2-formyl-pyrrol-1-ylmethyl)-pyridine-3-carboxylic acid methyl ester of Step B (13.65 g, 55.9 mmol) in methanol (50 mL) was added sodium hydroxide (2.2 g, 55.9 mmol.). The reaction mixture was refluxed under nitrogen for 2 hours, and then the solvent was removed in vacuo. A portion of the residual yellow solid.(5 g) was suspended in a mixture of benzyl alcohol (20 mL) and benzene (30 mL). Diphenylphosphoryl azide (6.54 g, 1.2 equiv.) was added, and the reaction was slowly heated to reflux. After refluxing for 1 hour, the mixture was cooled and washed with water, dried over anhydrous magnesium sulfate, filtered and evaporated to dryness to provide the title compound as a tan crystalline solid (4.4 g), m.p. 109-111° C.
Step D. 9,10-Dihydro-4H-3a,5,9-triaza-benzo[f]azulene
[0464] A stirred mixture of 1-(3-phenylacetyl-pyridin-2-ylmethyl0-1H-pyrrole-2-carbaldehyde of Step C (1.0 g), in ethyl acetate (10 mL) containing 10% palladium on charcoal (10 mg.), magnesium sulfate (0.010 g) and 5 drops of acetic acid was hydrogenated at atmospheric pressure until hydrogen uptake ceased. The reaction mixture was then filtered through Celite and the solvent removed in vacuo. The crude product (yellow crystalline solid, 0.530 g) was purified by chromatography on silica gel eluting with a gradient of ethyl acetate in petroleum ether to provide the title product as a yellow crystalline solid, m.p. 171-172° C.
Step E. (4-Bromo-3-methyl-phenyl)-(4H,10H-3a,5,9-triaza-benzo[f]azulen-9-yl)-methanone
[0465] To a stirred solution of the 9,10-dihydro-4H-3a,5,9-triaza-benzo[f]azulene of Step D (1.0 g) in dichloromethane (10 mL) was added 3-methyl-4-bromobenzoyl chloride (1.39 g) and triethylamine (1.1 mL). After stirring for 2.5 hours, the reaction mixture was washed with water, dried over anhydrous magnesium sulfate, filtered and the solvent removed in vacuo to provide the title product as a tan crystalline solid (2.3 g), which was used without further purification.
Step F. (2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-(4H,10H-3a,5,9-triaza-benzo[f]azulen-9-yl)-methanone
[0466] A stirred mixture of (4-bromo-3-methyl-phenyl)-(4H,10H-3a,5,9-triaza-benzo[f]azulen-9-yl)-methanone of Step E (1.0 g), 2-trifluoromethyl-boronic acid (1.49 g, 3.0 equiv.), potassium phosphate (2.2 g) and a catalytic amount (0.050 g) of tetrakis(triphenylphosphine) palladium (0) in dioxane (10 mL) was refluxed for 2 hours. The solvent was then removed in vacuo and the residue dissolved in dichloromethane. The solution was then washed with water, dried over anhydrous magnesium sulfate, filtered and evaporated to dryness. The residue was then chromatographed on silica gel eluting with 5% ethyl acetate in dichloromethane to yield a colorless gum which crystallized upon addition of a little diethyl ether to provide the title compound as a cream-colored crystalline solid (0.500 g), m.p. 153-155° C.
[0467] [0467] 1 H NMR (DMSO-d 6 , 400 MHz): δ1.85 (s, 3H), 5.10 (s, 2H), 5.40 (s, 2H), 5.90 (t, 1H), 6.00 (s, 1H), 6.90 (t, 1H), 6.94 (d, 1H), 7.03 (d, 1H), 7.12 (dd, 1H), 7.23 (d, 1H), 7.28 (s, 1H), 7.37 (d, 1H), 7.58 (t, 1H), 7.68 (t, 1H), 7.80 (d, 1H), 8.27 (d, 1H)
[0468] MS [(+)ESI, m/z]: 448 [M+H] + .
[0469] Anal. Calcd. for C 26 H 20 F 3 N 3 O: C, 69.79; H, 4.51; N, 9.39. Found: C, 69.91; H, 4.30; N, 9.26).
Step G. 2,2,2-Trichloro-1-{[9-(2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)carbonyl]-9,10-dihydro-4H-3a,5,9-triaza-benzo[f]azulen-3-yl}-ethanone
[0470] To a solution of (2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-(4H,10H-3a,5,9-triaza-benzo[f]azulen-9-yl)-methanone in methylene chloride was added trichloroacetyl chloride (1.1 equiv.) and triethylamine (1.5 equiv,) After stirring overnight at room temperature, the reaction was washed with water, dried over anhydrous magnesium sulfate, and evaporated to dryness to provide the crude title compound which was used as such in the next step.
Step H. 9-[(2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4yl)carbonyl]-9,10-dihydro-3a,5,9-triaza-benzo[f]azulen-3-carboxylic acid
[0471] To a solution of 2,2,2-trichloro-1-{[9-(2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)carbonyl]-9,10-dihydro-4H-3a,5,9-triaza-benzo[f]azulen-3-yl}-ethanone of Step G in acetone was added 2.5 N sodium hydroxide (1.0 equiv.). After stirring overnight, the solvent was removed in vacuo leaving the crude sodium salt of the carboxylic acid. This was dissolved in anhydrous ethanol and treated with 2 N hydrochloric acid (1.0 equiv.). The solvent was removed in vacuo, the residue redissolved in anhydrous ethanol and the solvent again removed in vacuo. The crude title compound was then dried in vacuo over phosphorus pentoxide.
Step I. {[[3-(Pyridin-2-ylmethyl)amino]carbonyl]-4H-10H-3a,5,9-triaza-benzo[f]azulen-9-yl}-(2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl)-methanone
[0472] To a solution of the 9-[(2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4yl)carbonyl]-9,10-dihydro-3a,5,9-triaza-benzo[f]azulen-3-carboxylic acid (3.38 mmol) of Step H in N,N-dimethylformamide (20 mL) was added 1-hydroxybenzotriazole (1.1 equiv.) and [3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (1.2 equiv.), followed by 2-(aminomethyl)pyridine (1.2 equiv.) and N,N-diisopropylethyl amine (1.5 equiv.). The reaction mixture was stirred overnight, then diluted with ethyl acetate and washed with water and saturated aqueous sodium bicarbonate. The organic phase was dried over anhydrous sodium sulfate, filtered and concentrated in vacuo. Purification of the residue was effected by chromatography on silica gel eluting with a gradient of methanol in ethyl acetate to provide the title compound as a white foam.
[0473] The compounds of following Examples 24-143 were prepared according to the General Procedures A-K described below.
[0474] General Procedure A
[0475] Step A. An appropriately substituted haloaryl carboxylic acid (1.1 mol) was converted to the acid chloride by using oxalyl chloride (1.5 mmol) and a catalytic amount of N,N-dimethylformamide in dichloromethane. Upon consumption of the acid as determined by HPLC analysis, all volatiles were removed in vacuo. The resulting residue was dissolved in dichloromethane and added dropwise to a stirred and cooled (0° C.) solution of an appropriately substituted 5H-pyrrolo[2,1-c][1,4]benzodiazepine (1 mmol) and N,N-diisopropylethyl amine (1.2 mmol) in dichloromethane. After 1-16 hours, the mixture was diluted with dichloromethane and washed with 10% aqueous sodium bicarbonate. The combined organic extracts were dried over anhydrous sodium sulfate, filtered and concentrated.
[0476] Step B. To the residue was added an appropriately substituted boronic acid (1.2 mmol), potassium carbonate (2.5 mmol), tetrabutylammonium bromide (1 mmol), palladium(II) acetate (3% mole) and water/acetonitrile (1:1, 2 mL). The contents were heated to 70° C. for 1.5 hours, then ethyl acetate was added and the organic phase washed with water. The solution was filtered through a small plug of Celite and concentrated to dryness.
[0477] Step C. The residue was dissolved in dichloromethane and N,N-diisopropylethyl amine (2 mmol) was added. The flask was purged with nitrogen and trichloroacetyl chloride was added dropwise to the stirred reaction mixture. After 16 hours, the reaction was quenched by adding aqueous potassium carbonate (100 g/300 mL) and the organic phase removed. The aqueous layer was extracted with additional dichloromethane and the combined extracts dried over anhydrous sodium sulfate, filtered and concentrated.
[0478] Step D. The crude product from Step C was dissolved in tetrahydrofuran (1 mL) and 2N sodium hydroxide (1.5 mL) was added. The mixture was heated (70° C.) for 1.5 hours, 2N hydrochloric acid was added and the product extracted with ethyl acetate. The organic phase was dried, filtered and concentrated. The residue was purified by column chromatography using a gradient of ethyl acetate in hexane contaning 1% glacial acetic acid as the eluant.
[0479] Step E. To a stirred solution of a carboxylic acid of Step D above (1.85 mmol) in anhydrous tetrahydrofuran (14 mL) was added 1,1′-carbonyl diimidazole in one portion. The mixture was stirred at room temperature (6-8 hours). The progress of the reaction was monitored by HPLC and when the starting carboxylic acid was consumed, the mixture was worked up to provide the intermediate imidazolide.
[0480] Step F. An aliquot of a tetrahydrofuran solution (400 μL, 0.05 mmole) containing the imidazolide of Step E (0.05 mmol) was treated with a 0.25 M solution of an appropriate amine (0.1 mmol). The mixture was heated at 60° C. and the progress of the reaction followed by HPLC. The solvent was removed and the residue dissolved in dichloromethane (1 mL). The organic phase was washed with brine-water (1:1, v/v, 1 mL) and the aqueous layer extracted with additional dichloromethane. The combined extracts were dried and evaporated to dryness and the residue purified by flash chromatography on silica gel. The column (prepacked in 2.5% methanol in dichloromethane contaning 1% triethylamine) was eluted with a solvent gradient from 2.5 to 5% methanol in dichloromethane, to provide the desired title compound. The desired title compounds were either obtained as crystalline solids by exposure to diethyl ether or were further converted into their salts by any of the following procedures.
[0481] Step G. Compounds prepared according to Step E that dissolved in diethyl ether were treated with a stoichiometric amount of 1N hydrochloric acid in diethyl ether whereby the hydrochloride salts precipitated out as white solids. Compounds that did not conform to the above category, were dissolved in the minimal amount of tetrahydrofuran, then diluted with diethyl ether. The hydrochloride salts were formed upon addition of 1N hydrochloric acid in diethyl ether with stirring. Compounds that did not immediately precipitate out of solution were stirred for 12-16 hours whereupon a white solid precipitated out.
[0482] General Procedure B
[0483] To a stirred solution of an appropriately substituted carboxylic acid of General Procedure A, Step D (2 mmol), 1-ethyl-3-(3-dimethylamino-propyl) carbodiimide (0.229 g, 2.2 mmol) and a catalytic amount of 4-(dimethylamino)pyridine in dichloromethane (6 mL) was added the appropriately substituted amine (2.2 mmol) in dichloromethane (2 mL). The reaction was allowed to stir at room temperature for 16 hours, then diluted with dichloromethane. The organic layer was washed with water, saturated aqueous sodium bicarbonate, dried over anhydrous sodium sulfate and evaporated to dryness. The residue was purified by flash chromatography on silica gel (prepacked in dichloromethane containing 2.5% methanol and 1% triethylamine and eluted with a solvent gradient of 2.5 to 5% methanol in dichloromethane) to provide the desired title compound.
[0484] General Procedure C
[0485] Triphosgene (742 mg, 2.5 mmol) was added to a stirred solution of a carboxylic acid of General Procedure A, Step D (5.0 mmol) in dichloromethane (10 mL). The clear solution was allowed to stir at room temperature (14 hours) after which time the solution turned red. To the reaction mixture was added a solution of the required amine (10.0 mmol) and N,N-diisopropylethyl amine (10.0 mmol) in dichloromethane (5 mL). The mixture was diluted with dichloromethane and washed with water and brine. The organic phase was dried, filtered and concentrated to afford a residue which was purified by flash chromatography on silica gel. The column (prepacked in 2.5% methanol in dichloromethane contaning 1% triethylamine) was eluted with a solvent gradient from 2.5 to 5% methanol in dichloromethane, to provide the title compound.
[0486] General Procedure D
[0487] A stirred solution of a carboxylic acid of General Procedure A, Step D (3.54 mmol) and the appropriately substituted amine (3.72 mmol) in N,N-dimethylformamide (10 mL) was cooled to 0° C. N,N-diisopropylethyl amine (3.89 mmol) was added and the mixture stirred for five minutes. O-(1-Benzotriazolyl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HBTU) (1.42 g, 3.72 mmol) was added to the mixture in one portion. HPLC analysis revealed that the reaction was complete within five minutes. The solvent was removed at reduced pressure. The residue was diluted with water and extracted with ethyl acetate. The combined extracts were dried and concentrated to dryness. The residue was purified by flash chromatography on silica gel (prepacked in ethyl acetate containing 2% triethylamine and eluted with 100% ethyl acetate) to provide the title compound.
[0488] General Procedure E
[0489] To a 0.25 M solution of a carboxylic acid of General Procedure A, Step D (200 μL) in N,N-dimethylformamide was added sequentially a 0.5 M solution of N,N-diisopropylethyl amine (200 μL) in N,N-dimethylformamide and a 0.25 M solution of O-(7-aza-1-benzotriazolyl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HATU) (210 μL) in N,N-dimethylformamide. The mixture was stirred vigorously at room temperature and then a 0.25 M solution of the appropriately substituted amine (200 μL) in N,N-dimethylformamide was added. Stirring was continued for 24 hours at room temperature, then the mixture was diluted with ethyl acetate, and washed with 1:1 water/brine. The organic layer was dried and concentrated to dryness. The residue was purified by flash chromatography on silica gel (prepacked in ethyl acetate containing 2% triethylamine and eluted with 100% ethyl acetate) to provide the title compound.
[0490] General Procedure F
[0491] Step A. To a solution of an appropriately substituted anilino carboxylic acid in methanol was added thionyl chloride. The mixture was heated for 16 hours. The volatiles were removed under reduced pressure and the hydrochloride salt of the carboxylic acid methyl ester was recovered after trituration with methanol/diethyl ether. The solid was dissolved in concentrated hydrochloric acid and cooled. An aqueous solution of sodium nitrite was added and the mixture was stirred at 0° C. for one hour. An aqueous solution of KI/I 2 was prepared and added to the cooled mixture so that the reaction temperature did not exceed 0° C. After 1-2 hours the reaction was complete as evidenced by TLC/HPLC analysis. The product was recovered by extraction with ethyl acetate. The combined extracts were dried, filtered and concentrated to afford the desired substituted aryl iodide which could be further purified by recrystallization.
[0492] Step B. To a solution of an appropriately substituted aryl halide methyl ester of Step A (2 mmol) and an appropriately substituted boronic acid (2 mmol) in 20% aqueous acetone was added cesium carbonate (3 mmol) followed by palladium(II) acetate (60 μmol). The mixture was heated (70° C.) with stirring for 8-16 hours. The reaction was concentrated to remove the acetone after TLC/HPLC analysis indicated the reaction was complete. The aqueous phase was extracted with ethyl acetate and the combined extracts were filtered through a pad of Celite. The filtrate was washed with 5% aqueous sodium bicarbonate and brine, dried over anhydrous sodium sulfate, filtered and evaporated to dryness. The residue was purified by flash chromatography on silica gel.
[0493] Step C. The product from Step B was dissolved in tetrahydrofuran (1 mL) and 2N sodium hydroxide (1.5 mL) was added. The mixture was heated (70° C.) for 1.5 hours, 2N hydrochloric acid was added and the product extracted with ethyl acetate. The organic phase was dried, filtered and concentrated. The residue was purified by column chromatography using ethyl acetate in hexane contaning 1% glacial acetic acid as the eluant.
[0494] Step D. To a suspension of the carboxylic acid of Step C (60 μmol) in dichloromethane (100 μL) was added a 0.45 M solution of oxalyl chloride (200 μL) in dichloromethane followed by dichloromethane (100 μL) containing a catalytic amount of N,N-dimethylformamide. The mixture was allowed to sit at room temperature for 16 hours, then the volatiles were removed in vacuo to afford the crude acid chloride. A solution of the acid chloride in tetrahydrofuran (0.3 M, 200 μL), was utilized to acylate a solution (0.3 M, 200 μL) of an appropriately substituted 5H-pyrrolo[2,1-c][1,4]benzodiazepine in tetrahydrofuran according to the General Procedure A, Step A.
[0495] General Procedure G
[0496] A mixture of an appropriately substituted aryl bromide methyl ester (or an aryl iodide methyl ester of General Procedure F, Step A) (8.3 mmol), an appropriately substituted boronic acid (9.1 mmol), potassium carbonate (20.8 mmol), tetrabutylammonium bromide (or iodide) (8.3 mmol), palladium(II) acetate and water (8-9 mL) was stirred with heating (70° C.) for 1.5 hours, whereupon the reaction was deemed complete by HPLC analysis. The oily upper layer was extracted with ethyl acetate, the extracts washed with brine, dried and concentrated to dryness. The residue was filtered through a column of silica gel to provide the desired coupled product of General Procedure F, Step B.
[0497] General Procedure H
[0498] The coupling of an appropriately substituted aryl bromide methyl ester (or an aryl iodide methyl ester of General Procedure F, Step A) (8.3 mmol) to an appropriately substituted pyridyl borane was carried out using potassium hydroxide as the base, in the presence of tetrabutylammonium bromide (or iodide) and a tetrakis(triphenylphoshine) palladium (0) catalyst essentially according to the published procedure of M. Ishikura, Synthesis, 936-938 (1994), to provide the desired coupled product of General Procedure F, Step B.
[0499] General Procedure I
[0500] The coupling of an appropriately substituted aryl bromide methyl ester (or an aryl iodide methyl ester of General Procedure F, Step A) (8.3 mmol) to an appropriately substituted boronic acid was carried out essentially according to General Procedure F, Step B except that the solvent was acetonitrile.
[0501] General Procedure J
[0502] The desired substituted aryl iodide of General Procedure F, Step A was prepared by reaction of an appropriately substituted amino carboxylic acid in concentrated hydrochloric acid at 0° C. with an aqueous solution of sodium nitrite followed by the addition of an aqueous solution of KI/I 2 at 0° C., followed by esterification of the resulting iodo aryl carboxylic acid with methanolic hydrochloric acid.
[0503] General Procedure K
[0504] The acylation of an activated appropriately substituted arylpyridine carboxylic acid of Procedure H was carried out by dissolving the acid (0.06 mmol) in a solution of oxalyl chloride in dichloromethane (12 mg/200 μL) followed by a catalytic amount of N,N-dimethylformamide in dichloromethane (100 μL). After stirring at room temperature for 16 hours, the volatiles were removed and tetrahydrofuran added, followed by the addition of a solution of the appropriately substituted 5H-pyrrolo[2,1-c][1,4]benzodiazepine and N,N-diisopropylethyl amine (1:2 molar ratio) in tetrahydrofuran. After stirring for 20 hours, the reaction was worked up essentially as described in General Procedure A, Step A.
EXAMPLE 24
10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0505] HRMS [(+)ESI, m/z]: 543.23874. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 25
10-[(3′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0506] HRMS [(+)ESI, m/z]: 543.23831. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 26
10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0507] HRMS [(+)ESI, m/z]: 529.22343. Calcd. for C 33 H 29 N 4 O 3 : 529.22342
EXAMPLE 27
10-[(2′-Methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0508] HRMS [(+)ESI, m/z]: 513.22772. Calcd. for C 33 H 29 N 4 O 2 : 513.22851
EXAMPLE 28
10-[(2-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0509] HRMS [(+)ESI, m/z]: 543.23855. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 29
10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0510] HRMS [(+)ESI, m/z]: 577.20052. Calcd. for C 34 H 30 ClN 4 O 3 : 577.20010
EXAMPLE 30
10-[(6-Chloro-3,3′-dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0511] HRMS [(+)ESI, m/z]: 593.19557. Calcd. for C 34 H 30 ClN 4 O 4 : 593.19501
EXAMPLE 31
10-[3-Methoxy-4-(naphthalen-1-yl)benzoyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0512] HRMS [(+)ESI, m/z]: 579.23816. Calcd. for C 37 H 31 N 4 O 3 : 579.23907
EXAMPLE 32
10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0513] HRMS [(+)ESI, m/z]: 559.23363. Calcd. for C 34 H 31 N 4 O 4 : 559.23399
EXAMPLE 33
10-[(2,3′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0514] HRMS [(+)ESI, m/z]: 559.23423. Calcd. for C 34 H 31 N 4 O 4 : 559.23399
EXAMPLE 34
10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0515] HRMS [(+)ESI, m/z]: 583.18978. Calcd. for C 36 H 28 ClN 4 O 2 : 583.18953
EXAMPLE 135
10-{[2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-(2-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0516] HRMS [(+)ESI, m/z]: 581.21516. Calcd. for C 34 H 28 F 3 N 4 O 2 : 581.21589
EXAMPLE 36
10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0517] HRMS [(+)ESI, m/z]: 543.23845. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 37
10-[(2,2′-Dimethyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0518] HRMS [(+)ESI, m/z]: 527.24341. Calcd. for C 34 H 31 N 4 O 2 : 527.24416
EXAMPLE 38
10-[(3′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0519] HRMS [(+)ESI, m/z]: 543.23838. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 39
10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0520] HRMS [(+)ESI, m/z]: 529.22338. Calcd. for C 33 H 29 N 4 O 3 : 529.22342
EXAMPLE 40
10-[(2′-Methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0521] HRMS [(+)ESI, m/z]: 513.22773. Calcd. for C 33 H 29 N 4 O 2 : 513.22851
EXAMPLE 41
10-[(2-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0522] HRMS [(+)ESI, m/z]: 543.23838. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 42
10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0523] HRMS [(+)ESI, m/z]: 577.20054. Calcd. for C 34 H 30 ClN 4 O 3 : 577.20010
EXAMPLE 43
10-[(6-Chloro-3,3′-dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0524] HRMS [(+)ESI, m/z]: 593.19500. Calcd. for C 34 H 30 ClN 4 O 4 : 593.19501
EXAMPLE 44
10-[3-Methoxy-4-(naphthalen-1-yl)benzoyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0525] HRMS [(+)ESI, m/z]: 579.24077. Calcd. for C 37 H 31 N 4 O 3 : 579.23907
EXAMPLE 45
10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0526] HRMS [(+)ESI, m/z]: 559.23341. Calcd. for C 34 H 31 N 4 O 4 : 559.23399
EXAMPLE 46
10-[(2,3′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0527] HRMS [(+)ESI, m/z]: 559.23373. Calcd. for C 34 H 31 N 4 O 4 : 559.23399
EXAMPLE 47
10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0528] HRMS [(+)ESI, m/z]: 583.18952. Calcd. for C 36 H 28 ClN 4 O 2 : 583.18953
EXAMPLE 48
10-{[2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0529] HRMS [(+)ESI, m/z]: 581.21409. Calcd. for C 34 H 28 F 3 N 4 O 2 : 581.21589
EXAMPLE 49
10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0530] HRMS [(+)ESI, m/z]: 557.25366. Calcd. for C 35 H 33 N 4 O 3 : 557.25472
EXAMPLE 50
10-[(2,2′-Dimethyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0531] HRMS [(+)ESI, m/z]: 541.25935. Calcd. for C 35 H 33 N 4 O 2 : 541.25981
EXAMPLE 51
10-[(3′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0532] HRMS [(+)ESI, m/z]: 557.25363. Calcd. for C 35 H 33 N 4 O 3 : 557.25472
EXAMPLE 52
10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0533] HRMS [(+)ESI, m/z]: 543.23801. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 53
10-[(2′-Methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0534] HRMS [(+)ESI, m/z]: 527.24446. Calcd. for C 34 H 31 N 4 O 2 : 527.24416
EXAMPLE 54
10-[(2-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0535] HRMS [(+)ESI, m/z]: 557.25403. Calcd. for C 35 H 33 N 4 O 3 : 557.25472
EXAMPLE 55
10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0536] HRMS [(+)ESI, m/z]: 591.21606. Calcd. for C 35 H 32 ClN 4 O 3 : 591.21575
EXAMPLE 56
10-[(6-Chloro-3,3′-dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0537] HRMS [(+)ESI, m/z]: 607.21044. Calcd. for C 35 H 32 ClN 4 O 4 : 607.21066
EXAMPLE 57
10-[3-Methoxy-4-(naphthalen-1-yl)benzoyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0538] HRMS [(+)ESI, m/z]: 593.25470. Calcd. for C 38 H 33 N 4 O 3 : 593.25472
EXAMPLE 58
10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0539] HRMS [(+)ESI, m/z]: 573.24957. Calcd. for C 35 H 33 N 4 O 4 : 573.24964
EXAMPLE 59
10-[(2,3′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0540] HRMS [(+)ESI, m/z]: 573.24949. Calcd. for C 35 H 33 N 4 O 4 : 573.24964
EXAMPLE 60
10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0541] HRMS [(+)ESI, m/z]: 597.20525. Calcd. for C 37 H 30 ClN 4 O 2 : 597.20518
EXAMPLE 61
10-{[2-Methyl-2′-trifluoromethyl=[1,1′-biphenyl]-4-yl]carbonyl}-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0542] HRMS [(+)ESI, m/z]: 595.22982. Calcd. for C 35 H 30 F 3 N 4 O 2 : 595.23154
EXAMPLE 62
10-[(3′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0543] HRMS [(+)ESI, m/z]: 571.27074. Calcd. for C 36 H 35 N 4 O 3 : 571.27037
EXAMPLE 63
10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0544] HRMS [(+)ESI, m/z]: 605.23088. Calcd. for C 36 H 34 ClN 4 O 3 : 605.23140
EXAMPLE 64
10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0545] HRMS [(+)ESI, m/z]: 587.26595. Calcd. for C 36 H 35 N 4 O 4 : 587.26529
EXAMPLE 65
10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0546] HRMS [(+)ESI, m/z]: 571.27090. Calcd. for C 36 H 35 N 4 O 3 : 571.27037
EXAMPLE 66
10-[(2,2′-Dimethyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0547] HRMS [(+)ESI, m/z]: 555.27479. Calcd. for C 36 H 35 N 4 O 2 : 555.27546
EXAMPLE 67
10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0548] HRMS [(+)ESI, m/z]: 557.25425. Calcd. for C 35 H 33 N 4 O 3 : 557.25472
EXAMPLE 68
N-Methyl-10-[(2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0549] HRMS [(+)ESI, m/z]: 541.25992. Calcd. for C 35 H 33 N 4 O 2 : 541.25981
EXAMPLE 69
10-[(2-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0550] HRMS [(+)ESI, m/z]: 571.27107. Calcd. for C 36 H 35 N 4 O 3 : 571.27037
EXAMPLE 70
10-[(6-Chloro-3,3′-dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0551] HRMS [(+)ESI, m/z]: 621.22598. Calcd. for C 36 H 34 ClN 4 O 4 : 621.22631
EXAMPLE 71
10-[3-Methoxy-4-(naphthalen-1-yl)benzoyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0552] HRMS [(+)ESI, m/z]: 607.27097. Calcd. for C 39 H 35 N 4 O 3 : 607.27037
EXAMPLE 72
10-[(2,3′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0553] HRMS [(+)ESI, m/z]: 587.26443. Calcd. for C 36 H 35 N 4 O 4 : 587.26529
EXAMPLE 73
10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-N-methyl-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0554] HRMS [(+)ESI, m/z]: 611.22029. Calcd. for C 38 H 32 ClN 4 O 2 : 611.22083
EXAMPLE 74
N-Methyl-10-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-[2-(2-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0555] HRMS [(+)ESI, m/z]: 609.24719. Calcd. for C 36 H 32 F 3 N 4 O 2 : 609.24719
EXAMPLE 75
{10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0556] HRMS [(+)ESI, m/z]: 598.28159. Calcd. for C 37 H 36 N 5 O 3 : 598.28127
EXAMPLE 76
{10-[(2,2′-Dimethyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0557] HRMS [(+)ESI, m/z]: 582.28589. Calcd. for C 37 H 36 N 5 O 2 : 582.28636
EXAMPLE 77
{10-[(3′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0558] HRMS [(+)ESI, m/z]: 598.28309. Calcd. for C 37 H 36 N 5 O 3 : 598.28127
EXAMPLE 78
{10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0559] HRMS [(+)ESI, m/z]: 584.26487. Calcd. for C 36 H 34 N 5 O 3 : 584.26562
EXAMPLE 79
{10-[(2′-Methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0560] HRMS [(+)ESI, m/z]: 568.27112. Calcd. for C 36 H 34 N 5 O 2 : 568.27071
EXAMPLE 80
{10-[(2-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0561] HRMS [(+)ESI, m/z]: 598.28310. Calcd. for C 37 H 36 N 5 O 3 : 598.28127
EXAMPLE 81
{10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0562] HRMS [(+)ESI, m/z]: 632.24224. Calcd. for C 37 H 35 ClN 5 O 3 : 632.24230
EXAMPLE 82
{10-[(6-Chloro-3,3′-dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0563] HRMS [(+)ESI, m/z]: 648.23671. Calcd. for C 37 H 35 ClN 5 O 4 : 648.23721
EXAMPLE 83
{10-[(3-Methoxy-4-(naphthalen-1-yl)-benzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0564] HRMS [(+) ESI, m/z]: 634.28252. Calcd. for C 40 H 36 N 5 O 3 : 634.28127
EXAMPLE 84
{10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0565] HRMS [(+)ESI, m/z]: 614.27683. Calcd. for C 37 H 36 N 5 O 4 : 614.27619
EXAMPLE 85
{10-[(2,3′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0566] HRMS [(+)ESI, m/z]: 614.27583. Calcd. for C 37 H 36 N 5 O 4 : 614.27619
EXAMPLE 86
{10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(2-pyridinyl)-1-piperazinyl]methanone
[0567] HRMS [(+)ESI, m/z]: 638.23142. Calcd. for C 39 H 33 ClN 5 O 2 : 638.23173
EXAMPLE 87
(10-{[2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H -pyrrolo[2,1-c][1,4]benzodiazepin-3-yl)[4-(2-pyridinyl)-1-piperazinyl]methanone
[0568] HRMS [(+) ESI, m/z]: 636.25827. Calcd. for C 37 H 33 F 3 N 5 O 2 : 636.25809
EXAMPLE 88
10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0569] HRMS [(+)ESI, m/z]: 543.23946. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 89
10-[(2,2′-Dimethyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0570] HRMS [(+)ESI, m/z]: 527.24367. Calcd. for C 34 H 31 N 4 O 2 : 527.24416
EXAMPLE 90
10-[(3′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0571] HRMS [(+)ESI, m/z]: 543.23964. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 91
10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0572] HRMS [(+)ESI, m/z]: 529.22290. Calcd. for C 33 H 29 N 4 O 3 : 529.22342
EXAMPLE 92
10-[(2′-Methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0573] HRMS [(+)ESI, m/z]: 513.22881. Calcd. for C 33 H 29 N 4 O 2 : 513.22851
EXAMPLE 93
10-[(2-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0574] HRMS [(+)ESI, m/z]: 543.23950. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 94
10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0575] HRMS [(+)ESI, m/z]: 577.20008. Calcd. for C 34 H 30 ClN 4 O 3 : 577.20010
EXAMPLE 95
10-[(6-Chloro-3,3′-dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0576] HRMS [(+)ESI, m/z]: 593.19387. Calcd. for C 34 H 30 ClN 4 O 4 : 593.19501
EXAMPLE 96
10-[3-Methoxy-4-(naphthalen-1-yl)benzoyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0577] HRMS [(+)ESI, m/z]: 579.23927. Calcd. for C 37 H 31 N 4 O 3 : 579.23907
EXAMPLE 97
10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0578] HRMS [(+)ESI, m/z]: 559.23401. Calcd. for C 34 H 31 N 4 O 4 : 559.23399
EXAMPLE 98
10-[(2,3′-Dimethoxy-[1,1′-biphenyl]4-yl)carbonyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4benzodiazepine-3-carboxamide
[0579] HRMS [(+)ESI, m/z]: 559.23341. Calcd. for C 34 H 31 N 4 O 4 : 559.23399
EXAMPLE 99
10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0580] HRMS [(+)ESI, m/z]: 583.18912. Calcd. for C 36 H 28 ClN 4 O 2 : 583.18953
EXAMPLE 100
10-{[2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-(4-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0581] HRMS [(+)ESI, m/z]: 581.21569. Calcd. for C 34 H 28 F 3 N 4 O 2 : 581.21589
EXAMPLE 101
10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0582] HRMS [(+)ESI, m/z]: 557.25414. Calcd. for C 35 H 33 N 4 O 3 : 557.25472
EXAMPLE 102
10-[(3′-Methoxy-2-methyl-[1,1′-biphenyl]4-yl)carbonyl]-N-methyl-N-(3-pyridinyImethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0583] HRMS [(+)ESI, m/z]: 557.25453. Calcd. for C 35 H 33 N 4 O 3 : 557.25472
EXAMPLE 103
10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0584] HRMS [(+)ESI, m/z]: 573.24906. Calcd. for C 35 H 33 N 4 O 4 : 573.24964
EXAMPLE 104
10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0585] HRMS [(+)ESI, m/z]: 543.23907. Calcd. for C 34 H 31 N 4 O 3 : 543.23907
EXAMPLE 105
N-Methyl-10-[(2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0586] HRMS [(+)ESI, m/z]: 527.24394. Calcd. for C 34 H 31 N 4 O 2 : 527.24416
EXAMPLE 106
10-[(2-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0587] HRMS [(+)ESI, m/z]: 557.25454. Calcd. for C 35 H 33 N 4 O 3 : 557.25472
EXAMPLE 107
10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0588] HRMS [(+)ESI, m/z]: 591.21599. Calcd. for C 35 H 32 N 4 O 3 : 591.21575
EXAMPLE 108
10-[(6-Chloro-3,3′-dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0589] HRMS [(+)ESI, m/z]: 607.21037. Calcd. for C 35 H 32 ClN 4 O 4 : 607.21066
EXAMPLE 109
10-[3-Methoxy-4-(naphthalen-1-yl)benzoyl]-N-methyl-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0590] HRMS [(+)ESI, m/z]: 593.25393. Calcd. for C 38 H 33 N 4 O 3 : 593.25472
EXAMPLE 110
10-[(2,3′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl-N-methyl-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0591] HRMS [(+)ESI, m/z]: 573.24936. Calcd. for C 35 H 33 N 4 O 4 : 573.24964
EXAMPLE 111
10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-N-methyl-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0592] HRMS [(+)ESI, m/z]: 597.20513. Calcd. for C 37 H 30 ClN 4 O 2 : 597.20518
EXAMPLE 112
N-Methyl-10-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-(3-pyridinylmethyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0593] HRMS [(+)ESI, m/z]: 595.23096. Calcd. for C 35 H 30 F 3 N 4 O 2 : 595.23154
EXAMPLE 113
{10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0594] HRMS [(+)ESI, m/z]: 598.28145. Calcd. for C 37 H 36 N 5 O 3 : 598.28127
EXAMPLE 114
{10-[(2,2′-Dimethyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0595] HRMS [(+)ESI, m/z]: 582.28638. Calcd. for C 37 H 36 N 5 O 2 : 582.28636
EXAMPLE 115
{10-[(3′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0596] HRMS [(+)ESI, m/z]: 598.28161Calcd. for C 37 H 36 N 5 O 3 : 598.28127
EXAMPLE 116
{10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0597] HRMS [(+) ESI, m/z]: 584.26455. Calcd. for C 36 H 34 N 5 O 3 : 584.26562
EXAMPLE 117
{10-[(2′-Methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0598] HRMS [(+)ESI, m/z]: 568.27184. Calcd. for C 36 H 34 N 5 O 2 : 568.27071
EXAMPLE 118
{10-[(2-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo]2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0599] HRMS [(+)ESI, m/z]: 598.28188. Calcd. for C 37 H 36 N 5 O 3 : 598.28127
EXAMPLE 119
{10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0600] HRMS [(+)ESI, m/z]: 632.24169. Calcd. for C 37 H 35 ClN 5 O 3 : 632.24230
EXAMPLE 120
{10-[(6-Chloro-3,3′-dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0601] HRMS [(+)ESI, m/z]: 648.23779. Calcd. for C 37 H 35 ClN 5 O 4 : 648.23721
EXAMPLE 121
{10-[3-Methoxy-4-(naphthalen-1-yl)benzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0602] HRMS [(+)ESI, m/z]: 634.28198. Calcd. for C 40 H 36 N 5 O 3 : 634.28127
EXAMPLE 122
{10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0603] HRMS [(+) ESI, m/z]: 614.27656. Calcd. for C 37 H 36 N 5 O 4 : 614.27619
EXAMPLE 123
{10-[(2,3′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0604] HRMS [(+)ESI, m/z]:. 614.27612. Calcd. for C 37 H 36 N 5 O 4 : 614.27619
EXAMPLE 124
{10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(4-pyridinyl)-1-piperazinyl]methanone
[0605] HRMS [(+)ESI, m/z]: 638.23111. Calcd. for C 39 H 33 ClN 5 O 2 : 638.23173
EXAMPLE 125
10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0606] HRMS [(+)ESI, m/z]: 587.26570. Calcd. for C 36 H 35 N 4 O 4 : 587.26529
EXAMPLE 126
10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0607] HRMS [(+)ESI, m/z]:. 571.27020. Calcd. for C 36 H 35 N 4 O 3 : 571.27037
EXAMPLE 127
10-[(2,2′-Dimethyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0608] HRMS [(+)ESI, m/z]: 555.27738. Calcd. for C 36 H 35 N 4 O 2 : 555.27546
EXAMPLE 128
10-[(3′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0609] HRMS [(+)ESI, m/z]: 571.27053. Calcd. for C 36 H 35 N 4 O 3 : 571.27037
EXAMPLE 129
10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0610] HRMS [(+)ESI, m/z]: 557.25454. Calcd. for C 35 H 33 N 4 O 3 : 557.25472
EXAMPLE 130
N-Methyl-10-[(2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0611] HRMS [(+)ESI, m/z]: 541.25983. Calcd. for C 35 H 33 N 4 O 2 : 541.25981
EXAMPLE 131
10-[(2-Methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0612] HRMS [(+)ESI, m/z]: 571.27053. Calcd. for C 36 H 35 N 4 O 3 : 571.27037
EXAMPLE 132
10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0613] HRMS [(+)ESI, m/z]: 605.23199. Calcd. for C 36 H 34 ClN 4 O 3 : 605.23140
EXAMPLE 133
10-[(6-Chloro-3,3′-dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0614] HRMS [(+)ESI, m/z]: 621.22570. Calcd. for C 36 H 34 ClN 4 O 4 : 621.22631
EXAMPLE 134
10-[3-Methoxy-4-(naphthalen-1-yl)benzoyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0615] HRMS [(+)ESI, m/z]: 607.27001. Calcd. for C 39 H 34 N 4 O 3 : 607.27037
EXAMPLE 135
10-[(2,3′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0616] HRMS [(+)ESI, m/z]: 587.26451. Calcd. for C 36 H 35 N 4 O 4 : 587.26529
EXAMPLE 136
10-[2-Chloro-4-(naphthalen-1-yl)benzoyl]-N-methyl-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0617] HRMS [(+)ESI, m/z]: 611.22112. Calcd. for C 38 H 32 ClN 4 O 2 : 611.22083
EXAMPLE 137
N-Methyl-10-{[2-methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-N-[2-(4-pyridinyl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0618] HRMS [(+)ESI, m/z]: 609.24693. Calcd. for C 36 H 32 F 3 N 4 O 2 : 609.24719
EXAMPLE 138
{10-[(2′-Methoxy-2-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[2-(3-pyridinyl)-1-piperidinyl]methanone
[0619] HRMS [(+)ESI, m/z]: 597.28526. Calcd. for C 38 H 37 N 4 O 3 : 597.28602
EXAMPLE 139
{10-[(2′-Methoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[2-(3-pyridinyl)-1-piperidinyl]methanone
[0620] HRMS [(+)ESI, m/z]: 583.26953. Calcd. for C 37 H 35 N 4 O 3 : 583.27037
EXAMPLE 140
{10-[(6-Chloro-3-methoxy-2′-methyl-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[2-(3-pyridinyl)-1-piperidinyl]methanone
[0621] HRMS [(+)ESI, m/z]: 631.24693. Calcd. for C 38 H 36 ClN 4 O 3 : 631.24705
EXAMPLE 141
{10-[(2,2′-Dimethoxy-[1,1′-biphenyl]-4-yl)carbonyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[2-(3-pyridinyl)-1-piperidinyl]methanone
[0622] HRMS [(+)ESI, m/z]: 613.28118. Calcd. for C 38 H 37 N 4 O 4 : 613.28094
EXAMPLE 142
(10-{[2-Methyl-2′-trifluoromethyl-[1,1′-biphenyl]-4-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl)[2-(3-pyridinyl)-1-piperidinyl]methanone
[0623] HRMS [(+)ESI, m/z]: 635.26206. Calcd. for C 38 H 34 F 3 N 4 O 2 : 635.26284
EXAMPLE 143
[3-Methoxy4-(pyridin-3-yl)-phenyl]-{3-[4-(pyridin-4-yl)-piperazin-1-yl]carbonyl}-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-10-yl-methanone
[0624] MS [(+)ESI, m/z]: 585 [M+H] + . Calcd. for C 35 H 33 N 6 O 3 : 585.261
[0625] The compounds of following Examples 144-147 were prepared according to the general procedures described below.
[0626] General Procedure L
[0627] Step A. To a stirred cooled (0° C.) solution of an appropriately substituted 10-(4-amino)benzoyl-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine (10 mmol) in dichloromethane (20 mL) was added N,N-diisopropylethyl amine (2.09 mL, 12 mmol) followed by the addition of 9-fluorenylmethyl chloroformate (2.85 g, 11 mmol) in one portion. The reaction was allowed to warm to room temperature. TLC analysis was used to monitor the progress of the reaction and after 8 hours, indicated that a single product was formed. The reaction mixture was diluted with dichloromethane and washed with water and brine. The organic phase was dried over anhydrous sodium sulfate, filtered and concentrated. The resulting residue was purified by flash column chromatography (Biotage Flash 40S, gradient elution from 10 to 20% ethyl acetate in hexanes) to provide the desired appropriately substituted 4-(fluorenylmethoxycarbonyl)-10,1-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine.
[0628] Step B. Trichloroacetyl chloride (3.35 mL, 30 mmol) was added to a solution of an appropriately substituted 4-(fluorenylmethoxycarbonyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine of Step A (10 mmol) and N,N-diisopropylethyl amine (3.48 mL, 20 mmol) in dichloromethane, and the solution was stirred at ambient temperature for 2 hours. An aqueous solution of sodium bicarbonate (0.5 M) was added to the mixture and the organic layer was separated, dried over anhydrous sodium sulfate, filtered and concentrated. The residue was dissolved in a solution of piperidine in N,N-dimethyl formamide (20%, v/v) and stirred until the starting material was no longer observed by HPLC/TLC analysis. The mixture was diluted with ethyl acetate and washed with water. The organic phase was dried over anhydrous sodium sulfate, filtered and concentrated. The desired appropriately substituted 2,2,2-trichloro-1-[10-(4-aminobenzoyl)-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}-ethanone was isolated by flash chromatography (Biotage, Flash 40M, gradient elution from 20 to 30% ethyl acetate in hexanes).
[0629] Step C. An appropriately substituted 1,4-diketone (25 mmol) was added to a vial containing an appropriately substituted aniline of Step B (4.4 mmol) followed by the addition of acetic acid (1 mL). The contents of the vial were stirred and heated (80° C.) without the vial capped (to allow for the removal of water). After 1 hour the solution was diluted with ethyl acetate (20 mL). The organic phase was washed with water, aqueous sodium bicarbonate and brine. The organic layer was dried over anhydrous sodium sulfate, filtered and concentrated. The resulting residue was purified by flash column chromatography to afford the desired appropriately substituted 2,2,2-trichloro-1-{10-{4-(1H-pyrrol-1-yl)-benzoyl]-10,11-dihydro[2,1-c][1,4]benzodiazepin-3-yl}-ethanone.
[0630] Step D. The material from Step C (3.85 mmol) was dissolved in tetrahydrofuran (10 mL) and treated with aqueous sodium hydroxide (2 N, 3 mL). The mixture was allowed to stir with heating (80° C.) overnight. After cooling to room temperature, aqueous hydrochloric acid (2 N, 3.2 mL) was added and product was recovered by extraction with ethyl acetate. The combined extracts were evaporated and the residue purified by flash column chromatography, eluting with a gradient of 20 to 50% ethyl acetate in hexanes to provide the desired appropriately substituted title compound.
EXAMPLE 144
10-[4-(2,5-Dimethyl-1H-pyrrol-1-yl)-3-methoxybenzoyl]-N-methyl-N-[2-(pyridin-2-yl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0631] HRMS [(+)ESI, m/z]: 574.28119. Calcd. for C 35 H 36 N 5 O 3 : 574.28127
EXAMPLE 145
{10-[4-(2,5-Dimethyl-1H-pyrrol-1-yl)-3-methoxybenzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(pyridin-2-yl)-1-piperazinyl]methanone
[0632] HRMS [(+)ESI, m/z]: 601.29180. Calcd. for C 36 H 37 N 6 O 3 : 601.29217
EXAMPLE 146
{10-[4-(2,5-Dimethyl-1H-pyrrol-1-yl)-3-methoxybenzoyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepin-3-yl}[4-(pyridin-4-yl)-1-piperazinyl]methanone
[0633] HRMS [(+)ESI, m/z]: 601.29177. Calcd. for C 36 H 37 N 6 O 3 : 601.29217
EXAMPLE 147
10-[4-(2,5-Dimethyl-1H-pyrrol-1-yl)-3-methoxybenzoyl]-N-methyl-N-[2-(pyridin-4-yl)ethyl]-10,11-dihydro-5H-pyrrolo[2,1-c][1,4]benzodiazepine-3-carboxamide
[0634] HRMS [(+)ESI, m/z]: 574.28047. Calcd. for C 35 H 36 N 5 O 3 : 574.28127
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This invention provides novel substituted tricyclic pyridyl carboxamides which act as oxytocin receptor competitive antagonists, as well as methods of their manufacture, pharmaceutical compositions and methods of their use in treatment, inhibition, suppression or prevention of preterm labor, dysmenorrhea, endometritis, suppression of labor at term prior to caesarean delivery, and to facilitate antinatal transport to a medical facility. These compounds are also useful in enhancing fertility rates, enhancing survival rates and synchronizing estrus in farm animals; and may be useful in the prevention and treatment of disfunctions of the oxytocin system in the central nervous system including obsessive compulsive disorder (OCD) and neuropsychiatric disorders.
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[0001] The present invention relates to laundry facilities. Specifically, a single device for both washing and drying clothes is disclosed using a common heat source for both washing and drying.
[0002] Commercial and home laundry facilities have typically required the use of separate appliances for washing and drying clothes, thereby dictating space requirements for the laundry facility. The machines are autonomous in that washing operations occur separate from drying operations, with independent washing and drying cycles and distinct operating controls of there own. A human operator must remove the clothes from the washer and load them in the dryer.
[0003] Commercial laundry facilities use larger capacity washing machines to wash clothes, linen and bedding. These facilities, including hospitals, nursing homes, hotels, etc., have a high volume of bedding, towels, and other common materials to wash and dry. Following the washing operation, an attendant must be available to transfer the washed materials to a separate large capacity dryer, and any delays in transferring the material results in a lower facility throughput.
[0004] The demands on commercial facilities for clean materials means that laundry facility throughput needs to be efficient and operating at a maximum level. The fact that washers and dryers are autonomous means that an attendant must promptly remove washed materials and load them in the dryer for maximum throughput efficiency, requiring the attention of at least one attendant who might otherwise be available for other tasks.
[0005] The high volume demands of these institutions typically means that a separate supply of hot water must be maintained on demand to meet the sanitary requirements for washing clothes which also impacts on space requirements.
[0006] The autonomous washing machine produces a load of centrifugally wrung materials which are transferred to a dryer at different times and at varying levels of moisture, depending on operator availability. In establishing an appropriate drying cycle, the beginning moisture level content of the wash load dictates, at least in part, the drying temperature and time for drying. In order to be certain that the drying temperature is at a safe level, so as not to scorch the dried materials, a lower, less than ideal temperature is set for the drying cycle. Accordingly, the drying cycle is longer and laundry throughput is lower than might otherwise be necessary due to each washed load having a different moisture content.
[0007] The present invention solves many of the foregoing problems which result from the use of separate autonomous washer and dryer appliances in a laundry facility.
SUMMARY OF THE INVENTION
[0008] The present invention provides for a single appliance and method for washing and drying clothes, particularly useful in a commercial laundry setting. In accordance with the invention, a combination washer/dryer is provided which has a common heat source for heating wash water and providing drying air during a drying cycle for the machine.
[0009] A sealed containment drum includes a rotating perforated clothes basket for rotating the load to be washed and dried. A water supply plenum extends around the rotating clothes basket and is in heat transfer relationship with a burner unit. The water plenum includes an outlet for discharging wash water through a controllable valve, as well as an inlet for receiving washing water. A drying air chamber extends from an opening in the top of the water plenum for delivering drying air from the heat source to the clothes basket, which passes through the perforated clothes basket to an exhaust chamber which discharges the moisture laden air.
[0010] In accordance with a preferred embodiment of the invention, the clothes basket is operated during a spin cycle to centrifugally remove a major quantity of water in the washed materials. In order to avoid caking, or compression of the wash load during a spin cycle, the spin cycle is alternately operated at a plurality of speeds, separated by pauses, to permit the clothing to separate from the wall of the perforated clothes drum.
[0011] In accordance with the preferred embodiment, a lint filter is supported in the exhaust chamber. The lint filter is cleaned by a jet of water directed to the lint screen, preferably prior to beginning a washing cycle, so that lint is forced from the filter surface down to the drain in the containment drum assembly to the waste water drain connection.
DESCRIPTION OF THE FIGURES
[0012] [0012]FIG. 1 is a perspective view of a washer/dryer in accordance with a preferred embodiment of the invention.
[0013] [0013]FIG. 2 is a perspective drawing of the washer/dryer containment drum and burner for heating wash water and providing drying air.
[0014] [0014]FIG. 3 is a perspective view of containment drum.
[0015] [0015]FIG. 4 is a partial section view of the washing agent container and containment drum.
[0016] [0016]FIG. 5 is a top view of the washing agent container.
[0017] [0017]FIG. 6 is a side sectional view of washing agent container.
[0018] [0018]FIG. 7 is a sectional view of the containment drum and burner for heating wash water and supplying drying air.
[0019] [0019]FIG. 8 illustrates the washer/dryer cycle as a function of the clothes basket RPM.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to FIG. 1, a perspective view of a washer/dryer in accordance with a preferred embodiment of the invention is shown. A housing 10 encloses a containment drum 11 which is open through the housing 10 and sealed by a door 14 . The containment drum 11 includes a rotating perforated basket 40 inside of a water plenum used for both washing and drying functions of fabrics which are loaded through the door 14 . Exhaust fan 15 provides a negative pressure to draw the moist drying air from containment drum 11 , and expelling the drying air through the exhaust 13 during the drying cycle.
[0021] A washing agent container 16 receives washing detergent, bleach, and other washing agents through door 17 , and as in a conventional washer, hose 18 carries the contents of the washing agent container 16 to the containment drum 11 . The plurality of waterjets 20 are cyclically operated by controller 12 to wash the contents of each compartment of the washing agent container 16 through the outlet hose 18 . Jet 21 periodically flushes the washing agent container 16 .
[0022] Controller 12 provides commands to a motor drive for rotating the basket within containment drum 11 in both washing and drying cycles to produce the washing/drying cycle of FIG. 8. Additionally, the controller 12 commands an on-board heater to generate heat at the appropriate times during the washing and drying cycles. Temperature sensors within the exhaust 13 and containment drum 11 provide feedback to the controller 12 so that temperatures are maintained at predetermined levels which can sanitize the washing load, and which establish optimum drying temperatures while avoiding excessive temperatures which can damage clothing.
[0023] [0023]FIG. 2 is a perspective view of the washer/dryer with the housing 10 removed. The containment drum 11 is supported in a frame 29 . Frame 29 is supported via spring 26 to a base 25 . Vibrational forces produced by the rotating basket 40 within containment drum 11 are dampened by shock absorber 27 . Additionally, a front face plate 30 of the containment drum supports the sealed door 14 .
[0024] The burner assembly 22 is supported on a burner support 23 fixed to the base 25 . The burner assembly 22 includes burner tubes 21 which supply heat to the containment drum 11 during the washing and drying cycles.
[0025] [0025]FIG. 3 is a rear perspective view of the containment drum 11 . The shaft 33 for supporting and driving the rotating basket is coupled to a motor (not shown) operated under control of controller 12 . The containment drum 11 has a drain 34 which is coupled via a flexible coupling 35 to a motor operated valve 36 . The motor operated valve 36 is also under control of the controller 12 for discharging wash water at the end of a wash cycle, rinse cycle and spin dry cycle. Also shown is flushing port 38 connected to a water supply valve (not shown) which operates under control of controller 12 for periodically providing a jet of water for ejecting the lint washed from the lint screen through the S shaped trap formed by drain 34 , flexible coupling 35 and valve 36 .
[0026] The exhaust fan 15 is shown with the exhaust outlet 13 removed. A drip channel 42 collects water during the spin cycle of the washer/dryer and returns the water back to the water plenum containing the rotating clothes basket.
[0027] [0027]FIGS. 4-6 are sectional views illustrating the washing agent dispenser compartment 16 with respect to the containment drum 11 and rotating basket 40 . A water inlet 24 supplies water through a solenoid valve under control of the controller 12 to the dispenser compartment 16 which drains due to gravity to the containment drum 11 through outlet 18 . The various washing agents are placed in each of the removable compartments 41 a, 41 b, 41 c, 41 d, and 41 e. Rotation of the door 17 to pivot along the lower edge allows access to the washing agent compartments 41 a, 41 b, 41 c, 41 d, and 41 e. Each individual washing agent compartment is arranged below the jets 20 a, 20 b, 20 c, 20 d, and 20 e. The controller 12 controls a plurality of solenoid valves connected to the various jets 20 to rinse the compartments 41 a - 41 e at the appropriate time where washing agents are dispensed through outlet 18 into the containment drum 11 .
[0028] The operation of the combination washer/dryer is now described with respect to FIGS. 7 and 8. Referring now to FIG. 7, a sectional view of the washer/dryer is shown. The containment drum 11 includes the rotating perforated basket 40 holding the wash load. During the washing cycle, the water level is established within a water plenum 46 in the containment drum as shown. The water plenum 46 is joined at an opening 49 at the top of the water plenum with the hot air supply plenum 47 . An opening in the bottom of the water supply plenum 46 is joined with an exhaust plenum 48 . During washing, the illustrated water level is confined in the water plenum 46 and the lower portion of the exhaust plenum 48 .
[0029] Burner assembly 22 is in heat transfer relationship with water plenum 46 within the containment drum 11 . The burner 22 is operated cyclically under control of the controller 21 to heat water within the water plenum 46 and lower portion of exhaust plenum 48 to a predetermined programmed temperature level, including a sanitizing level as set forth by various regulatory bodies. A temperature sensor 43 provides temperature feedback information to controller 12 so that the correct temperature is established for the washing solution.
[0030] The rotating basket 40 reciprocates as is common in most side loading washing machines for a period of time to efficiently clean the load. Once the wash time has timed out in controller 12 , the water is drained from the water plenum 46 through the drain 34 , and the washer/dryer enters the first spin drying mode.
[0031] As will be clearer with respect to FIG. 8, the rinse cycle re-establishes the water to a predetermined programmed level. Once the wash load is rinsed, the water is again drained, and the washer/dryer enters the final spin drying mode under the control of the controller 12 . The basket 40 is rotated at a multiplicity of speeds, coming to rest between each level of rotational velocity so as to prevent the wash load from adhering to the circumference of the clothes basket 40 .
[0032] The centrifugally wrung wash load has approximately 50% of the moisture removed from the wash load. During the centrifugal drying of the wash load, moisture spun from the clothes basket 40 may collect in channel 42 where it is returned by gravity to the water plenum 46 and to the drain 34 .
[0033] The drying cycle utilizes heat from burner 22 under control of the controller 12 to dry the moisture laden wash load. The hot air supply plenum 47 is formed between the outside wall 28 of the containment drum 11 and a wall 44 of the water plenum 46 . Hot air from the burner 22 rises through the hot air supply plenum 47 and enters the perforated clothes basket 40 at the top of the hot air supply plenum 47 through an opening 49 in the top of water supply plenum 46 . The hot moisture laden drying air is then withdrawn through the bottom of the clothes basket 40 through exhaust plenum 48 . The exhaust plenum 48 extends vertically from lower opening in water plenum 46 substantially diametrically opposite the end of the hot air supply plenum 47 . Fan 15 applies a negative pressure to the opposite end of the exhaust plenum 48 drawing moisture laden air from the perforated clothes basket 40 through the exhaust plenum 48 . The temperature of the drying air is monitored by sensor 45 which is connected to the controller 12 and is disposed at the top of the hot air supply plenum. The drying air temperature is regulated by controller 12 which cycles burner 22 in response to the measured air temperature so as not to exceed a predetermined programmed limit which will damage the wash load 7 . Since the initial conditions for drying including the moisture content of the load are fairly constant between loads, controller 12 may enter a drying routine with a drying temperature profile at its maximum drying efficiency and below a level which will damage the wash load.
[0034] A feature of the embodiment in accordance with FIG. 7 includes a lint trap having a filter 51 supported on a tray 50 which can be removed via handle 52 from the exhaust plenum for periodic inspection. Additionally, prior to starting the wash cycle, a water jet 59 may be operated by controller 12 to direct water on the filter forcing lint from the underside of filter 51 . The lint collects in a water pool at the bottom of water compartment 46 . Drain valve 36 is opened by controller 12 and a solenoid operates water valve connected to nozzle 38 is opened forcing the lint load and water to be ejected through drain 36 .
[0035] The washer/dryer in accordance with FIG. 7 maybe advantageously operated to provide for a wash/drying cycle under control of controller 12 as shown in FIG. 8 where the wash/dry cycle for the washer/dryer is illustrated with respect to the clothes basket 40 RPM.
[0036] The temperature for drying may be optimized for the finished wash load. Since the moisture content is at a known predetermined level, the drying temperature can be safely raised to a higher level than was previously utilized without incurring unacceptable risks of a fire or damage to a wash load.
[0037] The sequence of washing and drying begins by activating jet 59 for 5-10 seconds thereby forcing any lint collected on the lint filter 51 into the water plenum 46 and into the drain 34 . The drain valve 36 is opened by controller 12 , and the ejection nozzle 38 supplies a high velocity stream of water for 5-8 seconds flushing any collected residue through the drain 34 .
[0038] Following the cleansing of the lint filter 51 and operation of the drain valve, the containment compartment water plenum 46 is filled with wash water to the level shown in FIG. 7 by controller 12 to a predetermined programmed level. The controller 12 then enters a heating mode and enables burner assembly 22 to heat the water in water compartment 46 until the desired temperature is reached.
[0039] A wash cycle is entered and the basket is alternately rotated in each direction for a period of time selected by the user through controller 12 . Following the wash cycle, the drain valve 36 is opened and water drains from the water compartment 46 . The machine may then enter a spin cycle to centrifugally force water from the clothes into the drain 34 .
[0040] A rinse cycle commences for a period of time set in controller 12 . The water plenum 46 is refilled and the water is heated to an appropriately selected temperature set by controller 12 . The clothes basket 40 is then rotated in alternate directions for the duration of the rinse cycle. Following the rinse cycle, the drain valve 36 is reopened to drain the rinse water.
[0041] The spin cycle centrifugally removes 50% of the moisture in the load by initially rotating the clothes basket 40 at about 450 RPM. In order to prevent caking of the laundry load along the surface of the rotating basket 40 , a first pause is entered in the spin cycle for 5-10 seconds, wherein, in the preferred embodiment, the clothes basket 40 stops rotating. At this time, the clothes will drop from the exterior surface of the clothes basket 40 due to the force of gravity. The clothes basket is then operated at a second RPM, at least as high as the initial RPM of 450 RPM, but preferably at a higher RPM of about 750 RPM, to continue centrifugally drying the clothes. The spin cycle is again paused, to permit the clothing to drop from the surface of the clothes basket 40 preventing caking of the clothes to the surface of clothes basket and clumping together in a compact mass. Following a second pause of 5-10 seconds, the clothes basket is rotated through multiple steps to a final spin RPM. The final spin interval, being longer than the first two spin intervals, lasts approximately 4-5 minutes.
[0042] The foregoing sequence produces a load of an approximate known moisture content. The beginning of the final heated drying cycle therefore represents moisture conditions which are predetermined and constant from load-to-load. Accordingly, from the known starting point of moisture content, it is possible to select a final optimum drying temperature profile to minimize the time for drying, while maintaining a safe temperature margin for the wash load.
[0043] The heated drying cycle begins by actuating valve 36 by closing the drain. The drying cycle may be of the reversing type, wherein the clothes basket 40 is rotated in alternate directions for a predetermined period of time. Following a drying cycle of 30-60 minutes, a cool down cycle is begun wherein the temperature profile of the load is decreased for 3-5 minutes to reduce the possibilities of spontaneous combustion of line lints.
[0044] The completion of the drying cycle is signaled by the controller 12 to the facilities operator. From the beginning to end, operator intervention was unnecessary, and personnel involved in the laundry facility are permitted to engage in other tasks. Since the complete washing/drying cycle is automated, maximum throughput efficiency for the facility may be obtained.
[0045] The foregoing description of the invention illustrates and describes the present invention. Additionally, the disclosure shows and describes only the preferred embodiments of the invention in the context of a combination washer/dryer having common heat source, but, as mentioned above, it is to be understood that the invention is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings and/or the skill or knowledge of the relevant art. The embodiments described hereinabove are further intended to explain best modes known of practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with the various modifications required by the particular applications or uses of the invention. Accordingly, the description is not intended to limit the invention to the form or application disclosed herein. Also, it is intended that the appended claims be construed to include alternative embodiments.
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The combination washer/dryer and method for operating a combination washer/dryer. The washer/dryer has a containment drum which receives wash water, and includes a perforated clothes drum which rotates within the containment drum. A heat plenum is provided in heat transfer relationship with the containment drum, and a source of heat coupled to the heat plenum supplies heat for water in the containment drum. During a drying cycle, hot air from the heat source supplied from the fire box to the containment drum for heating wash water during a washing cycle, and for supplying hot air during a drying cycle. A drying air plenum is connected to receive drying air from the source of heat, delivering the drying air to the top of the containment drum, where it enters the rotating basket. An exhaust plenum discharges hot air laden with moisture from the containment drum through a lint filter.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method of controlling an elevator installation with multiple cars, by means of which several floors can be served with one stop, wherein the travel requests are allocated to the elevator car.
[0002] There has become known from the European patent specification EP 0 459 169 a destination call control for a elevator installation with multiple cars, wherein a call is allocated directly after input and the allocated elevator and the position of the elevator car are displayed on a display field of the actuated call registration device. Associated with each car deck is the call store in which are stored the calls that are input at the main stopping point and characterize the destination floors. A switching circuit is connected at the input side with the call stores in such a manner that in dependence on an allocated call the relevant multiple car is established as stopping at even-numbered/uneven-numbered or uneven-numbered/even-numbered floor pairs. At the output side, the switching circuit is connected by way of a switching device with a comparison device, so that, in dependence on a further call still to be allocated, neither the multiple cars stopping at even-numbered/uneven-numbered floor pairs or the multiple cars stopping at uneven-numbered/even-numbered floor pairs can participate in the comparison and allocation method.
[0003] A disadvantage of the known device is that the route of the multiple car is already limited to the main stopping point by the allocation of the even-numbered/uneven-numbered or the uneven-numbered/even-numbered floor, which in turn adversely influences the carrying capacity of the elevator installation.
SUMMARY OF THE INVENTION
[0004] The present invention concerns a method for the operation of an elevator installation meets the objective of avoiding the disadvantages of the known device and of providing for control of a elevator installation with multiple cars in which the allocation of the car decks improves the performance of the elevator installation.
[0005] The destination call control offers, with the call input at the floor and with the knowledge of the destination floor for each passenger, very important information which is of primary significance for the selection of the optimum elevator. Experiences with elevator installations with multiple cars and simulations show that it is very important in the case of elevator installations with multiple cars to minimize the number of stops of the multiple cars. This can only be achieved if the allocation of the car decks can be changed up to the last possible moment. It is of no significance to the user which deck brings him to the destination. The method according to the present invention has the purpose of a dynamic deck allocation to the individual destination calls. With the method, the allocation of each car deck is optimized on the basis of analysis of the allocations of other calls not only at the starting-point floor and the environment thereof, but also at the destination floor and the environment thereof.
[0006] The advantages achieved by the method according to the invention are essentially to be seen in that the number of necessary stops of the elevator car is automatically minimized. Moreover, there is prevention of unnecessary overlapping stops. An overlapping stop arises in the case of an elevator car with, for example, two car decks when only three instead of four floors are served with two stops. The allocation of the floors to several elevators of an elevator group can be optimized. In the case of between-floor traffic each of the elevators can be used; a division in even-numbered/uneven-numbered groups or uneven-numbered/even-numbered groups is not necessary. The users can be served in an optimum manner by matching the loading of the car decks or with full load of one car deck. The elevators can also be better utilized for special journeys, for example VIP operation.
[0007] An elevator group consists of, for example, a group of six elevators A, B, C, D, E, F each with a respective multiple car. It will be assumed that for a new destination call from the starting point floor S to the destination floor Z the allocation algorithm determines, in accordance with a known costs calculation principle for destination call controls, the elevator B as the most favorable elevator in terms of cost. Directly thereafter the car deck executing the travel request for the starting-point floor S to the destination floor Z is determined in accordance with the method according to the present invention. The method for dynamic allocation of the car decks is explained in more detail in the following description. The deck allocation is carried out internally of the control without communication to the user.
DESCRIPTION OF THE DRAWINGS
[0008] The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
[0009] [0009]FIG. 1 is a flow diagram showing an overview of the deck allocation method according to the present invention;
[0010] [0010]FIG. 2 is a flow diagram showing Part 1 of the method of FIG. 1 in more detail in which the deck allocation is performed on the basis of general criteria;
[0011] [0011]FIG. 3 is a flow diagram showing Part 1 A of the method of FIG. 1 in more detail in which the deck allocation is performed on the basis of predetermined stops at the starting-point floor;
[0012] [0012]FIG. 4 is a flow diagram showing Part 1 B of the method of FIG. 1 in more detail in which the deck allocation is performed on the basis of predetermined stops at the destination floor;
[0013] [0013]FIG. 5 is a flow diagram showing Part 2 A of the method of FIG. 1 in more detail in which the deck allocation is performed on the basis of possible stops at the starting-point floor;
[0014] [0014]FIG. 6 is a flow diagram showing Part 2 B of the method of FIG. 1 in more detail in which the deck allocation is performed on the basis of possible stops at the destination floor;
[0015] [0015]FIG. 7 is a flow diagram showing Part 3 A of the method of FIG. 1 in more detail in which the deck allocation is performed on the basis of predetermined position overlaps, caused by booked alighting passengers, in the region of the starting-point floor;
[0016] [0016]FIG. 8 is a flow diagram showing Part 3 B of the method of FIG. 1 in more detail in which the deck allocation is performed on the basis of predetermined position overlaps, caused by booked alighting passengers, in the region of the destination floor;
[0017] [0017]FIG. 9 is a flow diagram showing Part 4 A of the method of FIG. 1 in more detail in which the deck allocation is performed on the basis of possible position overlaps, caused by booked boarding passengers, in the region of the starting-point floor; and
[0018] [0018]FIG. 10 is a flow diagram showing Part 4 B of the method of FIG. 1 in more detail in which the deck allocation is performed on the basis of possible position overlaps, caused by booked boarding passengers, in the region of the destination floor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] The method of the present invention, which is shown in one embodiment illustrated in the drawings, for deck allocation relates to a elevator car with a lower and an upper deck (double-decker), wherein a load measuring device is provided for each deck. The method is also feasible for use on elevator cars with three or more decks. A typical double-decker car (also known as a double car elevator) with an associated group control is shown in the U.S. Pat. No. 5,086,883 which is incorporated herein by reference.
[0020] The abbreviations and references employed in the description of the method according to the present invention are defined as follows:
[0021] OD—Upper deck of the elevator car.
[0022] UD—Lower deck of the elevator car.
[0023] S—Starting-point floor (the travel request begins here with the input of the destination floor Z).
[0024] Region of the starting-point floor—Region comprising the adjacent floors S+1, S−1 or S+1, S+2, S−1, S−2 of the starting-point floor S.
[0025] Z—Destination floor (the travel request ends here).
[0026] Region of the destination floor—Region comprising the adjacent floors Z+1, Z−1 or Z+1, Z+2, Z−1, Z−2 of the destination floor Z.
[0027] LOD—Load of upper deck (load is measured each time before the start and stored).
[0028] LUD—Load of lower deck (load is measured each time before the start and stored).
[0029] OGLOD—Upper load limit of upper deck (selectable as a parameter).
[0030] OGLUD—Upper load limit of lower deck (selectable as a parameter).
[0031] UGLOD—Lower load limit of upper deck (selectable as a parameter).
[0032] UGLUD—Lower load limit of lower deck (selectable as a parameter).
[0033] PHBR—Braking phase of the elevator car (travel of the elevator car in coming to a stop before a floor stop).
[0034] PHH—Stop of the elevator car at a floor.
[0035] SP—Selector position (the selector leads during travel of the elevator car and scans the approaching floor).
[0036] SPOD—Selector position of upper deck.
[0037] SPUD—Selector position of lower deck.
[0038] Service OD—Use of the elevator car as a single-deck car (only the upper car deck serves as a transport deck).
[0039] Service UD—Use of the elevator car as a single-deck car (only the lower car deck serves as a transport deck).
[0040] Load balancing—Attempt towards loads of equal size in the two decks. The load balancing is selectable by means of parameters.
[0041] Predetermined stop VH—Required stop determined by boarding passengers or passengers located in the car (boarding stop or alighting stop). The elevator car must stop at this floor by the determined deck, because by virtue of the call allocation and deck allocation at least one passenger boards or alights.
[0042] Possible stop MH—A stop, which is planned by already booked passengers, with a planned deck at a floor. At least one boarding passenger or alighting passenger can still be served by one of the two car decks at this floor.
[0043] Reversal point—The lowest floor which the elevator reaches by the lower deck during a downward travel before the elevator changes the travel direction or the highest floor which the elevator reaches by the upper deck during an upward travel before the elevator changes the travel direction.
[0044] Position overlap—A position overlap arises with an elevator car with, for example, two car decks when only three, instead of four, floors are served by two stops.
[0045] Predetermined position overlap—Three adjacent floors are served by two stops, due to a Predetermined stop. Additional position overlaps are avoided by the method according to the invention.
[0046] Possible position overlap—Three adjacent floors are served by two stops, due to a Possible stop. Additional position overlaps are avoided by the method according to the invention.
[0047] Possible alighting passenger—It is provided for a specific floor that at least one already booked passenger, who has not yet boarded one of the decks, will alight. The previous deck allocation for this passenger could accordingly still be changed. Such a deck allocation change would, however, have a consequence of retrogressive action in the direction of the travel planning. Also, the previously applicable deck allocation would have to be changed for the boarding floor of this passenger, wherein this could cause further retrospective changes on other allocations. Accordingly, in this case a deck allocation change for the possible alighting passenger is renounced and, instead, a position overlap is accepted.
[0048] Possible boarding passenger—It is provided for a specific floor that at least one already booked passenger will board. The previous deck allocation for this passenger could accordingly still be changed. Such a deck allocation change would have an effect on the destination floor of this passenger. Such a deck allocation change for the destination floor could have the consequence of further changes in the deck allocations for other passengers in the region of this destination floor. These possible deck allocation changes lie in the direction of the travel planning after the floor in question. Thus, the probability is higher (as with retrospective changes) that less deck allocation changes for other booked passengers are meant. Accordingly, a rebooking of the deck allocation for the possible boarding passenger is accepted if a position overlap is thereby prevented.
[0049] In the flow charts of the drawings, usual symbols are used, which together with the above legends are self-explanatory.
[0050] [0050]FIG. 1 is a flow chart of a deck allocation method 20 according to the present invention that begins allocation on the basis of general criteria in a step 21 . The method 20 continues allocation based upon travel requests in the region of the starting-point floor in a step 22 and completes allocation based upon travel requests in the region of the destination floor in a step 23 .
[0051] [0051]FIG. 2 shows a group of steps 30 undertaken at the start of the method according to the present invention, according to which the servicing of the destination call has been allocated to the most favorable elevator with a multiple car. The selection begins at a step 31 and further steps lead to a deck allocation on the basis of general criteria (Part 1 step 32 ).
[0052] In case only one of the two car decks UD, OD is to execute travel requests (steps 33 and 35 ), the destination call or the travel request is immediately allocated to one of the two car decks UD, OD (steps 34 and 36 ). It is thereafter checked whether the selector position SPUD (step 37 ) or SPOD (step 38 ) of the one or other car decks UD, OD is the same as the starting-point floor S and whether the elevator car is disposed in the braking phase PHBR or is engaged at a stop PHH at the floor (steps 39 and 40 ). If the elevator car is disposed in the braking phase PHBR or is engaged at a stop PHH at the floor, the travel request is allocated to one of the two car decks UD, OD (steps 41 and 42 ).
[0053] Parameter load balancing is detected (step 43 ) and if it is activated, it is checked whether the load LOD, LUD (steps 44 through 47 ) of the car decks OD, UD is greater or smaller than preselectable load limits OGLOD, OGLUD, UGLOD, UGLUD in order to allocate the passenger to the car deck UD, OD (steps 48 and 49 ) with less loading. The method then exits the group of steps 30 and proceeds to Part 1 A (step 50 ).
[0054] [0054]FIG. 3 shows the deck allocation on the basis of predetermined stops in a group of steps 51 . The method enters the group 51 at the step 50 and initially it is checked whether the desired travel from the starting-point floor S to the destination floor Z is in upward direction (step 52 S<Z). If the check yields “N” (no, S>Z), the method is processed analogously to the solution illustrated in FIGS. 2 through 10 (step 53 ). In terms of content, the same interrogations are carried out, wherein the interrogations are adapted to the starting point floor or destination floor in accordance with the respective travel direction of the elevator.
[0055] The method of the following description applies to the case wherein travel from the starting-point floor S to the destination floor Z is in an upward direction and the elevator car travels to the starting-point floor S in an upward direction (step 54 SP<S) or in a downward direction (SP>S).
[0056] If the travel direction check (step 52 S<Z) yields “Y” (yes), it is checked on the basis of the selector position SP whether the elevator travels to the starting-point floor S in the upward direction (step 54 SP<S). If the step 54 check yields “Y”, the further steps relate to predetermined stops which are caused by boarding passengers or passengers already located in the elevator car for the floor S−1 (step 55 ) or the starting-point floor S (step 56 ) on the one hand, or the starting-point floor S (step 57 or the floor S+1 (step 58 ) on the other hand. If the check step 54 (SP<S) yields “N” (starting-point floor S traveled to in the downward direction), the further steps relate to the checking of the reversal point (steps 59 and 60 ). According to the respective checking output in the individual checking steps, the desired travel is allocated to the upper car deck OD (step 62 ) or the lower car deck UD (steps 61 and 63 ). The method then exits the group of steps 51 and proceeds to Part 1 B (step 64 ).
[0057] [0057]FIG. 4 shows the deck allocation on the basis of predetermined stops in a group of steps 65 . The stops (step 66 ) are caused by boarding passengers or passengers already located in the elevator car for the floor Z−1 (step 67 ) or the destination floor Z (step 68 ) on the one hand, or the destination floor Z (step 69 ) or the floor Z+1 (step 70 ) on the other hand. According to the respective checking output in the individual checking steps the desired travel is allocated to the upper car deck OD (step 71 ) or the lower car deck 15 UD (step 72 ). The method then exits the group of steps 65 and proceeds to Part 2 A (step 73 ).
[0058] [0058]FIG. 5 shows the deck allocation on the basis of possible stops in a group of steps 74 . The stops (step 75 ) are caused by booked, but not yet boarded, passengers for the floor S−1 (step 76 ) or the starting-point floor S (step 77 ) on the one hand, or the starting-point floor S ( 78 ) or the floor S+1 ( 79 ) on the other hand. These passengers can still be served by each car deck OD, UD. If the check (SP<S) yields “N” (starting-point floor S traveled to in downward direction), the further steps relate to checking of the reversal point. According to the respective checking output in the individual checking steps the desired travel is allocated to the upper car deck OD (step 80 ) or the lower car deck UD (step 81 ). The method then exits the group of steps 74 and proceeds to Part 2 B (step 82 ).
[0059] [0059]FIG. 6 shows the deck allocation on the basis of possible stops in a group of steps 83 . The stops (step 84 ) are caused by booked, but not yet alighted, passengers for the floor Z−1 (step 85 ) or the destination floor Z (step 86 ) on the one hand, or the destination floor Z ( 87 ) or the floor Z+1 ( 88 ) on the other hand. These passengers can still be served by each car deck OD, UD. According to the respective checking output in the individual steps the desired travel is allocated to the upper car deck OD (step 89 ) or the lower car deck UD (step 90 ). The method then exits the group of steps 83 and proceeds to Part 3 A (step 91 ).
[0060] If in the preceding Parts 1 A, 1 B, 2 A and 2 B no predetermined stops and no possible stops could be found, the attempt is continued by seeking position overlaps.
[0061] [0061]FIG. 7 shows the deck allocation on the basis of predetermined position overlaps in a group of steps 92 . The overlaps (step 93 ) are caused by predetermined stops for the floor S−2 (step 94 ), the floor S−1 (step 95 ), the floor S+1 (step 96 ) or the floor S+2 (step 97 ). In accordance with the respective checking output in the individual checking steps the desired travel is allocated to the upper car deck OD (step 99 ) or the lower car deck UD (step 98 ). The method then exits the group of steps 92 and proceeds to Part 3 B (step 100 ).
[0062] [0062]FIG. 8 shows the deck allocation on the basis of predetermined position overlaps in a group of steps 101 . The overlaps (step 102 ) are caused by predetermined stops for the floor Z−2 (step 103 ), the floor Z−1 (step 104 ), the floor Z+1 (step 105 ) or the floor Z+2 (step 106 ). In accordance with the respective checking output in the individual checking steps the desired travel is allocated to the upper car deck OD (step 108 ) or the lower car deck UD (step 107 ). The method then exits the group of steps 101 and proceeds to Part 4 A (step 109 ).
[0063] [0063]FIG. 9 shows the deck allocation on the basis of possible position overlaps in a group of steps 110 . The overlaps (step 111 ) are caused by possible stops for the floor S−2 (step 112 ) or the floor S+ 2 (step 119 ). For the floors S−1 and S+1 distinction is still made between “possible alighting passengers” (steps 113 and 116 ) and “possible boarding passengers” (steps 114 and 117 ) in order to decide about a possible deck allocation change (steps 115 and 118 ). According to the respective checking output in the individual checking steps the desired travel is allocated to the upper car deck OD (steps 121 and 123 ) or the lower car deck UD (steps 120 and 122 ). The method then exits the group of steps 110 and proceeds to Part 4 B (step 124 ).
[0064] [0064]FIG. 10 shows the deck allocation on the basis of possible position overlaps in a group 125 . The overlaps (step 126 ) are caused by possible stops for the floor Z−2 (step 127 ) or the floor Z+2 (step 134 ). For the floors Z−1 and Z+1 distinction is still made between “possible alighting passengers” (steps 128 and 131 ) and “possible boarding passengers” (steps 129 and 132 ) in order to decide about a possible deck allocation change (steps 130 and 133 ). According to the respective checking output in the individual checking steps the desired travel is allocated to the upper car deck OD (steps 137 , 138 and 140 ) or the lower car deck UD (steps 136 and 139 ).
[0065] If in the preceding parts 1 A, 1 B, 2 A, 2 B, 3 A, 3 B, 4 A and 4 B no predetermined stops, no possible stops, no predetermined position overlaps or no possible position overlaps could be found (step 135 ), the boarding passenger at the even-numbered starting-point floor is allocated to the upper car deck OD (step 140 ) and the boarding passenger at the uneven-numbered starting-point floor is allocated to the lower car deck UD (step 141 ).
[0066] The selection of the suitable car deck and thus the allocation of the travel request from the starting-point floor S to the destination floor Z takes place dynamically. The above-mentioned steps are performed continuously and the selection of the appropriate car decks optimized. The allocation takes place definitively, for example, only in the case of onset of braking for reaching the starting-point floor S.
[0067] In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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An elevator installation with multiple deck cars serves several floors simultaneously with one stop is controlled such that the travel requests are allocated to the most suitable elevator car of the elevator group and the allocation of a travel request from a starting-point floor to a destination floor to a car deck of the elevator car takes place shortly before reaching the starting-point floor. A travel request can also be redistributed or allocated to another deck at any time up to shortly before reaching the starting-point floor. The allocation of the travel request is carried out in dependence on general criteria and/or in dependence on allocated travel requests for the region of the starting-point floor and/or in dependence on allocated travel requests for the region of the destination floor.
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[0001] This application is a Continuing in Part application from U.S. patent application Ser. No. 12/076,000 filed on Mar. 14, 2008, now U.S. Pat. No. 8,177,266 which claims the claims the benefit of U.S. Provisional Application 60/918,465 filed Mar. 15, 2007 all of which are incorporated herein in their respective entirety, by this reference thereto.
FIELD OF THE INVENTION
[0002] The disclosed device relates to door safety and security. More particularly it relates to a door latching device which when installed maintains a door in a slightly ajar position. Release of the device is provided from either side of the secured door.
BACKGROUND OF THE INVENTION
[0003] Conventionally, doors are mounted in a rotational engagement using hinge pins secured to a door jamb wall. In this rotatable engagement the door is free to rotate about its hinges from an open position extending at an angle from the wall supporting a door jamb, to a closed position substantially flush with the wall and surrounded by the door jamb on four sides.
[0004] Because of the size and mass of most doors and the relatively small area between the side edges of the door and the surface of the surrounding door jamb, a great amount of force may be generated by a closing door. This force combined with a perpendicular leading angle to a closing door approaching the jamb can cause severe injury to the fingers of a child or to a child's hand that is in the wrong position as the door closes. With young children in the house, and in some cases even adults, finger injuries from closing doors have become ever more common and severe injury or amputation can occur when a finger becomes caught or pinched between the leading edge of a closing door and the door jamb in the wall.
[0005] An additional concern is damage to the door and jamb themselves should any objects be intentionally or accidentally positioned between the door and jamb from a deliberate or accidental insertion. This type of problem can occur when children are playing with a door, or slamming it or inserting toys or objects to prevent closure by another child.
[0006] Yet an additional consideration for many homeowners is the prevention of door closing in instances where it is desirous to maintain a door in a somewhat open position. For instance when a child is sleeping in a room it may be desirous to substantially close the door to limit noise to the room; however, it is also desirous to leave the door open slightly so that the child can be heard if awakened. Securing the door in a slightly open position also has the benefit of preventing other children and/or pets from entering the room while at the same time allowing for fresh air circulation. Another consideration for a slightly open door is that of pet owners who may want to leave a pet inside a room but avoid total closure of the door in order to allow the pet to hear what is going on elsewhere and to allow the owner to hear the pet. Fresh air circulation is very beneficial in this situation as well.
[0007] Yet an additional consideration for many homeowners is the prevention of children or pets from entering a room that is not safe or is off limits. The most popular products currently available for this purpose only work with a narrow range of doorknobs. The growing popularity of door levers and nonstandard doorknob shapes and sizes has significantly limited available solutions for many homeowners. Most of the remaining options require adhesives or hardware for installation, which is cumbersome and can cause damage to the door and/or frame.
[0008] As such, there is a continuing unmet need for an improved device which has the benefit of preventing the door from closing completely while at the same time preventing individuals from entering or leaving the secured room. Such a device should be easily engageable to the door independent of the style of door knob or lever being used. Further such a device should be adapted to prevent damage to the door and jamb. The installation height should also be adjustable to allow operation by shorter individuals while still preventing operation by those who are being denied passage in or out of the secured room.
[0009] Most conventional door safety devices are directed at prevention of operation of the handle, and therefore the ability to open the door. The logic is that if the child cannot open the door, the child cannot leave through it and therefore won't get his fingers into the door jamb during door closure since it remains closed. These devices generally are a cover for the door handle which slips if not gripped tightly enough, or if not manipulated in a mechanical fashion to engage and interlock to allow rotation of the handle. Most children do not have the strength to compress the spinning handle type devices nor the mechanical prowess to engage the mechanical door handle devices to allow rotation of the handle.
[0010] A few devices have made attempts to address the issue of maintaining a door in an ajar position for injury prevention while concurrently preventing opening.
[0011] U.S. Pat. No. 3,620,483 (Weinberger) teaches a door check in the form of a resilient yoke member which is engageable to the top edge of the door. The yoke member has a tail extension defining a channel adapted to be snap-fit over a bead on a rail member which is affixed to a supporting surface. Weinberger secures the door open; however, among other deficiencies, it is limited to an overhead mount on the door where many people would be unable to install or operate the device and it provides no means for storage to the door when not in use. The user would also be required to place his or her fingers in an unsafe position between the door and the door frame during operation.
[0012] U.S. Pat. No. 1,618,348 (Nicolai) teaches a device to prevent door opening and closure; however, Nicolai requires a permanent installation using screws in the door and provides no means for temporary storage engaged to the door itself to encourage usage.
[0013] U.S. Pat. No. 4,015,867 (Siden) discloses a device for securing and latching a door in a pre-determined position relative to the frame preventing a door from reaching the fully closed position. However, Siden requires a permanent installation limiting use to one door and marring the surface on removal. The device does not provide a means to prevent the door from being opened. Additionally, the Siden device can be implemented to allow closure making accidental injury a possibility even when installed.
[0014] Consequently, there exists a need for a door safety device which will maintain a door in a predetermined distance from the jam when installed. Such a device, by preventing closure and maintaining distance, will encourage use in situations where a child or pet is denied access to a secured room but air circulation is still desirable. Such a device, by preventing closure and maintaining distance, will encourage use in situations where a child or pet is left in a room and a passage for sound transmission is desired rather than total closure. Such a device should allow for a temporary installation which will encourage use since it will not mar or mark the door. In such a temporary installation, such a device will also encourage or allow use on one or a plurality of doors in a household, thereby allowing users to chose any door for use and injury prevention.
[0015] Further, such a device should provide means for temporary storage on the door itself to maintain the device adjacent to the door rather than storage in a remote area since immediate access to the device will encourage consistent use.
[0016] Still further, such a device should be automatically engaged when door closure is attempted and should be safely releasable from either side of the door and adapted for installation on a side edge at a height where it may be reached by shorter adults but out of reach by smaller children which it protects. Such a device should be easy enough for older children to operate while still denying access to younger siblings. Such a device should help prevent door pinch injuries in all of the above applications. Finally such a device should be adapted to function as a door stop only, thereby increasing overall utility.
[0017] With respect to the above, before explaining at least one preferred embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangement of the components or steps set forth in the following description or illustrated in the drawings. The various apparatus and methods of the invention are capable of other embodiments and of being practiced and carried out in various ways which will be obvious to those skilled in the art once they review this disclosure. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0018] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for designing of other door closure prevention devices, methods and systems for carrying out the several purposes of the present disclosed device. It is important, therefore, that the objects and claims be regarded as including such equivalent construction and methodology insofar as they do not depart from the spirit and scope of the present invention.
SUMMARY OF THE INVENTION
[0019] The device and method of employment herein provide a door latching and securement assembly which is adapted for engagement and operation on virtually any door which swings into a door jamb. The device employs a frictional engagement of housing upon a door side edge through the employment of a biased member to increase the frictional engagement thereby allowing installation on a side or vertical edge or a top or horizontal edge of the door. The point of installation along the side edge can therefore be chosen at a height where an adult may operate and release the device, but concurrently be above the reach of a child or in some cases a very smart pet. Or, the installation point may be chosen at a height where an older, more responsible child may reach it, but a younger sibling cannot.
[0020] The biased frictional engagement alleviates the need for mechanical installation using screws or nails which mar a door and discourage use and which maintain a device permanently on only one door requiring multiple devices in a household with more than one door to secure. Further, in other preferred modes the biased frictional engagement may be adjustable in order to accommodate a wide range of door thicknesses.
[0021] Once so engaged upon a door edge, the device is easily and safely operated from either side of the door through the translation of a biased bolt member. In one preferred mode, the unique operation of this bolt member provides that it may be released from either side of the door without placing fingers between the door and jamb at any time, thereby preventing accidental injury during installation and use. Further, in other modes the operation of the bolt member may require the user to reach between the door and jamb gap temporarily to release the member. However, in this mode, the device will still prevent the door from closing as the user releases the bolt member, insuring the safety of their fingers.
[0022] The biased bolt member is adapted with a beveled leading edge which acts to translate the bolt member around the door jamb during closure. Once the leading edge of the bolt member has traversed the side of the door jamb, it is biased automatically back into position to hold the door from opening through an engagement of the door frame molding conventionally installed to limit travel of the door through the jamb. In this engaged position in one preferred mode, the leading edge of the housing engaging the components of the device is positioned adjacent to the outside edge of the door frame. A distance between the interior side of the slot engaging the door and the leading edge of the housing maintains the door edge at a relative distance from the frame thereby forming a gap between the door and door frame that is maintained while the device is in the engaged position. In another mode, the gap may be defined by the distance between the interior side of the slot engaging the door and an intermediate stopper component disposed a distance between the housing and the distal end of the bolt member.
[0023] In all modes, this gap prevents serious finger injuries to children who might place their fingers therein. Concurrently the gap allows for ventilation to the secured area while restricting access to children and pets, if the device is installed to do so. Or, if the device is installed to maintain a child or pet in a room or area, the maintained gap also prevents the child or pet from being vocally isolated. Should a child accidentally become restrained within the area by the secured door, the gap provides a means for the child to call for help and be heard.
[0024] In accordance with a first preferred mode, another advantage of the invention is that it may be rotated to a reverse mounting position that still enables the doorstop feature but disables the latching feature. This mode of operation helps prevent slamming injuries and unintentionally locking an individual in an isolated area such as a bedroom. Further it would operate to prevent the door from hitting a wall when swung open. In another mode, the bolt member may be rotated and locked out of the as used position to allow the door to open and close normally without having to disengage the device from the door edge. In this mode the doorstop feature may or may not be provided.
[0025] Finally, in a particularly preferred mode of the device, the one of the housing or the bolt member is adapted to allow the device to be stored on the doorknob of the door when not being employed as either a door stop or injury prevention device. As shown herein, the distal end of the bolt member has a curved portion that not only functions to automatically translate the bolt member into position on closure, the opposite side edge of the curve is adapted to hang the device upon a door knob. This is particularly useful in that by placing the device adjacent to the door on which it is to be employed, consistent use is encouraged which might not be the case if stored remote from the door.
[0026] It is thus an object of the invention to provide a door closure safety device which prevents injuries to hands and fingers which might be caught between a closing door and jamb.
[0027] It is a further object of this invention to provide a device which also will secure a door from opening or closing upon closure of the door.
[0028] It is another object of this invention to provide such a door safety device which maintains a gap between the door and jamb during use to provide ventilation and sound passage between the secured area and the rest of the building.
[0029] An additional object of this invention is the provision of such a door closure safety device which is adapted for storage on the doorknob immediately ready for employment.
[0030] An additional object of this invention is the provision of such a door closure safety device which is easy to install and is independent of the style of doorknob being used.
[0031] An additional object of this invention is the provision of such a door closure safety device which is easy and safe to operate from either side of the door.
[0032] Yet another object of this invention is the provision of such a door closure safety device which is adapted for engagement to a vertical side edge of the door at any height chosen, thereby allowing access to individuals with sufficient height to reach it but denying access to children and pets.
[0033] These together with other objects and advantages which will become subsequently apparent reside in the details of the construction and method as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part thereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF DRAWINGS
[0034] FIG. 1 is a top perspective view of a preferred mode of the latch assembly.
[0035] FIG. 2 is an exploded view of the latch assembly of FIG. 1 .
[0036] FIG. 3 is a perspective view of the latch assembly in an installed position on a vertical side edge of a door prior to closure.
[0037] FIG. 4 is a perspective view of the latch assembly installed on a conventional door in the secured position maintaining the door closed while concurrently maintaining a gap between the door and jamb.
[0038] FIG. 5 is a sectional view taken along line A-A of FIG. 4 showing the device in the secured position with the bolt member engaging the door jamb and gap maintained by the housing.
[0039] FIG. 6 is a top view of the bolt member.
[0040] FIG. 7 is a perspective view of an alternate mode of the device herein employing adhesive means of engagement to the-door edge.
[0041] FIG. 8 is an exploded view of the alternate latch assembly shown in FIG. 7 .
[0042] FIG. 9 is a top view of the alternate latch assembly shown in FIG. 7 with a housing cover removed to reveal interior component operation.
[0043] FIG. 10 is a perspective view of the alternate latch assembly shown in FIG. 7 installed on a standard door in an unsecured position
[0044] FIG. 11 is a sectional view of the alternate latch assembly shown in FIG. 7 showing rotation upon the adhesive mount.
[0045] FIG. 12 depicts another preferred mode of the device having a curved bolt member.
[0046] FIG. 13 depicts an exploded view of FIG. 12 .
[0047] FIG. 14 depicts the curved bolt member of FIG. 12 showing the biasing means formed by curved portions of the bolt member operatively engageable with the housing.
[0048] FIG. 15 depicts another preferred mode of the device having an adjustable housing and rotatably engaged bolt member.
[0049] FIG. 16 shows a cross sectional view of the mode of FIG. 15 along line 16 - 16 of FIG. 15 .
[0050] FIG. 17 shows the mode of the device of FIG. 15 in a first as used position.
[0051] FIG. 18 shows the mode of the device of FIG. 15 in a second as used position.
[0052] FIG. 19 shows the mode of the device of FIG. 15 in a third as used position.
[0053] FIG. 20 shows the mode of the device of FIG. 15 in a third as used position.
[0054] FIG. 21 shows the mode of the device of FIG. 15 in a stored position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] The device herein is described and disclosed in FIGS. 1-21 wherein similar parts are identified by like reference numerals and may be found in one or more of the drawings.
[0056] As shown in a preferred mode of the device shown in FIG. 1 , the latch assembly 20 includes a bolt member 30 rotationally engaged inside of a housing which as depicted is formed of mating covers 50 and 50 ′. Of course those skilled in the art will realize that other housing configurations may be employed and such is anticipated. From a cost and manufacturing standpoint these components may be formed of plastic and injection molded.
[0057] In FIG. 2 , there can be seen the latch assembly 20 in an exploded view showing the components in their operative arrangement. Means for engagement of the covers 50 forming the housing to an operative engagement with the bolt member 30 may be by fasteners or using sonic welding or adhesive or other conventional techniques. As depicted, the bolt pins 39 align with and engage the cover apertures 52 , adding strength and rigidity to the assembly and registering the housing in engagement with the bolt member 30 . Also shown are cover bumpers 51 which are in the preferred mode of the device over-molded onto the edge of the covers 50 and formed of a resilient material such as rubber to provide a means for padding contact of the housing with the door or jamb.
[0058] Operative engagement of all of the embodiments of the device herein is shown in FIGS. 3-5 (components of FIG. 6 are also referenced) which depict engagement of the latch assembly on the vertical side edge of a door 60 which is rotationally engaged to a door jamb defined by the edge molding 71 . In use, to engage the latch assembly 20 to the door 60 the user slides a recess engaged to the base of the bolt member 30 which in a simple form of the device may be part of the bolt member 30 which would be resilient. Or in a more preferred mode of the device, the recess will be formed in the housing of the latch assembly 20 sized t slide over the edge 61 of the door 60 . Means for engaging the latch assembly 20 in place on or operatively adjacent to the door edge 61 vertically spaced from the floor is provided by frictional engagement. In a basic mode the device similar to that in FIG. 6 it can be made as a unitary structure with the base of the bolt member 30 including a slot for engagement to the door 60 or other means to engage it as noted herein. Also, in this configuration it may include a biasing means in the slot such as a clamp flexure 34 which deforms and imparts an additional bias against the door 60 increasing the frictional forces generated between the clamp flexure 34 , the clamp arm 44 and the door 60 .
[0059] In the more aesthetic and preferred modes of the device herein, the bolt member 30 is engaged to a casing formed by covers 50 or similar components and extends therefrom at an angle or biased to contact and traverse over the frame molding 71 and door frame stop 72 to engage a distal end behind it. If in a rotational engagement in a casing, the bolt member 30 would be biased toward the door frame when engaged to the door 60 . If however the slot or means of engagement of the bolt member 30 is unitary or part of the bolt member 30 then the bolt member 30 would be formed to extend from the door 60 at an angle toward the door frame molding 71 to cause a sliding contact thereon till it moves to a contact position behind the door frame stop 72 . The resiliency of the material forming the bolt member 30 and the angle toward the door frame molding 71 would substitute for the spring or other bias in the rotationally mounted mode of the device. The curved tip portion of the bolt member 30 is a most important aspect of all modes of the device herein to allow a tangential contact of the bolt member 30 with the door jamb and door frame stop 72 . This curved tip thereby provides a means for deflection of the bolt member during travel across the door jamb and over the frame stop 72 where it engages the back side to lock the device in the secured position between the door 60 and door jamb.
[0060] Employing this bias enhanced frictional engagement provided by the clamp flexure 34 or similar means to bias against the door surface, the latch assembly 20 can be mounted to the vertical door edge 61 at any chosen height between the top and bottom of the door 60 and will generally be fixed in its mounted position at a height that prevent shorter individuals, such as toddlers, from being able to reach or touch the latch assembly 20 and thereby preventing removal from the doorway being secured.
[0061] In the mounted position, as shown in FIGS. 3-5 , as the door 60 is closed a curved surface of the bolt ramp 37 engages and slides along the edge of the door frame stop 72 the force of which causes the bolt arm flexure 32 to deflect a distance. This deflection allows the bolt hook 35 to slide over door frame stop 72 which conventionally occupies a central area of the door jamb recess. After deflecting the distance of the frame stop 72 the bolt hook 35 engages the back side of door stop 72 which is on an opposite side from the approaching door 60 . This engagement of the bolt hook 35 to the door stop 72 prevents the door 60 from being rotated away from the door jamb and opened.
[0062] Means to maintain a gap between the door edge 61 and the door jamb defined by the frame molding 71 is provided by bumpers 51 projecting from the housing which contact the door frame molding 71 . The gap so maintained is defined by the distance between the inside edge of the stop member 44 and the outside edge of the bumper 51 . The bumper 51 if formed of resilient material will both pad and protect the molding 71 and impart a slight bias to the door away from the molding 71 to prevent rattling.
[0063] The door 60 as shown in FIG. 4 , is thus secured in a partially open position, with a defined gap G between door 60 and door frame molding 71 . While this gap is narrow enough to prevent an individual from entering the secured area, it is preferably wide enough to allow air circulation and prevent door pinch injuries to a child's fingers.
[0064] Optionally but preferred, a bolt hook bumper 36 formed of resilient material will protect the door frame stop 72 from damage and will provide a means to dampen the forces applied to the bolt hook 35 if the door is pulled upon while in the secured position. The bolt hook bumper 36 also provides a means to help prevent the bolt hook 35 from sliding off the door frame stop 72 thereby maintaining the latch assembly 20 in the secured position.
[0065] Particularly useful in all modes of the device herein is the means for disengagement of the bolt hook 35 of the latch assembly 20 from either side of the door 60 . From a first side of the door 60 pushing the button 33 will cause the bolt hook 35 to deflect away from the frame molding 71 allowing the door to be opened. From a second side of the door 60 opposite the first, a pulling of the curved hanger 38 portion of the bolt hook 35 will cause the bolt hook 35 to deflect away from the door frame stop 72 , and allow the bolt hook 35 to travel past the frame stop 72 to open the door 60 . Thus, means to deflect and thereby disengage the bolt hook 35 from either side of the door 60 is provided which does not require the user to insert their fingers into the gap or past the door 60 which is most important to prevent injuries.
[0066] The latch assembly 20 has a second mounting position wherein the bolt arm 31 positioned on the opposite side of the door 60 projects toward the user away from the door frame. This second position disables the latching feature while allowing the latch assembly 20 to function as a door stop to maintain the gap “G” during closure thereby preventing door pinch injuries. This second mounting position feature also prevents children from inadvertently locking themselves in an isolated area.
[0067] Further utility is provided in all modes of the latch assembly 20 device herein through the provision of means for supporting the latch assembly 20 on the door handle 80 for storage when not being employed. The latch assembly 20 would be stored in this position when complete closure of the door is desirable. As noted, by positioning the latch assembly 20 on the door handle 80 for storage, it places the device immediately adjacent to the door 60 for use and thereby encourages use better than storage at a remote location.
[0068] In FIG. 6 there is shown a top plan view of bolt member 30 . Features 31 thru 45 are integrated into bolt member 30 preferably by injection molding. The bolt arm flexure 32 deflects when force Fb is applied to button 33 or when force Fr is applied to the bolt ramp 37 or when force Fh is applied to hanger 38 . Deflection of the bolt arm flexure 32 results in movement of the bolt arm 31 until the stop member 41 contacts the deflection stop 42 . Force Ft applied to the bolt hook 35 results in movement of bolt arm 31 until stop member 41 contacts the tension stop 40 . As noted above, the bolt hook bumper 36 while optional is preferred as it helps dampen force Ft applied to bolt hook 35 . The hook bumper 36 is formed preferably a resilient material such as rubber and is over-molded onto bolt hook 35 .
[0069] The clamp flexure 34 deflects when force Fc is applied, causing the free end 45 to slide along surface 43 . Force Fc is created when latch assembly 20 is mounted on the door 60 of FIG. 5 . Opposing forces of the clamp arm 44 and clamp flexure 34 frictionally hold the latch assembly 20 on the door 60 . The hanger 38 portion of the bolt hook 35 is provided in the most preferred modes of the device herein to provide means to removably engage the latch assembly 20 upon a door handle 80 for storage. In operative engagement with the housing formed by the covers 50 , bolt arm flexure 32 , bolt arm 31 , stop member 41 , and clamp flexure 34 must be free to move and are therefore not bonded to the covers 50 . Of course those skilled in the art will realize that the rotational engagement of the bolt hook 35 projecting from the casing formed by the covers 50 may be accomplished in other manners of operative engagement and such is anticipated by this application.
[0070] While frictional engagement of the latch assembly device 20 to the door 60 is preferred since it prevents permanent damage to the door 60 and allows the latch assembly 20 device to be employed on a plurality of doors 60 easily, the latch assembly 20 might be engaged to a door 60 using means of engagement that is permanent such as screws, adhesive tape, or fasteners and such is anticipated. However, even permanently attached, the latch assembly 20 provides release from both sides of the door 60 and a maintained gap “G” which is particularly useful in its operation.
[0071] Further, other means to bias the bolt arm 35 toward the door jamb while the latch assembly 20 is in the engaged position may surely occur to those skilled in the art on reading this disclosure. For instance a spring or similar biasing means might be employed instead of depending on the bolt arm flexure 32 to motivate the bolt arm 31 . Consequently any means to bias the bolt arm 35 engaged in a casing away from the door edge 61 and toward the door jamb as would occur to those skilled in the art is anticipated within the scope of this application and its claims. In another mode of the latch assembly 20 the bolt arm 31 , instead of being a built-in feature of the bolt member 30 , could be a separate component mounted on a pivot and motivated by a built-in or separate spring as the biasing means.
[0072] In FIGS. 7-11 there is depicted another mode of the latch assembly 20 which incorporates many of the alternate modes of construction and operation listed above. As shown, the latch assembly would employ adhesive or other means for engagement along the side edge of the door 60 . In this mode of the latch assembly 20 , means for engagement to the side edge of the door is provided by a pivot 90 . The pivot 90 allows rotation of the latch assembly 20 away from the door 60 such that instead of removing the latch assembly 20 in order to allow a complete closure of the door 60 , the latch assembly 20 engaged to the pivot 90 is simply rotated out of the way.
[0073] Engagement of the pivot 90 is accomplished by adhesive means of attachment such as double sided mounting tape 120 . In operation, the latch assembly 20 b pivots from the operable position P 1 to the inoperable position P 2 , allowing door 60 to fully close. This mode of the latch assembly 20 would be particularly convenient in applications where the door 60 is frequently in the fully closed position, such as a bathroom.
[0074] As a means to bias the latch assembly 20 to ensure the latch assembly 20 b returns to the operable position P 1 once the door is reopened, a return spring 100 could be included in this embodiment. This could help prevent any dangerous situations where the user forgets to return the latch assembly 20 b to the operable position P 1 . The return motion between position P 2 and P 1 is dampened by the damper sleeve 131 , concentrically located in the damper cup 91 , which is filled with grease. The covers 130 and 140 form the housing for the rotational engagement of the bolt member 30 b and thus performs the same doorstop function in maintaining a gap between the door and jamb.
[0075] The force Fm applied to covers 130 and 140 is transferred to pivot 90 and any force sufficient to detach assembly 20 b from the door 60 is eliminated because the shock flexure 92 of pivot 90 deflects until the faces 132 and 142 of covers 130 and 140 contact the door 60 and transfer the force Fm to door 60 . When a force Ft is applied in the opposite direction, shock flexure 92 of pivot 90 deflects until faces 133 and 143 of covers 130 and 140 contact the pivot base 93 and transfer the force Fm to the door 60 . The bolt member 30 b mounts to cover pivots 134 and 144 , and rotates about this point when actuated to position P 3 . The bolt member return spring 110 returns the bolt member 30 b to position P I.
[0076] Another mode of the device operating with substantially the same principles herein shown in FIG. 11 a , may consist of a modified version of latch assembly 20 b and operate as the device shown in FIG. 11 . An additional swiveling component, upon a protruding post 95 , would mount between door 60 and a modified version of pivot 90 . This would allow the latch assembly to swivel parallel to the face of door 60 , after rotating in a plane normal to the door jamb, into position P 2 . When released, the modified latch assembly would come to rest against one face of door 60 , and door 60 would be able to close completely. In this configuration, the modified latch assembly would not automatically return to the operable position when door 60 was reopened. However, this would be particularly useful feature if the latch was not required for an extended period of time.
[0077] Another alternative configuration anticipated would consist of only two symmetric components, each with a cover 50 and half of the bolt member 30 built in. This configuration has fewer components but would require more complex tooling to allow for the free movement of the bolt arm flexure 32 and the clamp flexure 34 .
[0078] Another alternative could exclude the covers 50 and utilize only the bolt member 30 which would flex in an engagement to the door 60 and be self-biasing using the resilient nature of the material forming it. While this configuration could reduce the cost of the assembly, it would sacrifice aesthetic appeal and long term strength.
[0079] Yet another configuration of the device herein depicted in FIGS. 12-14 , would employ a curved embodiment of the bolt member 30 c in a projecting biased rotational engagement with a housing formed of two cover portions 50 c . A cover bumper 51 c would be engaged to the exterior of the housing and a bolt hook bumper 36 c operatively placed on the end of the bolt member 30 c to engage the door frame molding 71 and door frame stop 72 . The bolt member 30 c would be formed of resilient material and have a curved configuration at the housing end to impart a bias to the distal end of the bolt member 30 c toward the door frame molding 71 . A push button would project from the bolt member 30 c extending outside the housing to allow a finger depression to overcome the bias and release the distal end of the bolt member 30 c from contact with the frame molding 71 and door frame stop 72 . This mode of the device wherein the bolt member 30 c is formed to provide a pivot point within the housing and a self-imparted bias operates in a substantially similar fashion to the other embodiments and maintains a gap between the door 60 and jamb when in the secured position and provides means for release of the lock from both sides of the door 60 without inserting the users fingers in the gap.
[0080] Yet additional preferred modes of the device are shown in FIGS. 15 and 16 , the latch assembly 200 includes a bolt member 210 rotationally engaged to a first housing component 212 via a spring loaded hinge 216 . The spring loaded hinge 216 is provided to bias the bolt member 210 in the as used position as is shown later in FIGS. 17 and 18 .
[0081] The first housing component 212 is engaged to a second housing component 214 such that the second housing component 214 can translate to and away from the first 212 . This may be accomplished by telescopic engagement wherein the first component 212 has a cavity or slot 218 for receiving a complimentary portion 220 of the second component 214 . The provision of telescopic engagement, or other means for translational engagement that one skilled in the art would immediately recognize, allows the distance between the two components to be adjusted as needed to fit a door edge accordingly. The two components 212 , 214 may be secured by frictional engagement or other means for secured engagement such as a set screw (not shown). The device may additionally employ permanent means of engagement such as screws, adhesive tape, or fasteners and such is anticipated.
[0082] The bolt member 210 in this mode similarly includes a hook member 222 and hook bumper 224 . However, there is additionally included a intermediate stopper member 226 and an additional hook member 230 with a release tab portion 232 . The stopper member 226 and additional hook member 230 are preferably rotatable engaged to the bolt member 210 such as using hinges 228 and 234 respectively. The preferred operation of these components are shown and described in more detail in later figures. However briefly, the distance between the stopper member 226 and first housing component 212 define the gap G between the door and jamb. The additional hook member 230 provides a means to maintain the bolt member 210 into a stored position as shown later in FIG. 21 .
[0083] It must be noted that the depiction of the components of the current mode of the device 200 are provided to shown additional operations of the device 200 not provided in other modes. As such it must be noted that the simple nature of the components as shown and described is done so merely to portray the intended scope of the operations while those skilled in the art may immediately recognize other ways to accomplish the same operations and are anticipated. The device therefor should not be considered limited to the depictions in these and following figures.
[0084] FIGS. 17 and 18 show a first and second position of the device 200 of the current preferred mode in the as-used or engaged position. As is shown, the housing of the device 200 is engaged to a door 60 edge such as through the biased engagement of the first housing component 212 and second housing component 214 as described previously which combine to form the housing. The bolt member 212 is biased toward the door frame molding 71 due the spring loaded hinge 216 . In this mode of the device 200 the door 60 is limited to rotate only from a first position ( FIG. 17 ) shown with the door frame stop 72 abutted against the hook bumper 224 of the device 200 to a second position ( FIG. 18 ) with the door frame stop 72 abutted to the stopper element. As can be clearly seen a gap is maintained between the door 60 and frame 71 in both positions.
[0085] A particularly preferred aspect of the current mode of the device 200 not provided in other modes is the provision of allowing the door 60 to achieve a conventional closed position against the frame 72 without having to disengage the device 200 from the door 60 . As such, as will be come apparent shortly, it is preferred that the thickness of the walls of the first housing component 212 and second housing component 214 are thin enough to fit between the typical gap between the door 60 and frame 72 when in the conventional closed position. In a preferred mode, the housing components 212 , 214 may be formed from sheet metal or the like. Further it must be noted that the FIGS. 17-21 are not to scale.
[0086] Shown in FIG. 19 , the stopper element 226 has been rotated to allows the door 60 to further close such as to abut the exterior surface of the first housing component 212 against the frame stop 71 and frame 72 . The device 200 upon further rotation is shown in FIG. 20 . As the door 60 is closed further, the other end of the stopper element 226 contacts the frame stop 72 and returns the stopper element 226 to the first position as is shown. Also, the bolt member 210 may be slightly deflected to accommodate the protrusion of the stopper element 226 .
[0087] Referring still to FIG. 20 , the door 60 is allowed to achieve the conventional closed position against the frame 71 without the need to disengage the device 200 from the door 60 . Again noting that the housing components 212 , 214 are formed with sidewalls thin enough to be position within the gap between the door 60 and frame stop 72 when in the fully closed position. From the position shown in FIG. 20 , if the door 60 were to be slightly opened, such as by a young child, the spring bias of the hinge 216 will return bolt member 210 to the position shown previously in FIG. 18 . From there the device 200 would again be in the as used mode limited by the positions shown FIGS. 17 and 18 .
[0088] However, should the user decide to temporarily discontinue use of the device 200 , the bolt member 210 may be positioned to the store position as shown in FIG. 21 . In this stored mode, the bolt member 210 is maintained at a biased position away from the door frame stop 72 through the provision of the additional hook member 230 engaged to a lip 236 formed on the edge of the first housing component 212 . Since the spring loaded hinge 216 biases the bolt member 210 toward the door frame stop 72 and the as used position, the additional hook member 230 engaged to the lip 236 provides a means to maintain the stored position of the bolt member 210 away from the door frame stop 72 . In this mode the door 60 may now be operated normally with the device 200 stored out of the as used position, however not fully disengaged from the door 60 . To achieve the as used operation of the device 200 , the user will simply disengaged the additional hook member 230 from the lip 236 via the tab 232 .
[0089] While all of the fundamental characteristics and features of the door latch device herein have been disclosed and described, with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure and it will be apparent that in some instance, some features of the invention will be employed without a corresponding use of other features without departing from the scope of the invention as set forth. It should be understood that such substitutions, modifications, and variations may be made by those skilled in the art without departing from the spirit or scope of the invention. Consequently, all such modifications and variations are included within the scope of the invention as defined herein.
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A door latch assembly for engagement in a mounted position at or adjacent to a side edge of a door which abuts a door frame stop upon a full closure of the door into a surrounding door frame. The device features an angled or biased latch member which employs an end to engage the door stop molding of a door jamb and thereby secure the door in a slightly open position and prevent a full opening of the door. The latch member is engaged to a side edge of the door using frictional engagement or mechanical engagement. The latch member is releasable from either side of the door without placing a user's fingers in between the door and jamb.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of International Patent Application PCT/EP02/06504 filed Jun. 13, 2002, and which designates the United States. The disclosure of the referenced application is expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a texturing machine for producing a crimped yarn.
[0003] To improve a melt spun yarn, it is known to crimp and draw the flat yarn in a texturing process. To this end, texturing machines are used, which comprise a plurality of processing units as well as a takeup device. The processing units, such as, for example, feed systems, heaters, cooling devices, texturing units, entanglement devices, and yarn lubricators are combined in a machine frame to result in a yarn path, which often extends over two stories of a machine.
[0004] In the case of such texturing machines, special auxiliary devices are integrated in the texturing machine, so as to make it possible to thread the yarn into the processing units at the beginning of the process. For example, FR 2 695 631 A1 discloses a texturing machine, wherein the yarn is guided by a threading device between a heater and a takeup device. To this end, the threading device includes a plurality of guide tubes, which connect to injectors and guide the yarn pneumatically from the outlet of the heater to the takeup device.
[0005] However, the texturing machine as disclosed in FR 2 695 631 A1 has the disadvantage that an operator must transfer the advancing yarn from a manually guided suction gun to a suction inlet of a guide tube. In this connection, it is necessary to position the yarn very accurately on the one hand and to cut it at the same time. Missed attempts in the yarn transfer from the suction gun to the guide tube are therefore unavoidable.
[0006] It is therefore an object of the invention to further develop a texturing machine of the initially described type such that before the start of the process an operator is able to transfer the yarn in a very safe and simple manner to a threading device for advancing the yarn pneumatically.
SUMMARY OF THE INVENTION
[0007] In accordance with the invention, the above and other objects and advantages are achieved by the provision of a texturing machine which includes in the region of the suction inlet of a guide tube a cutting device, which cuts the yarn while it is being threaded into the suction inlet. The special advantage of the invention thus lies in the fact that the operator needs to position only the yarn for enabling a transfer to the threading device. The combination between the cutting device and the suction inlet of the guide tube accomplishes that both the catching of the yarn and the cutting thereof occur automatically, after a manually guided suction gun reaches the threading position.
[0008] For cutting the yarn, the cutting device may comprise movable or stationary cutting means. Preferably, a stationary cutting blade is used.
[0009] A particularly advantageous further development of the invention distinguishes itself in that a positioning of the manually guided suction gun is no longer necessary. To transfer the yarn into the suction inlet, the cutting blade of the cutting device is associated with a movable yarn guide. Both the yarn guide and the cutting blade cooperate to thread the yarn into the suction inlet. In this instance, the threading position is assumed by the yarn guide, which thus ensures that the yarn is both cut and taken into the suction inlet.
[0010] In this connection, it would be possible to form the yarn guide at a free end of an elongate wire strap, so that by pivoting the wire strap the yarn guide reaches the threading position in the range of suction of the suction inlet and cutting device.
[0011] With the use of a heater with a closed heating channel, it is possible to expand the threading device advantageously by associating the guide tube with the heater, so that the yarn inlet end of the heater forms the suction inlet for threading the yarn, thereby ensuring simultaneously that the yarn is threaded into the heating channel of the heater.
[0012] Since in the production of the crimped yarn, every contact of the yarn for its guidance causes tensions and an engagement of the yarn, an advantageous further development of the invention provides that the suction inlet of the guide tube or suction inlet of the heater are in alignment with the path of the yarn leaving an upstream feed system. This permits inserting the yarn into the suction inlet directly from the feed system without a further guidance and deflection of the yarn.
[0013] In a particularly preferred further development of the invention, the feed system is formed by a godet unit, which is looped by the yarn several times, and arranged on a pivotal support that mounts at the same time the yarn guide for threading the yarn. With that, it is possible to thread on the one hand the yarn into the feed system in a simple manner, and to transfer it on the other hand simultaneously to the threading device or suction inlet of the guide tube by pivoting the support.
[0014] To realize as much as possible a compact construction of the texturing machine, an advantageous further development provides to arrange the guide tube or the heater on the underside of a frame section. This frame section is formed by a processing module mounting at least one portion of the processing units, and by a takeup module mounting the takeup device. The suction inlet of the guide tube could be arranged in the region of the processing module. The yarn would then pneumatically advance through the guide tube to the adjacent takeup module.
[0015] To guide the yarn as far as the takeup device, at least one second guide tube may be provided with a second injector, the second guide tube being positioned downstream of the first guide tube and immediately upstream of the takeup device.
[0016] The takeup device preferably includes a suction device, which has an intake opening facing a blow outlet of the second guide tube, preferably in one plane. This permits guiding the yarn automatically into the takeup device. Once the yarn is held in the suction device, for example, a yarn guide could engage the yarn and start a catching or a winding procedure.
[0017] An advantageous further development is suitable for transferring the yarn in the region of a feed system from a first guide tube to a second guide tube in a highly reliable manner. In this development, the blow outlet of the first guide tube and the suction inlet of the second guide tube face each other in one plane upstream or downstream of a feed system.
[0018] Once the yarn is transferred, it would be possible to realize an automatic threading of the yarn in the feed system, for example, by a threading device.
[0019] The method of the present invention is characterized in that it is possible to feed the yarn to a guide tube with a threading device, independently of an operator, in a very safe and reproducible manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the following, the invention is described in greater detail with reference to several embodiments of the texturing machine according to the invention and to the attached drawings, in which:
[0021] [0021]FIG. 1 is a schematic view of a first embodiment of the texturing machine according to the invention;
[0022] [0022]FIG. 2 is a schematic view of a further embodiment of the texturing machine according to the invention; and
[0023] [0023]FIG. 3 is a schematic partial view of the embodiment of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] [0024]FIG. 1 schematically illustrates a processing station of a yarn texturing machine according to the invention. The texturing machine comprises a plurality of side by side processing stations, in each of which a yarn is textured and wound. Each of the processing stations is thus identically constructed, so that in the following the individual processing units are described with reference to the path of the yarn in one processing station.
[0025] In a creel 3 , a mandrel 2 mounts a feed yarn package 1 . The feed yarn package 1 holds a flat thermoplastic yarn 36 . From the feed yarn package 1 , the yarn 36 is withdrawn overhead by a first feed system 5 . To this end, a yarn guide 4 is arranged downstream of feed yarn package 1 . From the feed system 5 , the yarn 36 enters a texturing zone. The texturing zone is formed by a texturing unit 8 , a heating device 6 , and a cooling device 7 . In the present embodiment, the texturing unit 8 is realized as a false twist unit, so that the false twist produced in the yarn 36 is set within heater 6 and cooling device 7 . A deflection roll 9 precedes the texturing unit 8 .
[0026] A second feed system 10 withdraws the yarn 36 from the texturing zone, and advances it into an aftertreatment zone. In the aftertreatment zone, a second heater 11 is provided, which is followed by a third feed system 14 . The feed system 14 is realized as a godet unit comprising a godet 16 and a guide roll 17 .
[0027] The feed systems 5 and 10 are constructed, for example, as so-called nip-type feed systems, in which the yarn advances between a driven feed roll and a pressure roll lying against the circumference of the feed roll.
[0028] The feed system 14 is followed by a takeup device 20 . The takeup device 20 comprises a pivotally supported package holder 24 , the free end of which mounts a tube 23 . For winding a package, the tube 23 lies against the circumference of a drive roll 22 , which is driven by a drive at a substantially constant circumferential speed. Upstream of the contact point of yarn 36 on a package is a yarn traversing device 21 , which reciprocates the yarn within the package width. Such yarn traversing devices can comprise a traversing yarn guide, which is driven by a cross-spiraled roll, or a traversing yarn guide, which is driven by a belt drive.
[0029] To be able to thread the yarn 36 in a processing station at the start of a process, the texturing machine comprises a threading device for pneumatically advancing the yarn 36 . This threading device is essentially formed by guide tubes 12 and 18 . To this end, the guide tube 12 with an injector 13 connects to the outlet of the second heater 11 , thereby forming at the inlet end of heater 11 a suction inlet 33 , through which an air stream is taken in upon activation of injector 13 . The suction inlet 33 in the inlet region of heater 11 is associated with a cutting device consisting of a cutting blade 31 and a holder 32 . The cutting blade 31 is attached to holder 32 . Upstream of the suction inlet 33 and cutting blade 31 is a yarn guide 29 , which connects to an actuator 30 . The actuator 30 is used to move yarn guide 29 in the direction of suction inlet 33 .
[0030] The guide tube 12 connected to heater 11 comprises at its opposite end a blow outlet 34 . The blow outlet 34 terminates at an inlet end of feed system 14 . Opposite thereto, at the outlet end of feed system 14 , a suction inlet 28 of second guide tube 18 is arranged. In this arrangement, the blow outlet 34 of the first guide tube 12 and the suction inlet 28 of the second guide tube 18 face each other in one plane. The guide tube 18 connects to an injector 19 , which generates in guide tube 18 an air stream that is directed in the direction of the advancing yarn. The guide tube 18 ends directly upstream of takeup device 20 . The blow outlet 27 at the end of guide tube 18 faces, in one plane, an intake opening 26 of a suction device 25 . The suction device 25 is associated with the takeup device 20 for receiving and removing the yarn 36 during package doffs.
[0031] [0031]FIG. 1 shows the processing station of the illustrated embodiment of the texturing machine directly before the start of the process. In this instance, the advancing yarn 36 has already passed through the processing units 5 , 6 , 7 , 8 , 10 , 11 , and 14 which are successively arranged in its path. Within the takeup device 20 , the suction device 25 takes in the yarn 36 and removes it to a waste container.
[0032] For threading the yarn 36 , same is first manually guided by means of a suction gun 35 . Once the yarn 36 is threaded in processing units 5 , 6 , 7 , 8 , and 10 , it is inserted by means of suction gun 35 into a guide groove of yarn guide 29 (shown in phantom lines). This concludes the threading procedure by an operator. The subsequent threading of yarn 36 as far as the takeup device 20 occurs automatically. To this end, the actuator 30 moves the yarn guide 29 in the direction of the suction inlet 33 of heater 11 . In this process, the yarn 36 enters the range of suction of suction inlet 33 . At the same time, the cutting blade 31 of the cutting device cuts the yarn end advancing between suction inlet 33 and the held suction gun 35 . The yarn 36 now advances in guide tube 12 to blow outlet 34 . The yarn 36 that is ejected from guide tube 12 , is taken in by the suction inlet 28 of the second guide tube 18 . With the use of a threading device 15 , it is now possible to thread the yarn 36 that already advances parallel to the feed system 14 , automatically into the godet unit. The threading device 15 could comprise, for example, a pivot drive and a pivotal yarn guide, which threads the yarn into feed system 14 by looping it several times.
[0033] Once the yarn 36 is received by guide tube 18 , it is ejected from the blow outlet 27 by the air current generated in guide tube 18 , and received by the intake opening 26 of suction device 25 . This concludes the threading procedure of yarn 36 in the processing station of the texturing machine. The process can now be started by pivoting package holder 24 and transferring the yarn to the yarn traversing device 21 or an auxiliary device.
[0034] In the arrangement shown in FIG. 1, it is also possible to associate the cutting blade 31 with the suction inlet 33 in the inlet region of heater 11 in such a manner that a transfer and cutting of the yarn is already effected by advancing the yarn 36 thereto by means of suction gun 35 . In this case, the yarn guide 29 would not be needed.
[0035] In the embodiment shown in FIG. 1, the frame sections, which mount the processing units, are left out for the sake of clarity. In contrast, FIG. 2 is a view of an embodiment of the texturing machine according to the invention, which shows the machine frame for accommodating the processing units. The embodiment of the texturing machine of FIG. 2 comprises a feed module 38 , a processing module 39 , and a takeup module 40 , which are arranged in a machine frame 37 with frame sections 37 . 1 , 37 . 2 , 37 . 3 . The feed module 38 is supported by frame section 37 . 1 , and the takeup module 40 by frame section 37 . 3 . The frame sections 37 . 1 and 37 . 3 are interconnected by frame section 37 . 2 , which is arranged above feed module 38 and processing module 39 . Between the processing module 39 and feed module 38 , a servicing aisle 42 is formed below frame section 37 . 2 .
[0036] In the frame section 37 . 2 , the processing module 39 is arranged on the side facing servicing aisle 42 and the takeup module 40 on the opposite side thereof. A doffing aisle 43 is provided along the takeup module 40 .
[0037] In its longitudinal direction (the drawing plane of FIG. 2 corresponds to the transverse plane), the texturing machine comprises a plurality of processing stations, one for each yarn. The takeup devices 20 occupy a width of three processing stations. For this reason, three takeup devices 20 overlie one another in a column in the takeup module 40 .
[0038] The processing units arranged in the machine frame 37 , are basically identical with the foregoing embodiment, so that in the following only their essential differences are described. The first feed system 5 on feed module 38 is associated with a creel 3 , which accommodates three feed yarn packages 1 , one above the other. The creel 3 also holds a reserve yarn package in facing relationship with each feed yarn package 1 . In the direction of the advancing yarn, downstream of the first feed system 5 , a heater 6 and a cooling device 7 extend, which are successively arranged in one plane and supported by frame section 37 . 2 above the servicing aisle 42 . In this arrangement, the yarn advances between creel 3 , feed system 5 , and heater 6 over a plurality of deflection rolls 9 . 1 , 9 . 2 , and 9 . 3 .
[0039] The processing module 39 mounts, one below the other in the direction of the advancing yarn, a texturing unit 8 , as well as two successive feed systems 10 . 1 and 10 . 2 .
[0040] On the underside of frame section 37 . 3 , the third feed system 14 on takeup module 40 is arranged in facing relationship with feed system 10 . 2 . From the third feed system 14 , the yarn advances to the takeup device 20 , which is arranged on the takeup module 40 . In comparison with the above-described embodiment, the takeup device 20 includes a tube magazine 41 and auxiliary devices not shown, so as to be able to perform an automatic package doff.
[0041] For threading the yarn, the frame section 37 . 3 mounts a threading device, which is formed by guide tubes 12 and 18 and their associated injectors 13 and 19 .
[0042] The suction end of guide tube 12 as well as the feed system 10 . 2 upstream thereof are schematically illustrated in FIG. 3 which is a partial view of FIG. 2. The feed system 10 . 2 comprises a driven godet 49 and a guide roll 50 , which are arranged on a support 44 . At its one end, the support 44 is held on a pivot axle 46 and can be pivoted between a contacting position and a threading position. FIG. 2 illustrates the support 44 in the threading position, and FIG. 3 shows it shortly before reaching the threading position. The free end of support 44 mounts the yarn guide 29 . In the threading position, the support 44 moves the yarn 29 directly in front of the suction inlet 33 of guide tube 12 . Associated with the suction inlet 33 of guide tube 12 is cutting blade 31 , which is attached to holder 32 .
[0043] For threading the yarn on feed system 10 . 2 , the support 44 is pivoted to a threading position that extends into servicing aisle 42 , as is shown in phantom lines in FIG. 2. By means of suction gun 35 , the operator loops the yarn several times about feed system 10 . 2 , and inserts it from its takeoff point on feed system 10 . 2 into the yarn guide 29 at the end of wire strap 45 . Subsequently, the support 44 is pivoted to the threading position, which represents at the same time the operating position of feed system 10 . 2 . In this process, the yarn guide 29 moves the yarn 36 in front of suction inlet 33 . The yarn 36 is then cut by cutting blade 31 in its length that advances toward a suction gun, and pneumatically advanced through guide tube 12 .
[0044] As shown in FIG. 2, the blow outlet 34 at the end of guide tube 12 faces a deflection plate 48 . Arranged at an angle of about 90° therewith is the suction inlet 28 of the second guide tube 18 . 1 , 18 . 2 , or 18 . 3 . In the intersections with the blow direction of the first guide tube 12 and with the suction direction in the second guide tube, the deflection plate 48 extends preferably with a deflection curvature corresponding to the direction. This accomplishes that the loose yarn, which is ejected from the blow outlet 34 of guide tube 12 , can be directly taken in by the activated suction inlet 28 of second guide tube 18 . 1 , 18 . 2 , or 18 . 3 .
[0045] At its opposite end, the guide tube 18 comprises a blow outlet 27 in facing relationship with a suction system of takeup device 20 , which is not shown.
[0046] In the texturing machine shown in FIG. 2, the yarn is guided in each processing station through the successively arranged guide tubes 12 and 18 . 1 , 18 . 2 , and 18 . 3 . In the region of takeup module 40 , successive guide tubes 18 . 1 , 18 . 2 , and 18 . 3 are shown, which guide a yarn to respective ones of the takeup devices 20 .
[0047] The embodiments shown in FIGS. 1 and 2 of the texturing machine are exemplary in the arrangement and configuration of the processing units. Basically, it is possible to drive, for example, adjacent feed systems jointly or each by an individual drive. Important is that the arrangement of the processing units in the texturing machine is such that it permits a simple and reproducible threading of the yarn by means of a threading device for advancing the yarn pneumatically. For example, the embodiment of FIG. 2 could be supplemented with a second heater, which would be arranged between the feed systems 10 . 2 and 14 . Likewise possible are additional processing units, such as an entanglement device, which could be arranged between the feed systems 10 . 1 and 10 . 2 , or yarn lubrication devices upstream of the takeup devices 20 .
[0048] The cutting device shown in the embodiments and consisting of a stationary cutting blade and a holder, is likewise exemplary. The cutting device could also comprise a movable cutting blade, which cooperates, for example, with a stationary yarn guide. It is also possible that the cutting device includes a plurality of cutting blades for cutting the yarn by the operating principle of scissors.
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A texturing machine for producing a crimped yarn and which has a plurality of serially arranged yarn processing units leading to a takeup device. A threading device is provided for threading a yarn for the first time before the start of a process. For this purpose, the threading device comprises at least one guide tube and an air injector connected thereto, with the guide tube including a suction inlet for receiving the yarn. In accordance with the invention, a cutting device is arranged in the region of the suction inlet of the guide tube, with the cutting device cutting the yarn while being threaded into the suction inlet.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Stage Application of International Application No. PCT/EP2013/062296 filed Jun. 13, 2013, which designates the United States of America, and claims priority to DE Application No. 10 2012 210 301.5 filed Jun. 19, 2012, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention generally relates to the technical field of the operation of internal combustion engines in a motor vehicle. The present invention especially relates to (a) a method for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine. The present invention further relates to (b) a method for the regulation of the smooth running of an internal combustion engine, (c) a method for determining the cylinder pressure in different cylinders of an internal combustion engine with at least two cylinders, wherein one cylinder is a lead cylinder fitted with a cylinder pressure sensor and the at least one other cylinder is an auxiliary cylinder, and (d) a method for checking the plausibility of a measurement signal of a cylinder pressure sensor of an internal combustion engine comprising at least two cylinders, each fitted with a cylinder pressure sensor. Moreover, the present invention relates to (e) a device for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine, (f) an engine controller with such a device and (g) a computer program that is configured to carry out one of the above-mentioned methods.
BACKGROUND
[0003] In internal combustion engine the masses of fuel that are injected per working cycle into the individual cylinders vary significantly because of manufacturing tolerances of a fuel injection system and by the occurrence of ageing of components of the fuel injection system. However, differences in the masses of the injected fuel result in torque differences between the individual cylinders that have an adverse effect on the smooth running of the internal combustion engine. Modern internal combustion engines, especially diesel engines, are therefore fitted with at least one so-called cylinder pressure sensor, which detects the time profile of the pressure in the interior of a cylinder. The torque provided by the cylinder involved can be estimated from the pressure profile and especially from the level of the pressure during the so-called working stroke in which the fuel combustion takes place. Based on a knowledge of such torque differences, balancing of the cylinders, i.e. equal torque contributions by all cylinders, can be achieved by means of an adjusted cylinder-specific fuel injection.
[0004] However, the output signal of a cylinder pressure sensor can be incorrect for many reasons. If such errors are not detected, this typically results in an incorrect cylinder-specific adjustment of the fuel injection. The smooth running of the internal combustion engine may not only not be improved but may even be significantly worsened.
[0005] A method for so-called cylinder balancing in relation to the injected masses of injected fuel in the different cylinders of an internal combustion engine is known From DE 197 20 009 A1. With this method the revolution rate or the rate of rotation during expansion and the revolution rate or the rate of rotation during compression is calculated for each cylinder. The difference in revolution rate between expansion and compression is filtered by means of a smoothing average value generation. Based on said filtered difference in revolution rates, an individual correction for the mass of fuel is calculated for each individual cylinder and said individual correction is taken into account during the calculation of the entire mass of fuel to be injected. The smooth running of the internal combustion engine can thus be improved by means of a mathematically relatively complex algorithm.
[0006] A method for compensating a systematic error in injection processes for an internal combustion engine is known from DE 197 00 711 A1. With this method, a correction value for the injection timing is used depending on the rough running.
[0007] A method and a system for cylinder balancing in reciprocating piston engines by compensating the harmonic components of the revolution rate of the crankshaft are known from DE 10 2005 047 829 B3. With this method a time interval of at least one revolution of the camshaft or two revolutions of the crankshaft is considered and within said time window a revolution rate signal of the crankshaft is subjected to a Fourier analysis.
[0008] The most frequent and fundamental cause of rough running of an internal combustion engine is, however, as explained above, a variation of the injected masses of fuel in the different cylinders. Assuming complete fuel combustion, different fuel-injected masses nevertheless result in different amounts of energy being released by fuel combustion in the working stroke of a cylinder of a four-stroke internal combustion engine.
SUMMARY
[0009] One embodiment provides a method for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine. The method includes the recording of a time profile of the revolution rate of the crankshaft of the internal combustion engine using toothing times, each representing a period of time within which two adjacent teeth of a sensor disk, which is connected to the crankshaft and which comprises an alternating arrangement of teeth and tooth spaces along its circumference, pass a reference position; associating the toothing times with a respective working cycle of a selected cylinder of the internal combustion engine; determining a cylinder-specific average value over the toothing times associated with the working cycle of the selected cylinder; determining cylinder-specific toothing time deviations of the toothing times associated with each working stroke of the selected cylinder from the determined cylinder-specific average value; determining a cylinder-specific characteristic toothing time by determining the geometric sum of the determined cylinder-specific toothing time deviations; and determining the amount of energy released in the working stroke of the selected cylinder of the internal combustion engine depending on the determined cylinder-specific characteristic toothing time, wherein the amount of energy released is indirectly proportional to the determined cylinder-specific characteristic toothing time.
[0010] In a further embodiment, all toothing times occurring within a working stroke of the selected cylinder are recorded and are associated with the relevant working stroke of the selected cylinder.
[0011] In a further embodiment, the cylinder-specific average value over the toothing times associated with the working stroke of the selected cylinder is determined based on toothing times that have been recorded during a working stroke of a preceding working cycle of the internal combustion engine.
[0012] In a further embodiment, any existing trend related to a variation of the toothing times, especially because of an increase or a reduction in the revolution rate of the crankshaft of the internal combustion engine, is taken into account during the determination of the cylinder-specific average value.
[0013] Another embodiment provides a method for the regulation of the smooth running of an internal combustion engine with a plurality of cylinders, the method comprising determining, for each cylinder of the internal combustion engine, the amount of energy released in the working stroke of said cylinder by a method as disclosed above, and adjusting at least one combustion-relevant parameter, so that the amounts of energy released in the different cylinders are at least approximately the same.
[0014] In a further embodiment, the at least one combustion-relevant parameter relates to a fuel supply path for the internal combustion engine.
[0015] Another embodiment provides a method for determining the cylinder pressure in different cylinders of an internal combustion engine with at least two cylinders, wherein one cylinder is a lead cylinder fitted with a cylinder pressure sensor and the at least one other cylinder is an auxiliary cylinder, the method comprising determining, for each cylinder of the internal combustion engine, a relative value for the amount of energy released in the working stroke of said cylinder by a method as disclosed above, measuring an absolute value for the cylinder pressure in the lead cylinder by means of the cylinder pressure sensor, determining a quantitative correlation between (a) the determined relative value for the amount of energy released in the working stroke of the lead cylinder and (b) the absolute value for the cylinder pressure in the lead cylinder, and calculating, for the at least one auxiliary cylinder of the internal combustion engine, the absolute value of the cylinder pressure in the at least one auxiliary cylinder based on (a) the determined quantitative correlation and (b) the determined relative value of the amount of energy released for the respective at least one auxiliary cylinder.
[0016] Another embodiment provides a method for checking the plausibility of a measurement signal of a cylinder pressure sensor of an internal combustion engine that comprises at least two cylinders, each fitted with a cylinder pressure sensor, the method comprising: determining, for each of the at least two cylinders of the internal combustion engine, a value for the amount of energy released in the working stroke of said cylinder by a method as disclosed above; measuring, for each of the at least two cylinders of the internal combustion engine, a value for the cylinder pressure in the respective cylinder by means of the respective cylinder pressure sensor; and determining, for each of the at least two cylinders of the internal combustion engine, a respective quantitative correlation between (a) the determined value for the amount of energy released in the working stroke of the respective cylinder and (b) the measured value for the cylinder pressure in the respective cylinder, and considering the at least two measured values for the respective cylinder pressure as correct measurement values if the at least two determined quantitative correlations are equal within a specified tolerance.
[0017] In a further embodiment, the method further comprises: considering at least one value for each cylinder pressure of the at least two measured values for the respective cylinder pressure as an incorrect measurement value if the at least two determined quantitative correlations differ from each other by more than the specified tolerance; and converting the at least one measurement value deemed to be incorrect into a modified measurement value for the cylinder pressure in each cylinder, so that a modified quantitative correlation between (i) the determined value for the amount of energy released in the working stroke of the respective cylinder and (ii) the modified measurement value is equal within the specified tolerance to at least one quantitative correlation between (i) a determined value for the amount of energy released in the working stroke of the respective cylinder and (ii) an associated measured value for the cylinder pressure in the respective cylinder, wherein the same relates to at least one quantitative correlation for a cylinder fitted with a cylinder pressure sensor whose measured values for the cylinder pressure are considered to be correct measurement values.
[0018] In a further embodiment, the method further comprises: operating the internal combustion engine in a stable operating state, in which all cylinders make an at least approximately equal torque contribution to the total torque of the internal combustion engine; measuring, in the stable operating state, for each of the at least two cylinders of the internal combustion engine, a value for the cylinder pressure in the respective cylinder by means of the respective cylinder pressure sensor; comparing the values measured in the stable operating state with each other; and if the values measured in the stable operating state deviate from each other by more than a further specified tolerance, adjusting a sensor characteristic of at least one cylinder pressure sensor such that, taking into account the at least one adjusted sensor characteristic, the associated measurement values for the cylinder pressure in the different cylinders are equal at least within the further specified tolerance.
[0019] Another embodiment provides a device for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine, the device comprising: a recording unit for recording a time profile of the revolution rate of the crankshaft of the internal combustion engine using toothing times, each representing a period of time within which two adjacent teeth of a sensor disk, which is connected to the crankshaft and which comprises an alternating arrangement of teeth and tooth spaces along its circumference, pass a reference position; and a data processing device for associating each of the toothing times with a respective working cycle of a selected cylinder of the internal combustion engine, for determining a cylinder-specific average value over the toothing times associated with the working cycle of the selected cylinder, for determining cylinder-specific toothing time deviations of each of the toothing times associated with the working stroke of the selected cylinder from the determined cylinder-specific average value, for determining a cylinder-specific characteristic toothing time by determining the geometric sum of the determined cylinder-specific toothing time deviations, and for determining the amount of energy released in the working stroke of the selected cylinder of the internal combustion engine depending on the determined cylinder-specific characteristic toothing time, wherein the amount of energy released is indirectly proportional to the determined cylinder-specific characteristic toothing time.
[0020] Another embodiment provides an engine controller for an internal combustion engine of a motor vehicle, the engine controller comprising a device as disclosed above for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine, wherein the engine controller is configured to carry out and/or to control at least one of the following methods: a method as disclosed above for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine, a method as disclosed above for regulating the smooth running of an internal combustion engine with a plurality of cylinders, a method as disclosed above for determining the cylinder pressure in different cylinders of an internal combustion engine with at least two cylinders, wherein one cylinder is a lead cylinder fitted with a cylinder pressure sensor and the at least one other cylinder is an auxiliary cylinder, and a method as disclosed above for checking the plausibility of a measurement signal of a cylinder pressure sensor of an internal combustion engine that comprises at least two cylinders, each fitted with a cylinder pressure sensor.
[0021] Another embodiment provides a computer program for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine, wherein the computer program is configured to carry out any of the methods disclosed above when executed by a processor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Example embodiments are discussed in detail below with reference to the drawings, in which:
[0023] FIG. 1 shows a device for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine.
[0024] FIG. 2 shows a diagram in which the time profile of high resolution measured toothing times of a sensor disk coupled to a crankshaft of a four-cylinder four-stroke engine are plotted.
[0025] FIG. 3 shows an enlarged illustrated segment of the diagram shown in FIG. 2 .
[0026] FIG. 4 shows how an absolute calculation of the individual cylinder pressures can be carried out for an internal combustion engine in which only one cylinder is fitted with a cylinder pressure sensor by forming relationships of the amounts of energy released from the individual cylinders.
[0027] FIG. 5 shows a plausibility check of a plurality of measurement signals of each cylinder pressure sensor using a comparison with an estimate of a respective amount of energy released in a working stroke of a based on an analysis of measured toothing times.
[0028] FIG. 6 shows a possible procedure for a method of adjusting a sensor characteristic of a cylinder pressure sensor based on a cylinder-selective comparison between (a) an estimated value for the amount of energy released in the working cycle of the cylinder involved and (b) a measurement value for the cylinder pressure in the cylinder involved detected by a cylinder pressure sensor.
DETAILED DESCRIPTION
[0029] Embodiments of the invention determine the amount of energy released in the working stroke of an internal combustion engine very accurately and without a complex sensor system.
[0030] Of course, features and details that are disclosed in connection with one of the methods described herein also apply here in connection with the device, the engine controller and the computer program, and vice versa in each case, so that reference can always be alternatively made to the individual aspects of the invention in relation to the disclosure of this invention.
[0031] Some embodiments provide a method for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine. The method comprises (a) recording a time profile of the revolution rate of the crankshaft of the internal combustion engine using toothing times, each representing a period of time within which two adjacent teeth of a sensor disk, which is connected to the crankshaft and which comprises an alternating arrangement of teeth and tooth spaces along its circumference, pass a reference position, (b) associating the toothing times with a working stroke of a selected cylinder of the internal combustion engine in each case, (c) determining a cylinder-specific average value over the toothing times associated with the working stroke of the selected cylinder, (d) determining cylinder-specific toothing time deviations of each of the toothing times associated with the working stroke of the selected cylinder from the determined cylinder-specific average value, (e) determining a cylinder-specific characteristic toothing time by determining the geometric sum of the determined cylinder-specific toothing time deviations and (f) determining the amount of energy released in the working stroke of the selected cylinder of the internal combustion engine depending on the determined cylinder-specific characteristic toothing time, wherein the amount of energy released is indirectly proportional to the determined cylinder-specific characteristic toothing time.
[0032] The method described is based on the knowledge that the characteristic toothing time, which is given by the geometric (or Pythagorean) sum of each of the cylinder-specific toothing time deviations determined for a working stroke of the selected cylinder, is a direct measure of the amount of energy released in a working stroke of the selected cylinder.
[0033] This means that the toothing time defined here is equivalent to the respective amount of energy released. Hence an absolute value for the amount of energy released in the working stroke of the respective cylinder is not determined with the method described here, but only a relative value is determined. However, a proportionality factor between said relative value and the respective absolute amount of energy is the same for all cylinders, so that the relative values for different cylinders can be set in relation to each other and thereby important information about the operating state of the internal combustion engine and especially about the torque contributions of the individual cylinders can be obtained.
[0034] In comparison to known methods, the method described here has the advantage that only a geometric sum has to be calculated and that thus no mathematically rather complex Fourier analysis of the toothing times associated with each working stroke of a selected cylinder of the internal combustion engine has to be carried out. Furthermore, the method described here is suitable both for gasoline engines and also for diesel engines that are four-stroke internal combustion engines.
[0035] It is noted that the amount of energy released and thus also the characteristic toothing time is a direct measure or an equivalent of the torque that is generated in the relevant working stroke of the selected cylinder. In order to reduce any existing rough running of the internal combustion engine, based on the amounts of energy released for the different cylinders determined with the method described here, at least an approximate balancing of the cylinders can be achieved by adjusting combustion-relevant parameters cylinder-specifically for the individual cylinders, especially parameters describing the injection processes, so that as a result each cylinder makes a contribution to the total torque of the internal combustion engine that is as equal in magnitude as possible.
[0036] The sensor disk used for carrying out the method described can comprise an edge structure in a known manner, which comprises an alternating arrangement of a tooth and a tooth space in each case. A sensor associated with the sensor disk, which detects the presence and the absence of a tooth in the reference position, can produce a signal that can adopt at least two signal levels, wherein one of the signal levels is associated with a tooth and the other is associated with a tooth space. The signal or the different signal levels can be produced in any physical manner. In particular, the signal can be an electrical signal that is e.g. produced by a magnetic sensor (induction sensor), preferably a Hall sensor. However, other types of signal generation, e.g. optically by means of a light barrier, are also possible.
[0037] It is noted that in order to determine an absolute angular position of the crankshaft the sensor disk can comprise a reference marker that can be detected by a suitable sensor system, e.g. the above-mentioned magnetic sensor. In a known manner said marker can consist of e.g. two teeth being omitted from the otherwise regular arrangement of an alternating tooth and tooth space. Consequently, the sensor disk can e.g. comprise 60-2=58 teeth. In this connection it goes without saying that the toothing time that is associated with the omission of two teeth is either corrected in a suitable manner or is no longer taken into account for the subsequent process.
[0038] Expressed clearly, with the method described a revolution rate signal of an internal combustion engine can be analyzed so that the energy content or the amount of energy that is released in the working stroke of a cylinder of the internal combustion engine can be estimated in a mathematically particularly simple manner. A knowledge of said amount of energy can then be used to at least approximately achieve balancing of the individual cylinders of the internal combustion engine by cylinder-specific adjustment of injection parameters. The method described uses high resolution information about the toothing times sampled in a defined pattern over a specified observation time period and stored in a buffer, especially of an engine controller.
[0039] According to another embodiment, all toothing times occurring within a working stroke of the selected cylinder are recorded and associated with the relevant working stroke of the selected cylinder. This has the advantage that the time profile of the revolution rate of the crankshaft during the respective working stroke of the selected cylinder is recorded with the maximum possible accuracy. Hence the amount of energy released in the relevant working stroke of the selected cylinder can also be determined with particularly high accuracy.
[0040] Preferably, the toothing times are recorded with high time resolution, e.g. in the region of at least a few μs (1 μs=10 −6 seconds). The subsequent determinations or calculations of the cylinder-specific average value, the cylinder-specific toothing time deviations and the cylinder-specific characteristic toothing time preferably take place with the same time resolution. The result of this is also that the accuracy of the method described in relation to the determination of the amount of energy released is particularly high.
[0041] The term “working cycle” used below is to be understood in this document to mean the entirety of the four strokes of a four-stroke engine, which include as is well-known an induction stroke, a compression stroke, a working stroke and an exhaust stroke. During a working cycle the crankshaft of the internal combustion engine carries out two revolutions.
[0042] In the case of a sensor disk with 60 teeth there is thus a total of 120 transitions or toothing times between two adjacent teeth per working cycle of the (four-stroke) internal combustion engine. In the case of a four-cylinder engine there are thus 30 toothing times associated with each working stroke of a cylinder of the total of four cylinders. Consequently, optimal accuracy in the determination of the amount of energy released can be achieved if all 30 toothing times are taken into account for the determination of the amount of energy released in the relevant working stoke of the selected cylinder with the method described.
[0043] In this connection it is noted that at least with modern internal combustion engines accurate high time resolution information about the individual toothing times is already maintained in an engine controller. The method described can thus be implemented without equipment changes by the suitable programming of an engine controller of an internal combustion engine.
[0044] According to another embodiment, the cylinder-specific average value over the toothing times associated with the working stroke of the selected cylinder is determined on the basis of toothing times that have been determined during a working stroke of a preceding working cycle of the internal combustion engine. This means that some of the mathematical calculations carried out with the method described here have already been completed in advance in a preceding working cycle of the internal combustion engine. The requirement on a data processing device in which the mathematical calculations of the method described here are carried out can therefore be reduced. The method described can consequently be carried out with an engine controller of only medium computing power.
[0045] Preferably, the cylinder-specific average value is determined over those toothing times that were recorded in the working cycle that immediately precedes the current working cycle. In this way an unnecessarily long time period is avoided between the recording of the toothing times that are used exclusively for the cylinder-specific average value and the recording of those toothing times that are used (together with the toothing times that are also exclusively used for the cylinder-specific average value) for the determination of the cylinder-specific toothing time deviations. In this way a degradation of the accuracy as a result of the use of toothing times that are associated with different working cycles is reduced to a minimum.
[0046] According to another embodiment, during the determination of the cylinder-specific average value any prevailing trend relating to a variation of the toothing times, especially because of an increase or a reduction of the revolution rate of the crankshaft of the internal combustion engine, is taken into account. This has the advantage that even in the case of a systematic variation of the toothing times, e.g. because of an acceleration or a deceleration of a motor vehicle driven by the internal combustion engine, the cylinder-specific average value can already be determined in advance during a preceding working cycle without the fear of a degradation of the accuracy of the method described.
[0047] Other embodiments provide a method for the regulation of the smooth running of an internal combustion engine with a plurality of cylinders. Said method comprises (a) determining, for each cylinder of the internal combustion engine, the amount of energy released in the working stroke of said cylinder by means of a method of the above-mentioned type for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine, and (b) adjusting at least one combustion-relevant parameter so that the amounts of energy released in the different cylinders are at least approximately equal.
[0048] The method described is based on the idea that the fuel combustion in the individual cylinders can be adjusted based on a knowledge of the estimated cylinder-specific amounts of energy released in each working stroke, which are a direct measure of the torque contributions of the individual cylinders, so that all cylinders provide at least approximately the same torque contributions and thus maximum smooth running can be achieved.
[0049] Equalizing the individual torque contributions takes place by means of an adjustment of parameters that are relevant to the fuel combustion in each cylinder. Combustion-relevant parameters can relate to the air supply path for the internal combustion engine or preferably to the fuel supply path for the internal combustion engine.
[0050] A combustion-relevant parameter relating to the air supply path can e.g. be a charging pressure with which the air necessary for the combustion process is forced into the relevant cylinder of the internal combustion engine. Said charging pressure can be produced in a known manner, e.g. by a turbocharger. The combustion-relevant parameter can also be a rate of exhaust recycling that ensures in a known way that instead of pure air a mixture of air and exhaust gas from a previous combustion process of the cylinder involved is supplied. It is noted that the list of the combustion-relevant parameters relating to the air supply path described here is not conclusive.
[0051] According to one embodiment, the at least one combustion-relevant parameter relates to a fuel supply path for the internal combustion engine.
[0052] The at least one combustion-relevant parameter relating to the fuel supply path can e.g. be the start of a fuel injection, the injection pressure of the fuel, the injected quantity of fuel, the number of discrete injection processes (pre-injections) and/or the respective injection amounts in the case of the use of at least one pre-injection in addition to a main injection. The injection pressure can be measured and/or adjusted in a known manner in a fuel supply system, e.g. in a so-called common rail system. It is however noted that the list described here of combustion-relevant parameters is not conclusive.
[0053] The use of at least one of the combustion-relevant parameters described here relating to the fuel supply path has the advantage that the method described in this document can be implemented with conventional internal combustion engines and conventional fuel supply systems without this requiring a hardware technology conversion of the internal combustion engine and/or the fuel supply system.
[0054] Other embodiments provide a method for determining the cylinder pressure in different cylinders of an internal combustion engine with at least two cylinders, wherein one cylinder is a lead cylinder fitted with a cylinder pressure sensor and the at least one other cylinder is an auxiliary cylinder. This method comprises (a) determining, for each cylinder of the internal combustion engine, a relative value for the amount of energy released in the working stroke of said cylinder by means of a method of the above-mentioned type for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine, (b) measurement of an absolute value for the cylinder pressure in the lead cylinder by means of the cylinder pressure sensor, (c) determining a quantitative correlation between (c1) the determined relative value of the amount of energy released in the working stroke of the lead cylinder and (c2) the absolute value of the cylinder pressure in the lead cylinder, and (d) calculating, for the at least one auxiliary cylinder of the internal combustion engine, the absolute value of the cylinder pressure in the at least one auxiliary cylinder based on (d1) the determined quantitative correlation and (d2) the relative value determined for the amount of energy released for the at least one respective auxiliary cylinder.
[0055] The method described for determining the cylinder pressure is based on the idea that in a system with only one cylinder pressure sensor attached to a so-called lead cylinder the absolute cylinder pressures or cylinder pressure values in the auxiliary cylinders can be calculated by (a) forming a relationship between (a1) the absolute cylinder pressure measured with the cylinder pressure sensor and (a2) the with the above-mentioned method for determining the amount of energy released in the working cycle of a cylinder of an internal combustion engine and (b) by transferring the relationship formed to auxiliary cylinders, which are not fitted with a cylinder pressure sensor, e.g. for cost reasons.
[0056] Based on a knowledge of the absolute cylinder pressure values (during the working strokes) of all cylinders, the absolute or relative torque contributions of the individual cylinders can be determined in a known way. As already explained above, the amounts of energy released in the different cylinders can be adjusted by an adjustment of at least one combustion-relevant parameter so that the torque contributions of the individual cylinders to a total torque are at least approximately equal.
[0057] The internal combustion engine is then advantageously operated with maximum smooth running or with minimum rough running.
[0058] With the method described, simply speaking a dimensionless measure of the relative amount of energy of at least two cylinders is initially determined. Then for one of the two cylinders, which is designated as the lead cylinder, the absolute cylinder pressure is measured by means of a cylinder pressure sensor, which measures the pressure profile in the lead cylinder and outputs a corresponding cylinder pressure measurement signal. Said cylinder pressure measurement signal represents the torque contribution of the lead cylinder to the total torque of the internal combustion engine. A subsequently determined relationship, which is also referred to as a quantitative correlation and which can be defined by a simple proportionality factor, between the relative value of the amount of energy released and the measured cylinder pressure is then applied to the auxiliary cylinder. The absolute values of the cylinder pressure in the at least one auxiliary cylinder for this are calculated based on (a) said relationship and (b) the respective determined relative values for the respective released energy.
[0059] In this connection the term “cylinder pressure” can especially mean the so-called indicated mean pressure during the working stroke of the relevant cylinder. The term “cylinder pressure” can, however, also mean a pressure profile as a function of time or as a function of a crankshaft angle, the pressure profile arising during the working stroke of the cylinder involved.
[0060] With the method described for determining the (absolute) cylinder pressure in different cylinders of an internal combustion engine, a simple cylinder pressure sensor system with only one cylinder pressure sensor can be used with an estimate of the relative individual torques, which as described above are correlated with the respective amount of energy released, and based on a single absolute cylinder pressure determination, to calculate the absolute values of the torque contributions of all cylinders of the internal combustion engine. Full cylinder pressure regulation can be achieved with only a single cylinder pressure sensor by suitable cylinder-specific adjustments of combustion-relevant parameters and thus accurate control of the individual torque contributions can be achieved. For example, the manufacturing tolerances of fuel injectors can be compensated in this way in a simple manner. Furthermore, by analyzing the cylinder-specific differences regarding the toothing time or the torque contribution derived therefrom, impermissibly large deviations can be diagnosed. In the case of excessive differences between the different cylinders, a conclusion may then be drawn regarding an incorrect operating state of the internal combustion engine.
[0061] Expressed simply, based on a knowledge of the individual torque contributions, regulation of the individual torques can be carried out both with respect to their differences from each other (targeted balancing of the cylinders), which are to be avoided if possible, and also with respect to their absolute values. The resulting control interventions such as e.g. an adjustment of the injection, can be used for a diagnosis of the operating state of the internal combustion engine. This can e.g. take place by monitoring limit values for the required control interventions.
[0062] Furthermore, diagnostic functionality can advantageously be implemented with the described method, by means of which impermissibly large differences between the individual cylinders, e.g. with respect to the respective (i) toothing times, (ii) torques and/or (iii) values derived from the toothing times can be detected. If excessive differences are detected, then a conclusion can be drawn regarding an incorrect operating state of the internal combustion engine and e.g. a repair measure or maintenance work can be initiated.
[0063] Other embodiments provide a method for checking the plausibility of a measurement signal from a cylinder pressure sensor of an internal combustion engine comprising at least two cylinders, each cylinder being fitted with a cylinder pressure sensor. This method comprises (a) determining, for each of the least two cylinders of the internal combustion engine, a value for the amount of energy released in the working stroke of said cylinder by means of the above-mentioned method for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine, (b) measuring, for each of the at least two cylinders of the internal combustion engine, a value for the cylinder pressure in each of the cylinders by means of the respective cylinder pressure sensor, (c) determining, for each of the at least two cylinders of the internal combustion engine, a quantitative correlation between (c1) the determined value for the amount of energy released in the working stroke of the respective cylinder and (c2) the measured value for the cylinder pressure in the respective cylinder, and (d) regarding the at least two measured values for the respective cylinder pressure as correct measurement values if the at least two determined quantitative correlations are equal within a specified tolerance.
[0064] The method described for checking the plausibility of a measurement signal from a cylinder pressure sensor of an internal combustion engine is based on the idea that by a comparison of the quantitative correlations between (a) each estimated (relative) value for the amount of energy released in the working stroke of the respective cylinder and (b) each measured (relative or absolute) value for the cylinder pressure in the respective cylinder, it can be determined in a simple manner whether said quantitative correlations, which can each especially be a simple proportionality factor, are the same for all cylinders of the internal combustion engine within a specified deviation that is also seen as tolerable. If this is the case, then it can be assumed therefrom with high reliability that the entire cylinder pressure sensor system and especially all cylinder pressure sensors involved therein are working properly. If in the event of a comparison of the different determined quantitative correlations it should be revealed that at least one correlation deviates too much from the other correlation(s), then it can be assumed therefrom that at least one cylinder pressure sensor has a certain defect.
[0065] As already explained above, the term “cylinder pressure” can mean the indicated mean pressure during the working cycle of the cylinder involved. The term “cylinder pressure” can, however, also be a pressure profile as a function of time or as a function of a crankshaft angle, said pressure profile arising during the working stroke of the cylinder involved.
[0066] In some embodiments, the method further comprises (a) considering at least one value for the respective cylinder pressure of the at least two measured values for the respective cylinder pressure as an incorrect measurement value if the at least two determined quantitative correlations deviate from each other by more than the specified tolerance, and (b) converting the at least one measurement value that is considered to be incorrect into a modified measurement value for the cylinder pressure in the respective cylinder, so that (b1) a modified quantitative correlation between (i) the determined value for the amount of energy released in the working stroke of the respective cylinder and (ii) the modified measurement value is equal within the specified tolerance to (b2) at least one quantitative correlation between (i) a determined value for the amount of energy released in the working stroke of the respective cylinder and (ii) an associated measured value for the cylinder pressure in the respective cylinder, wherein the same relates to at least one quantitative correlation for a cylinder that is fitted with a cylinder pressure sensor, whose measured values for the cylinder pressure are considered to be correct measurement values. Thus in the case of a defective cylinder pressure sensor system a correction can be carried out for that cylinder pressure sensor or for those cylinder pressure sensors by adjusting e.g. a sensor characteristic in a suitable manner.
[0067] Expressed simply, the cylinder-specific torque contributions to a total torque of the internal combustion engine can be determined for an internal combustion engine that is fitted with a cylinder pressure sensor system comprising a plurality of cylinder pressure sensors by using the measured cylinder pressures. The different cylinders can be balanced with respect to their respective torque contributions by a cylinder-specific adjustment of combustion-relevant parameters. If, however, the cylinder pressure sensor system is defective, e.g. because of production errors and/or ageing effects, said defect can be identified with high reliability with the method described here for checking the plausibility of a measurement signal from a cylinder pressure sensor of an internal combustion engine, and may even be compensated by using a sensor characteristic modified in a suitable manner.
[0068] According to one embodiment, the method further comprises (a) operating the internal combustion engine in a stable operating state in which all cylinders provide an at least approximately equal torque contribution to the total torque of the internal combustion engine, (b) measuring, in the stable operating state, for each of the at least two cylinders of the internal combustion engine, a value for the cylinder pressure in the respective cylinder by means of the respective cylinder pressure sensor, (c) comparing the values measured in the stable operating state with each other, and (d) if the values measured in the stable operating state deviate from each other by more than another specified tolerance, adjusting a sensor characteristic of at least one cylinder pressure sensor such that by taking into account the at least one adjusted sensor characteristic the associated measurement values for the cylinder pressure in the different cylinders are equal at least within the further specified tolerance. This has the advantage that matching of the individual sensor characteristics can be carried out during the operation of the internal combustion engine. It is only necessary that the described stable operating state of the internal combustion engine exists at least for a relatively short time period. As a result, defects in the cylinder pressure measurement equipment can be diagnosed and compensated at the same time by a suitable adjustment of at least one sensor characteristic.
[0069] The stable operating state can e.g. be a deceleration phase of the internal combustion engine, during which no fuel injection takes place in any of the cylinders. A deceleration phase is typically particularly characterized by maximum smooth running. This is because there is no fuel combustion in a deceleration phase. Therefore there can be no differences in the amounts of energy released in the different cylinders. Therefore with correct sensor characteristics in such a stable operating state with little rough running all basically operational cylinder pressure sensors provide a similar measurement signal.
[0070] The adjustment of the sensor characteristic can e.g. consist of a change of a gradient or of a proportionality factor between the physical output signal of the cylinder pressure sensor involved and the respective cylinder pressure measurement signal indicating the actual cylinder pressure.
[0071] Alternatively or in combination, the adjustment of the sensor characteristic can also include the use of a new offset-value.
[0072] Other embodiments provide a device for determining the amount of energy released in the working cycle of a cylinder of an internal combustion engine. The described device comprises (a) a recording unit for recording a time profile of the revolution rate of the crankshaft of the internal combustion engine using toothing times, each of which is a period of time within which two adjacent teeth of a sensor disk, which is connected to the crankshaft and which comprises an alternating arrangement of teeth and tooth spaces along its circumference, pass a reference position, and (b) a data processing device (b1) for associating each of the toothing times with a working stroke of a selected cylinder of the internal combustion engine, (b2) for determining a cylinder-specific average value over the toothing times associated with the working stroke of the selected cylinder, (b3) for determining cylinder-specific toothing time deviations of the respective toothing times associated with the working stroke of the selected cylinder from the determined cylinder-specific average value, (b4) for determining a cylinder-specific characteristic toothing time by determining the geometric sum of the determined cylinder-specific toothing time deviations and (b5) for determining the amount of energy released in the working stroke of the selected cylinder of the internal combustion engine depending on the determined cylinder-specific characteristic toothing time, wherein the amount of energy released is indirectly proportional to the determined cylinder-specific characteristic toothing time.
[0073] The described device is also based on the idea that the characteristic toothing time, which is given by the geometric (or Pythagorean) sum of the respective cylinder-specific toothing time deviations determined for a working stroke of the selected cylinder, is a direct measure of the amount of energy released in a working stroke of the selected cylinder of the internal combustion engine. As already explained above, the characteristic toothing time defined here is a direct measure or an equivalent of the torque that is generated in the working stroke involved of the selected cylinder. Therefore, in order to reduce any rough running of the internal combustion engine, balancing of the cylinders can be at least approximately achieved by adjusting cylinder-specific combustion-relevant parameters based on the amounts of energy released.
[0074] Other embodiments provide an engine controller for an internal combustion engine of a motor vehicle. The described engine controller comprises a device of the above-mentioned type for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine. The engine controller described here is suitable for carrying out and/or for controlling at least one of the above-mentioned methods (a) for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine, (b) for regulating the smooth running of an internal combustion engine with a plurality of cylinders, (c) for determining the cylinder pressure in different cylinders of an internal combustion engine with at least two cylinders, wherein one cylinder is a lead cylinder fitted with a cylinder pressure sensor and the at least one other cylinder is an auxiliary cylinder, and (d) for checking the plausibility of a measurement signal of a cylinder pressure sensor of an internal combustion engine that comprises at least two cylinders, each of which is fitted with a cylinder pressure sensor.
[0075] The engine controller described is based on the idea that the above-described device can be implemented in an engine controller for an internal combustion engine of a motor vehicle and that in this way, e.g. by means of suitable software, the amount of energy released in the working stroke of a cylinder of an internal combustion engine can be determined in a simple manner.
[0076] In this connection it is noted that the engine controller described can also work in conjunction with other components of the internal combustion engine or of a motor vehicle in order to carry out some procedural steps of the method described here. The engine controller can thus work in conjunction e.g. with an induction sensor to record toothing times and/or with at least one cylinder pressure sensor to measure the cylinder pressure in the cylinder involved.
[0077] Other embodiments provide a computer program for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine. The computer program is configured to carry out the above-mentioned method when executed by a processor.
[0078] For the purposes of this document, the naming of such a computer program is synonymous with the concept of a program element, of a computer program product and/or of a computer-readable medium, which contains instructions for controlling a computer system for coordinating the operation of a system or of a method in a suitable manner to achieve the effects associated with the method according to the invention.
[0079] The computer program can be implemented as a computer-readable instruction code in any suitable programming language such as e.g. in JAVA, C++ etc. The computer program can be stored on a computer-readable storage medium (CD-ROM, DVD, Blueray disk, removable drive, volatile or non-volatile memory, built-in memory or processor etc.). The instruction code can program a computer or other programmable device, such as especially a controller for an internal combustion engine of a motor vehicle, such that the desired functions are carried out. Furthermore, the computer program can be provided in a network such as e.g. the Internet, from which it can be downloaded when required by a user.
[0080] Embodiments of the invention can be implemented both by means of a computer program, i.e., by means of software, and also by means of one or more special electrical circuits, i.e. in hardware or even in any hybrid form, i.e. by means of software components and hardware components.
[0081] Further advantages and features of the present invention are revealed in the following exemplary description of currently preferred embodiments.
[0082] It is noted that the embodiments described below only represent a limited selection of possible embodiment versions of the invention. In particular, it is possible to combine the features of individual embodiments with each other in a suitable manner so that with the embodiment versions explicitly illustrated here a number of different embodiments can be viewed as being publicly disclosed for the person skilled in the art.
[0083] FIG. 1 shows a device 100 for determining the amount of energy released in the working stroke of a cylinder of an internal combustion engine. The device 100 or some components of the device 100 can be implemented in an engine controller for a motor vehicle. The device 100 comprises a recording unit 102 for recording a time profile of the revolution rate of the crankshaft of the internal combustion engine using toothing times, each of which represents a period of time within which two adjacent teeth of a sensor disk, which is connected to the crankshaft and which comprises an alternating arrangement of teeth and tooth spaces along its circumference, pass a reference position. The device further comprises a data processing device 104 . The data processing device 104 is configured or programmed (a) to associate the toothing times with a respective working cycle of a selected cylinder of the internal combustion engine, (b) for determining a cylinder-specific average value over the toothing times associated with the working stroke of the selected cylinder, (c) to determine cylinder-specific toothing time deviations of each toothing time associated with the respective working stroke of the selected cylinder from the determined cylinder-specific average value, (d) for determining a cylinder-specific characteristic toothing time by determining the geometric sum of the determined cylinder-specific toothing time deviations and (e) for determining the amount of energy released in the working stroke of the selected cylinder of the internal combustion engine depending on the determined cylinder-specific characteristic toothing time, wherein the amount of energy released is indirectly proportional to the determined cylinder-specific characteristic toothing time.
[0084] FIG. 2 shows a diagram in which the time profile of high resolution measured toothing times of a sensor disk coupled to a crankshaft of a four-cylinder four-stroke engine is plotted. The toothing time here is the period of time within which two adjacent teeth of a sensor disk, which is coupled to the crankshaft of the internal combustion engine involved and which comprises an alternating arrangement of teeth and tooth spaces along its circumference, pass a reference position. The toothing time, which can be determined in a known manner, e.g. by means of a magnetic sensor, consequently represents the current rate of rotation or revolution rate of the crankshaft with high time resolution. A long toothing time corresponds to a low rate of rotation, a short toothing time corresponds to a high rate of rotation.
[0085] From the illustrated time profile of the toothing times an association with the working strokes of the individual cylinders of the internal combustion engine can be carried out in a simple manner. Here the fact can be used that in the cylinder of the four-cylinder internal combustion engine that is just in the working stroke the crankshaft accelerates at the start of the working stroke starting from a relatively low rate of rotation. After a maximum rate of rotation has been achieved within said working stroke, the rate of rotation decreases slightly again before the next cylinder enters its working stroke and in a similar manner initially provides an increase of the rate of rotation therein, and again provides a reduction of the rate of rotation after exceeding a maximum.
[0086] Because the rate of rotation is indirectly proportional to the toothing time, a characteristic shape results in the diagram of FIG. 2 for each working stroke of a cylinder, the shape being similar to the shape of a parabola that is open at the top and which is bounded in the horizontal direction by two dashed vertical lines, one on the left side and one on the right side.
[0087] The profile illustrated in FIG. 2 results in the case of a four-cylinder internal combustion engine. For this reason the illustrated profile also comprises a periodicity of four such characteristic shapes. In FIG. 2 each of said characteristic shapes is associated with a cylinder Z 1 , Z 2 , Z 3 or Z 4 of the four-cylinder internal combustion engine.
[0088] The horizontal dashed lines indicate the average value of the toothing times arising within the respective working stroke of the cylinder involved.
[0089] FIG. 3 shows a segment of the diagram shown in FIG. 2 in an enlarged illustration. In the case of the exemplary embodiment described here, the high resolution toothing time is sampled over a certain observation time period of e.g. two working cycles of the internal combustion engine involved with a defined pattern and is stored in a buffer or a data memory, especially a data memory of an engine controller. In the data memory e.g. 30 toothing times per working cycle of the cylinder involved can be stored.
[0090] In contrast to previously known methods, the contents of the data memory in the case of the method described here are not subjected to a complex frequency analysis. Only the average value over the different toothing times is calculated and subtracted from each individual toothing time. Then the geometric sum is formed over the toothing times corrected in this way by the average value. The next equation describes said procedure in a mathematical way:
[0000] ZZ char =√{square root over (Σ i=1 N ZZ i 2 )}
[0091] ZZ i stands for the toothing time in the data memory at position i corrected by the average value. N is the number of toothing times or elements in the data memory. The data memory is a temporary toothing time memory. The expression ZZ char is the so-called characteristic toothing time, which represents an equivalent to the amount of energy that is released in the respective working stroke of the cylinder involved.
[0092] According to a version of the invention that is not explained in detail here, prior to forming the geometric sum a constant component (e.g. from the last cycle or working cycle) or any toothing time trend (in the case of a potentially present slight acceleration or deceleration of the crankshaft) can also be removed.
[0093] The characteristic toothing time ZZ char defined here represents an equivalent (indirect proportionality) of the torque contribution to the total torque that is provided by the cylinder involved with each working stroke. By using an equality function with a suitable change of the injection parameter (and thus of the respective torque contribution), the torque contributions of the individual cylinders can be brought into agreement, so that as a result the smooth running of the internal combustion engine is improved considerably.
[0094] In the case of the method described here, a complex FFT analysis can be dispensed with by removing the average value in the toothing time buffering and forming the sum.
[0095] FIG. 4 shows how an absolute calculation of the individual cylinder pressures can be carried out in the case of an internal combustion engine in which only one cylinder is fitted with a cylinder pressure sensor by forming relationships of the amounts of energy released by the individual cylinders. The upper diagram of FIG. 4 is identical to the diagram of FIG. 2 . In the lower diagram of FIG. 4 the respective characteristic toothing times are shown for each working stroke of one of the cylinders of the internal combustion engine involved, which, as explained above, represent an indirectly proportional equivalent to the amount of energy released in each working stroke.
[0096] Because only the average value over the toothing times involved has to be formed prior to the calculation of a characteristic toothing time, the characteristic toothing times are shifted slightly to the right in comparison to the minima of the above-mentioned characteristic shapes at the end of each working stroke.
[0097] In the case of the exemplary embodiment described here, the second cylinder Z 2 is the so-called lead cylinder. The other cylinders Z 1 , Z 3 and Z 4 are so-called auxiliary cylinders. This means that only said lead cylinder is fitted with a cylinder pressure sensor, e.g. for cost reasons. Therefore also only the torque contribution of said lead cylinder can be directly determined using the measurement data provided by the cylinder pressure sensor.
[0098] However, the individual amounts of energy that are released in the working strokes of the different cylinders, and that are illustrated by circles in FIG. 4 , can be related to each other. The corresponding relationships between the lead cylinder Z 2 on the one hand and the other cylinders Z 1 , Z 3 and Z 4 on the other hand are illustrated in FIG. 4 by the curved arrows that are shown in dashed form.
[0099] In order to indirectly determine the cylinder pressures in the cylinders Z 1 , Z 3 and Z 4 , it is assumed that the amounts of energy released and the respective associated cylinder pressures for all cylinders are in the same ratio to each other. Expressed simply, in a system with only one cylinder pressure sensor a calculation of the individual cylinder torques is carried out by forming the relationships of the amounts of energy released in the individual cylinders with each other (e.g. by a ratio equation).
[0100] Based on said information, e.g. regulation of the relative cylinder torques in respect of minimizing the differences between the individual cylinder torques (balancing) can then be carried out. Moreover, the absolute values of the cylinder pressures of the other cylinders can also be regulated to specified target values based on the knowledge of the absolute cylinder pressure in the lead cylinder. The control interventions resulting therefrom can also be used for a diagnosis of the operation (state) of the internal combustion engine, e.g. by adjusting the parameters for fuel injection. This can e.g. be carried out by monitoring limits for the control interventions for a defined time period. Furthermore, diagnostic functionality can be provided that can detect differences of the individual cylinders (e.g. toothing times, torque or values derived from the toothing times) and can reliably identify impermissibly high deviations.
[0101] The method described here has the following advantages among others:
[0102] (A) The cylinder pressures in all cylinders can also be determined with high accuracy if only one (lead) cylinder is fitted with a cylinder pressure sensor. Because of this the complete provision of suitable cylinder pressure measurement equipment for each cylinder can be omitted.
[0103] (B) The regulation of cylinder pressure enables more accurate control of the torque contributions of the individual cylinders. Because of this, the manufacturing tolerances can be compensated in a simple and effective manner, e.g. in the case of the fuel injectors used.
[0104] (C) Impermissibly high deviations can be diagnosed by suitable analysis of the cylinder differences with respect to the characteristic toothing time or with respect to the torque contributions derived therefrom. In this way a repair of the internal combustion engine can be effected in many cases at the correct time, i.e. before any further damage to the internal combustion engine occurs.
[0105] (D) A variable describing the deviation of the individual cylinders from each other, such as especially the characteristic toothing time, can be used as an input for regulation that acts upon a suitable final control element (e.g. the injection). As a result, especially rough running of the internal combustion engine can be minimized.
[0106] It is noted that instead of the second cylinder Z 2 of course any other cylinder can also be the lead cylinder fitted with the cylinder pressure sensor.
[0107] FIG. 5 shows a plausibility check of a plurality of measurement signals of each cylinder pressure sensor using a comparison with an estimate of a respective amount of energy released in a working stroke based on an analysis of measured toothing times. In contrast to FIG. 4 , in the lower diagram of FIG. 5 the dashed arrows are no longer present. Moreover, the associated cylinder pressure that occurs during the respective working stroke in the respective cylinder is plotted on an additional right ordinate. The cylinder pressures that have each been measured with a cylinder-specific cylinder pressure sensor are each shown by a triangle.
[0108] As is apparent from FIG. 5 , in the selected arbitrary scaling of the two ordinates for the cylinders Z 1 , Z 2 and Z 4 the triangles are each located at about half the height of the circles. Only in the case of cylinder Z 3 is the triangle noticeably higher than half the height of the corresponding circle. On condition that the determination of the characteristic toothing times or the amounts of energy released is not incorrect, it can be assumed therefrom that the cylinder pressure sensor of cylinder Z 3 , or an analyzer connected downstream of said cylinder pressure sensor for the measurement signal of the cylinder pressure sensor, is defective. It may be that the error in the cylinder pressure measurement signal for the second cylinder can be compensated by an adjustment of a corresponding sensor characteristic.
[0109] FIG. 6 shows a possible procedure for a method for adjusting a sensor characteristic of a cylinder pressure sensor based on a cylinder-selective comparison between (a) an estimated value for the amount of energy released in the working stroke of the cylinder involved and (b) a measurement value for the cylinder pressure in the cylinder involved detected by a cylinder pressure sensor.
[0110] In the case of the method described here, a check is initially made in a step S 2 as to whether a stable operating point or load point exists for the internal combustion engine. Such a stable operating point or load point e.g. exists if the fuel-injected amounts have small fluctuations from working cycle to working cycle (the injected mass is slightly dynamic) and/or if the ambient conditions, such as e.g. the engine temperature of the internal combustion engine, which can especially be indicated by the oil temperature, lies within determined limits. If a stable operating point or load point does not exist, then the procedure is to wait until such a stable operating point or load point occurs at a later point in time. If no stable operating point or load point exists then the characteristic toothing time or the amount of energy released is determined for the cylinder involved in a step S 4 as explained above. Then the internal torque is determined for the cylinder involved in a step S 6 by means of the cylinder pressure sensor mounted on the cylinder. In a subsequent step S 8 a check is made as to whether (a) the result of the estimation for the cylinder-specific torque contribution based on the analysis of the toothing times involved and (b) the measurement results for the torque contribution provided by the cylinder pressure measurement equipment are the same within predefined limits. If this is the case, then there is no error. If not, then there is a suspected error, which can optionally be verified (not shown in FIG. 6 ) at another stable operating point or load point of the internal combustion engine. According to the exemplary embodiment illustrated here, in the case of an error a sensor characteristic can be adjusted in a step S 10 , e.g. by a change of a gradient or of a proportionality factor between the physical output signal of the cylinder pressure sensor involved and the respective cylinder pressure measurement signal indicating the actual cylinder pressure and/or by the use of a new offset value. Using said adjusted sensor characteristic, the cylinder pressure sensor involved can then be used again for an engine controller in the usual manner.
[0111] The method described here has the advantage that calibration of the cylinder pressure sensor system can be carried out during the operation of an internal combustion engine. It is only necessary that the internal combustion engine is operated at least for a short time at a stable operating point or load point. Moreover, with the method described defects in the cylinder pressure measurement equipment can be reliably detected and potentially also diagnosed.
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A method for determining an amount of energy released in the working cycle of an internal combustion engine cylinder includes: (a) recording a time curve of the rotational speed of the engine crankshaft using tooth timings measured using a toothed sensor disc, (b) assigning each tooth timing to a working cycle of a selected cylinder, (c) determining a cylinder-specific average value from the tooth timings assigned to the selected cylinder, (d) determining cylinder-specific tooth timing deviations from the determined cylinder-specific average value, for the tooth timings assigned to each working cycle of the selected cylinder, (e) determining a cylinder-specific characteristic tooth timing by summing the determined tooth timing deviations, and (f) specifying the amount of energy released in the working cycle of the selected cylinder as a function of the determined cylinder-specific characteristic tooth timing, the amount of energy released being indirectly proportional to the determined cylinder-specific characteristic tooth timing.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/769,116, filed Jun. 27, 2007, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to garments for nursing women to facilitate breastfeeding of their babies. More specifically, it relates to a garment covering a woman's torso, such as a T-shirt, that enables nursing an infant while minimizing adjustment of the woman's clothing and has the appearance of a regular, non-nursing garment.
[0004] 2. Description of the Related Art
[0005] Mothers of newborn babies and infants have long been advised to breastfeed their children. However, because of women's typically active work schedules and lifestyles, they must often wear clothing that allows them to breastfeed in many locations other than in the home. Nursing women may also prefer wearing a garment that does not have the appearance of being a nursing garment for aesthetic reasons. Consequently, a need has existed for a garment, such as a long or short sleeve T-shirt style garment, that allows for breastfeeding with minimal exposure of the mother's torso and that appears to be a regular, non-nursing T-shirt.
[0006] Presently, T-shirts and similar garments that facilitate breastfeeding have visible features that make it apparent that the T-shirt is a nursing garment. Many women feel that these features detract from the garment's appeal, style, and aesthetic. Some nursing women would prefer to wear a regular or conventional looking T-shirt or other more fashionable garment but still be able to breastfeed comfortably while wearing the garment. For example, many women would like to wear a contemporary, form-fitting T-shirt or top that contains no obvious indicia of being a nursing garment. Some women would also prefer to avoid having to unhook, untie, or unzip any part of the garment or T-shirt or have to adjust or move layers of clothing or material attached in some manner to the garment or that work in conjunction with the garment. These obvious functional features of present nursing garments detract from their appearance to some mothers and make it obvious that the woman is wearing a nursing garment. Thus, there is a need for a T-shirt style nursing garment that has the appearance of a regular T-shirt, does not require significant adjustment, and minimizes exposure of the mother while breastfeeding.
SUMMARY OF THE INVENTION
[0007] In one aspect, a nursing garment is provided. The nursing garment includes a front panel and a back panel coupled to the front panel along a side seam. The side seam includes an upper segment and a lower segment that is distinct from said upper segment. A portion of the front panel is removably coupled to the back panel at the upper segment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] References are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments of the present invention:
[0009] FIG. 1 is a frontal view of a nursing garment in accordance with one embodiment of the present invention.
[0010] FIG. 2 is a side view of a nursing garment with the side opening sealed.
[0011] FIG. 3 is a side view of a nursing garment showing an open seal thereby exposing a breast for breastfeeding in accordance with one embodiment of the present invention.
[0012] FIG. 4 is a frontal view of a nursing garment showing a seal in the open position thereby exposing a breast for breastfeeding.
[0013] FIG. 5 is a frontal view of a woman breastfeeding a baby wearing a nursing garment in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Exemplary embodiments of a nursing garment according to the present invention are described. These examples and embodiments are provided solely to add context and aid in the understanding of the invention. Thus, it will be apparent to one skilled in the art that the present invention may be practiced without some or all of the specific details described herein. In other instances, well-known concepts and garment components have not been described in detail in order to avoid unnecessarily obscuring the present invention. Other applications and examples are possible, such that the following examples, illustrations, and contexts should not be taken as definitive or limiting either in scope or setting. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the invention, these examples, illustrations, and contexts are not limiting, and other embodiments may be used and changes may be made without departing from the spirit and scope of the invention.
[0015] A garment that facilitates breastfeeding by a woman styled as a T-shirt that does not have the appearance of a nursing garment and minimizes exposure of a woman's breast while breastfeeding is described in the various figures. Presently, many nursing garments have obvious or at least some apparent features indicating that the garment is not a regular garment but is specially tailored or styled as a garment that enables a woman to breastfeed an infant. In the described embodiment, a T-shirt styled garment has the appearance of a regular, non-nursing garment yet allows a woman to nurse with minimal exposure. In addition, the garment does not require partial disrobing by the woman or removal of any undergarments. Various alternative embodiments of the present invention are described further below.
[0016] As shown in FIG. 1 , a T-shirt 10 has a collar component 14 and a design 12 on a front panel 13 in accordance with the described embodiment of the present invention. Embellishment 12 may be a screen print, embroidery work, beading, and the like that may appear on any other non-nursing male or female T-shirt. Garment 10 has sleeves 20 b and 20 a, which can be long sleeve or short sleeve. Sleeves 20 a and 20 b begin on the top shoulder portion at points 16 a and 16 b, respectively, and begin at the bottom underarm portion at points 18 a and 18 b, respectively. Two areas 22 a and 22 b of front panel 13 are also shown. The relevance of these areas is described below. Garment 10 has no internal or underlying components and the appearance of garment 10 as shown in FIG. 1 (and in FIG. 5 below) is what an observer may see while the garment is being worn. As is apparent from FIG. 1 , garment 10 looks like a regular, non-nursing item of clothing.
[0017] FIG. 2 is a side view of a nursing garment with a side aperture sealed in accordance with one embodiment of the present invention. Collar 14 is shown on top of garment 10 and portions of embellishment 12 can be seen. As described in FIG. 1 , there is front panel 13 and side portion 22 b near the under arm area shown in FIG. 2 . Also shown in FIG. 2 is a rear or back panel 26 which extends to a bottom 36 of garment 10 , as does front panel 13 . Garment 10 has a side seam 28 that extends from bottom point 18 b of the sleeve, as described in FIG. 1 , to garment bottom 36 , and that connects front panel 13 with back panel 26 .
[0018] In the described embodiment of the present invention, side seam 28 has two segments. A bottom side segment extends from a point 27 to garment bottom point 36 and is normally stitched or sewn in a permanent manner. In other embodiments, point 27 can be higher or lower than that shown in FIG. 2 . Point 27 is preferably at a point below the woman's breast and, as such, its position along side seam 28 may vary. In the described embodiment, a top side segment extends from point 27 to point 18 b. This top side segment is not permanently sewn or stitched, as indicated by the dashed line 29 . In the described embodiment, point 27 is vertically positioned along side seam 28 to allow a woman to pull front panel side portion 22 b towards the middle of the woman's chest in a manner that provides access to the woman's breast and will not pull rear panel 26 , as described and shown in FIGS. 3 and 4 .
[0019] FIG. 3 is a side view of a nursing garment showing an unsealed or open top side segment creating an aperture for exposing a breast for breastfeeding in accordance with one embodiment of the present invention. A top side segment 32 shows the segment shown in FIG. 2 by dashed line 29 in an unsealed or open position. An aperture 30 provides access to breast 34 . This is done by the woman pulling on front panel side portion 22 b, thereby opening the seal and creating aperture 30 . Aperture 30 may extend from point 27 to point 18 b. The woman wearing garment 10 and wanting to breastfeed can pull portion 22 b as far towards the center of the woman's chest as desired. In the described embodiment, the lower point 27 is along side seam 28 , the larger the aperture may be when pulled toward the center of the woman's chest. If point 27 is positioned higher along seam 28 , the more difficult it may be to create a sufficiently sized aperture for breastfeeding. This may also cause rear panel 26 to be pulled toward the front of the woman's torso in an uncomfortable manner.
[0020] FIG. 4 is a frontal view of nursing garment 10 shown worn on a woman's torso with aperture 30 providing access to breast 34 . As shown in FIGS. 3 and 4 , top side segment 32 is open to maximize access to breast 34 . Top side segment 32 need not be opened completely to enable nursing. A woman may partially open seal 29 starting from either bottom point 27 or from top point 18 b. In the described embodiment of the present invention, there are no other clothing components, such as internal or external flaps, that are part of garment 10 to facilitate breastfeeding. For simplicity, garment 10 is shown in the figures without any undergarments, such as a bra, camisole, etc. However, garment 10 may facilitate breastfeeding if a woman is wearing such undergarments. Upon unsealing the top side segment of the garment and creating an aperture, a woman can unhook, move aside, or otherwise remove any underlying garment.
[0021] FIG. 5 is a frontal view of a woman breastfeeding a baby wearing nursing garment 10 in accordance with one embodiment of the present invention. A woman 38 wearing garment 10 is nursing an infant 40 . Aperture 30 is created by pulling front side portion 22 a as shown in FIG. 1 toward the center of the chest. Once pulled, side portion 22 a (not shown in FIG. 5 ) may assume an unsealed position thereby comfortably forming and maintaining aperture 30 , which in the described embodiment begins at about top point 18 a. The size of aperture 30 can be adjusted by woman 38 wearing garment 10 thereby controlling exposure of breast 34 . Given that in the described embodiment, there is no extra material or clothing that is needed to cover the breast while nursing, it allows the nursing mother to maintain eye contact between mother and nursing child, thereby promoting calm, steady nursing as recognized by mothers and nursing specialists.
[0022] As described, seal 29 can be opened to create aperture 30 . Various mechanisms can be used to create seal 29 . Preferably ones that allow a woman to open and close the seal with one hand and do not involve extraneous or additional material should be used. For example, a Velcro® attachment or any other type of multiple hook-and-loop material can be used. In this embodiment, the “hook” side of the material may be attached to a tab running vertically along the side of seal 29 . The “loop” side of the material may run vertically on a tab on the inside of seal 29 . In another example, tabs and character strips used as a fastener in diapers may also be used to create seal 29 . Other common garment seals such as zippers, laces, snap, and buttons may be used, although, as noted, it is preferable that the seal be easily opened by the woman wearing the garment and remain closed when sealed. Further, the effectiveness of sealing and re-sealing the opening should be generally maintained upon long-term use, which may limit the utility of, for example, the tab and character strip fastener. In the described embodiment, it is preferable that garment 10 not require any releasing or adjusting of any fastening devices for opening and sealing seal 29 . As is evident to one of ordinary skill in the art, there are many variations and possible implementations of the mechanism or material used to create seal 29 .
[0023] In other embodiments of the present invention, garment 10 may be a bodice portion of a dress or other type of torso component of a full-length woman's garment. Garment 10 may also be a sports or active wear style T-shirt having a form-fitting design or a more formal top, such as a blouse. Garment 10 may also be sleepwear or an undergarment. Generally, garment 10 may have various styles, patterns, shapes and can be made of different types of fabric, such as a flexible fabric that stretches easily (e.g., a Jersey knit fabric).
[0024] In the described embodiment, aperture 30 , seal 29 , and other components and features described above are on both sides of garment 10 . In another embodiment, aperture 30 may only be formed on one side of garment 10 . The other side may have a permanent side seal that extends from bottom point 36 to point 18 a or 18 b, as in a regular, non-nursing garment on the other side.
[0025] Although illustrative embodiments and applications of this invention are shown and described herein, many variations and modifications are possible which remain within the concept, scope, and spirit of the invention, and these variations would become clear to those of ordinary skill in the art after perusal of this application. Numerous stylistic modifications can be made to garment 10 without exceeding the scope of the present invention. Accordingly, the embodiments described are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.
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A nursing garment including a front panel and a back panel coupled to the front panel along a side seam. The side seam includes an upper segment and a lower segment that is distinct from said upper segment. A portion of the front panel is removably coupled to the back panel at the upper segment.
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FIELD OF THE INVENTION
[0001] The invention relates to apparatus for filling and weighing bulk bags, and particularly relates to vibrating table assemblies for use in such apparatus.
BACKGROUND OF THE INVENTION
[0002] Efficient filling and weighing of bulk bags (also known as flexible intermediate bulk containers) is performed with an apparatus on which a bulk bag is suspended by loops above a bag support table. During filling of the bag, the bag bottom is partly supported by the support table, which typically has a top portion shaped like a flattened, truncated pyramid. A pair of unbalanced counter-rotating motors are located inside the support table to vibrate and compact the contents of the bag as it is being filled.
[0003] The bag support table is brought into contact with the bulk bag either by lowering the bag or raising the support table. Two types of apparatus in which the support table can be raised and lowered are disclosed in U.S. Pat. Nos. 4,718,464 and 5,336,853. In U.S. Pat. No. 4,718,464, the support table is raised and lowered by a piston and cylinder device attached to the frame of the bag filling apparatus. In U.S. Pat. No. 5,336,853, the support table is raised and lowered by a screw and collar system incorporated into the frame.
[0004] To ensure that a bulk bag is filled with the correct amount of material, it may be weighed several times during the filling cycle. In order to accurately weigh the bulk bag, it must be separated from the bag support table. Each time the bulk bag is weighed, the motors in the support table are allowed to wind down, and the bag support table is lowered. As the motors wind down, they lose their synchronization and generate significant vibrational forces on the bag support table. With the support table attached to the frame of the apparatus, these vibrations are effectively absorbed.
[0005] However, attachment of the bag support table and the lifting mechanism to the frame prevents the bag support table from being used for retrofit applications, for example to be incorporated into an older style bag filling apparatus not having a bag support table. Therefore, there is a need for a self-contained bag support table which does not rely on the frame of the bag filling apparatus for support or for vibration damping.
SUMMARY OF THE INVENTION
[0006] The present invention overcomes the above limitations of the prior art by providing a vibrating table assembly for a bag filling apparatus. The vibrating table assembly according to the invention is a self-contained unit comprising a bag support table of similar or identical shape to the tables shown in the prior art, vibrating means for vibrating the bag support table, a lifting device for raising and lowering the bag support table, with the lifting device being located below the bag support table, and at least one resilient connector through which the lifting device is connected to the bag support table.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a side elevational view of a preferred table assembly according to the present invention, with the bag support table at its upper height limit;
[0008] FIG. 2 is a front elevational view of the table assembly of FIG. 1 , with the bag support table at its upper height limit;
[0009] FIG. 3 is a front elevational view of the table assembly of FIG. 1 , with the bag support table at its lower height limit; and
[0010] FIG. 4 is a side elevation showing the table assembly of FIG. 1 mounted to the frame of a bag filling apparatus.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0011] FIGS. 1 to 3 illustrate a preferred table assembly 10 according to the present invention.
[0012] Table assembly 10 comprises a bag support table 12 , a vibrating device 14 for vibrating the bag support table 12 , a lifting device 16 for raising and lowering the bag support table 12 and at least one resilient connector 17 through which the bag support table 12 and the lifting device 16 are connected. As shown in the drawings, the lifting device 16 is located below the bag support table 12 .
[0013] The bag support table 12 and vibrating device 14 are similar to those described in prior U.S. Pat. Nos. 4,718,464 and 5,336,853, mentioned above. Specifically, the bag support table 12 is rectangular, preferably square, in plan view, having a rectangular upper surface 18 , four vertical side surfaces 20 , and four sloped side surfaces 22 connecting the vertical side surfaces 20 and the upper surface 18 . The side surfaces 20 , 22 extend outwardly and downwardly from the upper surface 18 to a lower edge 19 of the table 12 . The table 12 has four corners 21 at which the side surfaces 20 converge with one another and with the lower edge 19 . It will be appreciated that the table need not have the rectangular shape shown in the drawings, but may be of any other suitable shape, including circular in plan view.
[0014] The vibrating device 14 comprises one or more vibrating motors, and preferably comprises two unbalanced counter-rotating motors 24 which are at least partially enclosed in a hollow space 23 defined by the upper surface 18 and the side surfaces 20 , 22 , and are preferably mounted inside the bag support table 12 by a mounting bracket 26 .
[0015] As shown in the drawings, the lifting device 16 is located centrally below the bag support table 12 , such that a central vertical axis 27 of the table assembly 10 extends through the centre of the bag support table 12 and the centre of the lifting device 16 . Locating the lifting device 16 centrally below the bag support table 12 assists in absorbing side loads caused by vibrations generated during winding down of the motors 24 .
[0016] The connection between the lifting device 16 and the bag support table 12 is preferably made through a rectangular, preferably square, mounting plate 28 having an upper surface 30 and a lower surface 32 . As shown, the bag support table 12 is mounted on the upper surface 30 of mounting plate 28 , with the lifting device 16 being attached to the lower surface 32 .
[0017] In order to absorb vibration caused by motors 24 , the bag support table 12 is preferably connected to the mounting plate 28 in a manner which will dampen vibration of the motors 24 . In the preferred embodiment shown in the drawings, the bag support table 12 and mounting plate 28 are connected through one or more resilient connectors 17 which, in the preferred embodiment shown in the drawings, comprise a plurality of spring supports 34 . As shown in the drawings, four such spring supports 34 are preferably provided, each of which is secured at its lower end to a respective corner of the mounting plate 28 . The upper ends of the spring supports 34 are secured to an elongate, L-shaped bracket 36 ( FIG. 2 ) which forms part of the bag support table and which is secured by welding or other suitable means to the inside of the bag support table 12 . Each spring support 34 comprises a coil spring 38 secured at its upper and lower ends by spring retainers 40 and bolts 42 which may preferably be threaded into tapped openings (not shown) in the mounting plate 28 and L-shaped bracket 36 .
[0018] Although the preferred resilient connectors described and shown in this application are spring supports comprising axially-extending coil springs positioned at the corners of the support table, it will be appreciated that resilient connectors other than spring supports can be used. For example, the resilient connectors may comprise elastomeric supports which are comprised of a resilient polymeric material such as rubber, the elastomeric supports being mounted between the lifting device and the bag support table. It will also be appreciated that the table assembly according to the invention could include more or fewer resilient connectors than shown in the drawings, depending on the shape of the table and the degree of vibration damping required. For example, a resilient connector may be centrally located between the lifting device and the support table.
[0019] As shown in the drawings, the lifting device 16 preferably comprises a convoluted air bellows 44 having a top plate 46 and bottom plate 48 made of metal, and an expandable central portion 50 between the top plate 46 and bottom plate 48 . Preferably, the central portion 50 is made of an elastomeric material such as rubber, and can be inflated by a pressurized gas such as air. The top plate is preferably provided with a gas inlet/outlet 52 which is preferably connected by a flexible hose 54 to a source of pressurized gas (not shown).
[0020] The top plate 46 is secured to the lower surface 32 of mounting plate 28 , preferably by bolts 55 , with the gas inlet/outlet 52 of the air bellows 44 extending through an aperture 56 in the mounting plate 28 .
[0021] The table assembly 10 further comprises a rectangular base plate 58 having an upper surface 60 on which the bottom plate 48 of air bellows 44 is mounted, preferably by bolts 62 which are countersunk into the base plate 58 .
[0022] The inventors have found that the use of a convoluted air bellows is particularly preferred over other types of lifting devices, as it permits the table assembly 10 to be very compact. For example, with the air bellows 44 in its fully collapsed condition, shown in FIG. 3 , the entire table assembly 10 preferably has a height of about 17 inches, which is comparable to that of prior art table assemblies in which the raising and lowering means are contained in the frame of the bag filling apparatus. Such a low profile may not be possible with other conventional lifting devices. Furthermore, the entire table assembly can fit within the footprint of the filling and weighing apparatus.
[0023] The convoluted air bellows is also preferred since it is effective to absorb side loads which result when the bag support table 12 is lowered during winding down of the motors 24 . Such side loading could cause other types of lifting devices to bind.
[0024] In the preferred embodiment shown in the drawings, the air bellows is a triple convoluted air bellows, comprising three inflatable sections 64 .
[0025] In order to prevent deformation of the mounting plate 28 when the bag support table 12 is raised against the bottom of a bulk bag, the lower surface 32 of mounting plate 28 is preferably provided with a peripheral, downwardly extending skirt 66 .
[0026] The table assembly 10 is also provided with stop members for preventing downward movement of the bag support table 12 beyond a lower height limit ( FIG. 3 ), and for preventing upward movement of the bag support table 12 beyond an upper height limit ( FIGS. 1 and 2 ).
[0027] The assembly 10 includes a plurality of lower stop members which are preferably mounted on the base plate 58 or the mounting plate 28 , and which limit downward movement of the mounting plate 28 relative to the base plate 58 . In the preferred embodiment shown in the drawings, there are four lower stop members, each in the form of a hollow sleeve 68 extending downwardly from the lower surface 32 of the mounting plate 28 . Each sleeve 68 has an outwardly extending base flange 69 by which it is secured to the mounting plate 28 by welding or the like, as well as a lower surface 70 . The length of each sleeve 68 is substantially the same as the height of the air bellows 44 in its collapsed condition, as shown FIG. 3 . With air bellows 44 in this condition, the lower surface 70 of each sleeve 68 abuts the upper surface 60 of mounting plate 58 . With the air bellows 44 collapsed as shown in FIG. 3 , the bag support table 12 is at its lower height limit, preferably having a height, measured from the base plate 58 to the upper surface 18 of support table 12 , of about 17 inches.
[0028] As best seen in FIGS. 2 and 3 , table assembly 10 is provided with a pair of upper stop members 72 . Each upper stop member 72 comprises an elongate member 74 which may preferably comprise a bolt. The elongate member 74 has an enlarged upper end 76 which may preferably comprise a bolt head or other suitable enlargement. The lower end 78 of elongate member 74 is attached to the upper surface 60 of base plate 58 . In the preferred embodiment, the bolt comprising elongate member 74 is provided with threads at its lower end 78 . The threads engage the threads of a nut 80 which is secured to the upper surface 60 of base plate 58 .
[0029] Attached to the lower surface 32 of mounting plate 28 are a pair of brackets 82 , each of which comprises a U-shaped channel having a lower portion 84 which is substantially horizontal, and a pair of substantially vertical sides 86 which are connected to the mounting plate 28 . The lower portion 84 of bracket 82 has an aperture 88 through which the elongate member 74 extends. The aperture 88 is sized to closely receive the portion of elongate member 74 which is intermediate the ends 76 , 78 , and has an area which is less than the area of enlarged upper end 76 of elongate member 74 , such that when the bag support table 12 is at its upper height limit (shown in FIGS. 1 and 2 ) the enlarged upper end 76 of elongate member 74 abuts the lower portion 84 of bracket 82 and is located between the lower portion 84 of bracket 82 and the lower surface 32 of the mounting plate 28 .
[0030] As seen in FIG. 3 , the brackets 82 preferably also function as lower stop members, with the lower portion 84 abutting the upper surface 60 of base plate 58 when the air bellows 44 is in its collapsed condition. In order to accomplish this, the aperture 88 in the lower portion 84 of bracket 82 preferably has a diameter sufficient to accommodate nut 80 .
[0031] In the preferred embodiment shown in the drawings, a pair of upper stop members 72 are provided. Each of the upper stop member 72 is located adjacent a short edge of base plate 58 ( FIG. 2 ) and preferably spaced centrally between the longer sides of base plate 58 ( FIG. 1 ).
[0032] It will be appreciated that the table assembly 10 can be provided with more or fewer upper stop members 72 than shown in the drawings. However, at least two such stop members 72 are preferred in order to prevent binding of the elongate member 74 due to side loading which occurs during winding down of motors 24 .
[0033] As the air bellows 44 collapses under the weight of the bag support table 12 , the mounting plate 28 and bag support table 12 move downwardly relative to the upper end 76 of elongate member 74 . Therefore, the mounting plate 28 is provided with apertures 92 ( FIG. 2 ) which are located directly above each upper stop member 72 to permit the elongate member 74 to pass through the mounting plate 28 as shown in FIG. 3 . Similarly, the L-shaped brackets 36 are provided with apertures 94 ( FIG. 2 ) through which the upper stop member 72 can pass. Preferably, with the bag support table 12 at its lower height limit as shown in FIG. 3 , the upper end 76 of elongate member 74 is received between L-shaped bracket 36 and the side surfaces 20 , 22 of bag support table.
[0034] Although the upper stop members 72 assist in guiding the vertical movement of the support table 12 , the assembly 10 is preferably provided with one or more additional guide members to keep the vertical axis 27 aligned with the vertical during raising and lowering the support table 12 . In the preferred embodiment shown in the drawings, the vertical guide members comprise four vertically extending rods 96 , each having an upper end 98 and a lower end 100 , with the lower end 100 being secured to the base plate 58 by countersunk screws 102 . With the bag support table 12 at its upper height limit, the upper end 98 of each rod 96 is received in one of the sleeves 68 comprising the lower stop member. As the support table 12 is lowered, the upper end 98 of each rod 96 passes through an aperture 104 in the mounting plate 28 . When the support table 12 is at its lower height limit, as shown in FIG. 3 , the upper end of each rod 96 is received just below the upper surface 18 of the support table 12 , between the vibrating motors 24 and one of the L-shaped brackets 36 .
[0035] The table assembly 10 is preferably either mounted to the floor below the bag filling apparatus or to the frame of the filling apparatus. For floor mounting, the base plate 58 is secured to the floor by fasteners such as bolts or the like, preferably at or near its four corners. One possible arrangement for mounting a bag filling apparatus 100 is illustrated in FIG. 4 , which shows only two vertical frame members 102 and a horizontal cross member 104 of the apparatus 100 . It will be appreciated that the apparatus 100 partially illustrated in FIG. 4 preferably has four vertical members 102 forming a rectangular frame, with two cross members 104 extending between the vertical members 102 in spaced, parallel relation, as in U.S. Pat. Nos. 4,718,464 and 5,336,853. In the embodiment shown in FIG. 4 , the table assembly is mounted to the horizontal frame members, with the base plate 58 being secured at or near its corners to the horizontal frame members 104 . The base plate 58 is preferably secured by fasteners such as bolts 106 or the like, with only the heads of bolts 106 being visible in FIG. 4 . As the frame structure shown in FIG. 4 is common to many existing bag filling apparatus, the mounting arrangement shown in FIG. 4 permits the table assembly 10 to be incorporated into an existing apparatus with minimal modification.
[0036] Although the invention has been described in connection with certain preferred embodiments, it is not intended to be limited thereto. Rather, the invention is intended to include all embodiments which may fall within the scope of the following claims.
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A vibrating table assembly for an apparatus for filling and weighing bulk bags comprises a bag support table, vibrating means for vibrating the bag support table, and a lifting device for raising an lowering the bag support table, the lifting device being located below the bag support table. Preferably, the lifting device comprises a convoluted air bellows. Location of the lifting device below the table overcomes problems encountered with known bag filling apparatus where the bag support table and the lifting mechanism are connected to the frame of the apparatus.
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FIELD OF THE INVENTION
The present invention relates to a system for preparing antimicrobial fabrics, coated with metal oxide nanoparticles by a novel sonochemical method.
BACKGROUND OF THE INVENTION
Antibacterial fabrics are widely used for production of outdoor clothes, under-wear, bed-linen, and bandages. Antimicrobial resistance is very important in textile materials, having effects amongst others on comfort for the wearer. The deposition of metal oxides known to possess antimicrobial activity, namely ZnO, MgO and CuO, can significantly extent the applications of textile fabrics and prolong the period of their use.
Zinc oxide has been recognized as a mild antimicrobial agent, non toxic wound healing agent, and sunscreen agent. Because it reflects both UVA and UVB rays, zinc oxide can be used in ointments, creams and lotions to protect against sunburn and other damage to the skin caused by ultraviolet lights [Godfrey H. R. Alternative Therapy Health Medicine, 7 (2001) 49]. At the same time ZnO is an inorganic oxide stable against temperatures encountered in normal textile use, contributing to its long functional lifetime without color change or oxidation. The antibacterial properties of MgO and CuO nanoparticles were also demonstrated [ Controllable preparation of Nano - MgO and investigation of its bactericidal properties . Huang L., Li D. Q, Lin Y. J., Wei M., Evans D. G., Duan X. L. Inorganic Biochemistry, 99 (2005) 986, and Antibacterial Vermiculite Nano - Material . Li B., Yu S., Hwang J. Y., Shi S. Journal of Minerals & Materials Characterization & Engineering, 1 (2002) 61].
An antimicrobial formulation containing ZnO powder, binding agent, and dispersing agent was used to protect cotton and cotton-polyester fabrics [“Microbial Detection, Surface Morphology, and Thermal Stability of Cotton and Cotton/Polyester Fabrics Treated with Antimicrobial Formulations by a Radiation Method”. Zohby M. H., Kareem H. A., El-Naggar A. M., Hassan, M. S., J. Appl. Polym. Sci. 89 (2003) 2604] This formulation was applied to fabrics under high energy radiation of Co-60 γ or electron beam irradiation and then subjected for fixation by thermal treatment. A superior antimicrobial finish was achieved with cotton fabrics containing 2 wt % ZnO and with cotton-polyester fabrics containing 1 wt % ZnO. The particle size of ZnO in these samples according to SEM measurement was 3-5 μm. In spite of good antimicrobial activity, the disadvantages of this method are the use of additional binding and dispersing agent, and requirements of high energy radiation and an additional stage of thermal curing. It was also reported that ZnO-soluble starch nanocomposite was impregnated onto cotton fabrics to impart antibacterial and UV-protection functions with ZnO concentration 0.6-0.8 wt % [ Functional finishing of cotton fabrics using zinc oxide - soluble starch nanocomposites . Vigneshwaran N., Kumar S., Kathe A. A., Varadarajan P., Prasad V., Nanotechnology 17 (2006) 5087]. The particle size of ZnO in zinc oxide-starch composition was reported as 38 nm. However, in this work the special stabilizing agent, namely, acrylic binder is used which should undergo the additional stage of polymerization at 140° C.
Hence, an improved method of dispersion metal oxide nanoparticles onto textiles is still a long felt need.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to understand the invention and to see how it may be implemented in practice, a plurality of embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which
FIG. 1 presents an XRD pattern indicating hexagonal phase of ZnO matching PDF file: 89-7102.
FIG. 2A-C presents HR SEM images of the fabric coated with ZnO: a—before coating, b—after coating, c—high magnification of figure b.
FIG. 3A , B present images of fabric coated with ZnO: a—before coating, b—after coating.
FIG. 4A , B presents a Comparing hydroxyl radicals generated from microscale and nanoscale ZnO, using DMPO as a spin-trapping agent and Theoretical (Computer) simulation of the ESR spectrum of hydroxyl radicals.
FIG. 5 presents the amount of the hydroxyl radicals in a medium containing both ZnO and bacteria.
FIG. 6 presents ESR hydroxyl radical spectra of water suspensions with different ZnO samples, showing clearly that as the grain size decreases the hydroxyl signal increases.
SUMMARY OF THE INVENTION
The present invention comprises a system and method for sonochemical dispersion of metal oxide nanoparticles onto textiles.
It is within the core of the present invention to provide a method for ultrasonic impregnation of textiles with metal oxide nanoparticles consisting of steps of:
a. preparing a water-ethanol solution; b. adding M(Ac) 2 to said solution, forming a mixture; c. immersing said textiles in said mixture; d. adjusting the pH of said mixture to basic pH by means of addition of aqueous ammonia; e. purging said mixture to remove traces of CO 2 /air; f. irradiating said mixture with a high intensity ultrasonic power; g. washing said textile with water to remove traces of ammonia; h. further washing said textile with ethanol, and drying in air.
thereby producing a textile—metal oxide composite containing homogeneously impregnated metal oxide nanoparticles, without use of electromagnetic radiation.
It is further within provision of the invention to provide the aforementioned method where said water-ethanol solution is in a ratio of approximately 1:9.
It is further within provision of the invention to provide the aforementioned method where M(Ac) 2 is added in a concentration of between 0.002 and 0.02 M.
It is further within provision of the invention to provide the aforementioned method where M is selected from a group consisting of metals Zn, Mg, Cu.
It is further within provision of the invention to provide the aforementioned method where said basic pH is approximately 8.
It is further within provision of the invention to provide the aforementioned method where said step of purging is carried out with argon for 1 hour.
It is further within provision of the invention to provide the aforementioned method where said step of irradiating said mixture is carried out for 1 hour
It is further within provision of the invention to provide the aforementioned method where said step of irradiating said mixture is carried out by means of an ultrasonic horn
It is further within provision of the invention to provide the aforementioned method where said step of irradiating said mixture is carried out using ultrasonic waves at a frequency of approximately 20 kHz.
It is further within provision of the invention to provide the aforementioned method where said step of irradiating said mixture is carried out using ultrasonic waves at a power of approximately 1.5 kW
It is further within provision of the invention to provide the aforementioned method where said step of irradiating said mixture is carried out under a flow of argon
It is further within provision of the invention to provide the aforementioned method where said step of irradiating said mixture is carried out at approximately 30° C.
It is further within provision of the invention to provide the aforementioned method where said textile composite contains between 0.1 wt % and 10 wt % of metal oxide (MO).
It is further within provision of the invention to provide the aforementioned method where MO nanocrystals are between 10 nm and 1000 nm in diameter.
It is further within provision of the invention to provide textiles imparted with bacteriostatic properties by means of ultrasonic irradiation of said textiles in an aqueous metal oxide mixture, thereby attaining uniform impregnation of said textiles with metal oxide nanoparticles.
According to another embodiment of the present invention, when commercial MO nanoparticles are introduced in the sonication mixture or MO nanoparticles commercially available (prepared by another method and not sonochemically). The ultrasound can still be used for “throwing stones” at the fabric surface, and good antibacterial properties are obtained.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following description is provided, alongside all chapters of the present invention, so as to enable any person skilled in the art to make use of said invention and sets forth the best modes contemplated by the inventor of carrying out this invention. Various modifications, however, will remain apparent to those skilled in the art, since the generic principles of the present invention have been defined specifically to provide a means and method for providing a wood-resin composite.
In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. However, those skilled in the art will understand that such embodiments may be practiced without these specific details. Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention.
The term ‘sonochemical irradiation’ hereinafter refers to exposure to sonic power, generally in the ultrasonic range of frequencies.
The term ‘sonochemistry’ refers to the study or use of sonochemical irradiation.
The term ‘nanoparticles’ hereinafter refers to particles of size ranging from about 10 micrometers to about 10 nanometers.
The term ‘oxide’ hereinafter refers to any inorganic oxide such as ZnO, MgO, CuO, and the like. In the following when ZnO is used specifically, it is used in exemplary fashion and can be replaced by any oxide as will be obvious to one skilled in the art.
The term ‘plurality’ refers hereinafter to any positive integer e.g, 1, 5, or 10.
It is within provision of the instant invention to offer a new process for preparation of textiles impregnated with nanometric oxide particles. The sonochemical method is applied for the deposition of ZnO nanocrystals on textile materials to impart them excellent antimicrobial activity. A comparison of the suggested ZnO-textile nanocomposite shows a clear advantage of the ultrasound radiation over all other available methods as will be described below.
We have demonstrated that sonochemical irradiation is a suitable method for synthesis of nanomaterials, and their deposition/insertion on/into ceramic and polymer supports. One of the many advantages demonstrated for sonochemistry is that a homogeneous dispersion of the nanoparticles on the surface of the substrate is achieved in one step. In this step the nanoparticles of the desired products are formed and accelerated onto/into the surface or body of the polymer or ceramics via microjets or shock waves that are created when a sonochemically produced bubble collapses near a solid's surface. The current patent is based on the work done by the inventors—see The Preparation of Metal - Polymer Composite Materials using Ultrasound Radiation , S. Wizel, R. Prozorov, Y. Cohen, D. Aurbach, S. Margel, A. Gedanken. J. Mater. Res. 13, (1998) 211; Preparation of amorphous magnetite nanoparticles embedded in polyvinylalcohol using ultrasound radiation “. R. Vijaykumar, Y. Mastai, A. Gedanken, Y. S. Cohen, Yair Cohen, D. Aurbach, J. Mater. Chem. 10 (2000) 1125; Sonochemical Deposition of Silver Nanoparticles on Silica Spheres V. G. Pol, D. Srivastava, O. Palchik, V. Palchik, M. A. Slifkin, A. M. Weiss. A. Gedanken, Langmuir, 18, (2002) 3352; Synthesis and Characterization of Zinc Oxide - PVA Nanocomposite by Ultrasound Irradiation and the Effect of the Crystal Growth of the Zinc Oxide” R. Vijayakumar, R. Elgamiel, O. Palchik, A. Gedanken, J. Crystal Growth and Design, 250 (2003) 409; Sonochemical Deposition of Silver Nanoparticles on Wool Fibers . L. Hadad, N. Perkas, Y. Gofer, J. Calderon-Moreno, A. Ghule, A. Gedanken, J. Appl. Polym. Sci. 104 (2007)1732. These publications studied the deposition of large variety of nanoparticles on different kinds of substrates. The deposition was conducted either with materials that were dissolved in the irradiated solution or dispersed (not dissolved) in the solution.
The use of the sonochemical method helps to achieve all the principal requirements of the antimicrobial textile coated with nanomaterials: small particle size, regular shape, and homogeneous distribution of ZnO nanoparticles on the fabrics. Amongst the advantages of using ultrasound over other methods is that ultrasonic shockwaves effectively blast the oxide nanocrystals onto a fabric's surface at such speed that it causes local melting of the substrate, guaranteeing firm embedding of the nanocrystals within the textile fibers. Textiles sonochemically impregnated with ZnO displays outstanding antimicrobial activity in the case of both gram-positive and gram-negative bacteria.
An experimental procedure was developed as follows for testing and evaluation purposes. Other routes will be obvious to one skilled in the art, and the following is provided only by way of example.
PREPARATION PROCEDURE
1. A textile sample (such as a cotton square of about 100 cm 2 ) is placed in a 0.002-0.02 M solution of M(Ac) 2 , (where M stands for metals Zn, Mg, Cu; and Ac stands for acetate ion) in a water:ethanol (1:9) solution.
2. The pH is adjusted to 8 with an aqueous solution of ammonia.
3. The reaction mixture is then purged with argon for 1 hour in order to remove traces of CO 2 /air.
4. The solution is irradiated for 1 hour with a high intensity ultrasonic horn (Ti-horn, 20 kHz, 1.5 kW at 70% efficiency) under a flow of argon at 30° C.
5. The textile is washed thoroughly with water to remove traces of ammonia, then further washed with ethanol and dried in air.
It is also within provision of the invention to prepare the metal solutions as above using metal nitrates or other salts, as will be obvious to one skilled in the art.
As will also be obvious to one skilled in the art, the coating process can be accomplished without producing nanoparticles ‘in house’, by adding nanoparticles obtained by some other means to solution and ultrasonically treating as above in steps 2-5. The yield (amount of nanoparticles on the textile) in this case would be lower but enough to get antibacterial properties.
RESULTS
A sample coated by the above process with MO was tested for its antibacterial properties with gram-positive ( S. aureusa ) and gram-negative ( E. coli ) cultures. Antibacterial effects were shown in treated textiles even at a coating concentration of less than 1%, for all metal oxides mentioned above (Zn, Mg, Cu). We observed 98% reduction of the two strains of the bacteria after 1 hour.
Our experiments have also demonstrated that antibacterial treatment of ZnO coated bandages can increase the sensitivity of bacteria cells to two kinds of antibiotics; a 43% additional reduction in colonies was detected for Chloramphenicol due to the metal oxide and 34% for Ampicillin. The concentrations of antibiotics used in these experiments were much lower than those normally expected to cause any significant change in the bacteria growth. Thus, our results indicate a cooperative or synergic effect of metal oxide textile impregnation and antibiotic treatment.
The textile composite so produced contains on the order of 1 wt % of metal oxide (MO). The MO nanocrystals are of size ˜150 nm, and are homogeneously distributed on the surfaces of the textile fibers.
The metal oxide concentration in the fabrics prepared as above can be varied in the range 0.5-10.0%.
We now refer to FIG. 1 which displays XRD patterns of fabrics coated with zinc oxide, confirming the presence of ZnO nanocrystals. The homogeneous distribution of ZnO nanocrystals on the textile fibers was demonstrated in high-resolution SEM micrographs ( FIG. 2 ). After sonochemical deposition of ZnO nanocrystals on the fabrics the color and texture of the material didn't change ( FIG. 3 ).
As is known in the art, the existence of free radicals can aid in destruction of bacteria. In our investigation, the generation of both active oxygen species (O 2 − and OH.) from the ZnO powder was demonstrated using ESR measurements. Moreover, we found that at the nanoscale regime of ZnO particle size, the amount of the generated OH. was considerably higher than that of the microscale size, probably due to a higher specific surface area of the smaller particles ( FIG. 4 ). Similar spectra were obtained when a piece of ZnO-cotton coated bandage was introduced in the ESR tube. These results are in good agreement with the measured influence of particle size on the antibacterial activity of ZnO powders, as it was found that the antibacterial activity of ZnO increased with decreasing particle size. This is supported by the following table of results measuring bacteria reduction for two bacteria types ( E. coli and S. aureusa ) after various treatment times, for different particle sizes of ZnO crystallites. Sample ZnO-1 has diameter ˜8 nm, sample ZnO-2 has diameter ˜275 nm, and sample ZnO-3 has diameter ˜600 nm.
TABLE 1
bacteria population reduction for different grainsizes and treatment
times.
E. coli
S. aureus
Duration of
% Reduction
% Reduction
Sample
treatment [h]
[CFU mL −1 ]
N/N 0
in viability
[CFU mL −1 ]
N/N 0
in viability
ZnO-1
0
6.5 × 10 7
1
0
1.2 × 10 7
1
0
1
5.2 × 10 6
8.0 × 10 −2
92
3.5 × 10 6
2.9 × 10 −1
21
2
6.5 × 10 5
1.0 × 10 −2
99
2.0 × 10 6
1.7 × 10 −1
83
3
1.3 × 10 3
2.0 × 10 −3
99.8
2.4 × 10 5
2.0 × 10 −2
98
ZnO-2
0
6.5 × 10 7
1
0
1.2 × 10 7
1
0
1
10 × 10 7
1.6 × 10 −1
84
6.4 × 10 6
5.3 × 10 −1
47
2
3.3 × 10 6
5.1 × 10 −2
95
4.1× 10 6
3.4 × 10 −1
66
3
3.3 × 10 5
2.0 × 10 −3
99.5
1.3 × 10 6
1.1 × 10 −1
89
ZnO-3
0
6.5 × 10 7
1
0
1.2 × 10 −7
1
0
1
2.0 × 10 7
3.1 × 10 −1
69
1.0 × 10 7
8.7 × 10 −1
13
2
1.69 × 10 7
2.6 × 10 −1
74
8.2 × 10 6
5.8 × 10 −1
42
3
8.5 × 10 6
21.3 × 10 −1
87
3.8 × 10 6
3.2 × 10 −1
68
As is clear from the table above, the bacteria populations are reduced with greater exposure time and smaller ZnO grain size. The above explanation for these results is further substantiated in FIG. 6 which presents ESR hydroxyl radical spectra of water suspensions with different ZnO samples, showing clearly that as the grainsize decreases the hydroxyl signal increases.
The textiles sonochemically impregnated with ZnO demonstrate high stability; the amount of ZnO remaining in the textile after 50 washing cycles remains constant. The stability of nanoparticles on the fabric was measured after 50 washing cycles by both TEM measurements, and titrating the fabric with EDTA to determine the amount of ZnO.
In another experiment, we measured the amount of the hydroxyl radicals in a medium containing both ZnO and bacteria ( e. coli and s. aureusa in saline). An enhancement of the amount of hydroxyl radicals could be detected comparing to samples without the bacteria ( FIG. 5 ). We assume that this enhancement comes from an oxidative stress of the bacteria in a medium containing the ZnO.
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We disclose a system for preparing antimicrobial fabrics, coated with metal oxide nanoparticles by means of a novel sonochemical method. These antibacterial fabrics are widely used for production of outdoor clothes, under-wear, bed-linen, bandages, etc. The deposition of metal oxides known to possess antimicrobial activity, namely ZnO, MgO and CuO, can significantly extent the applications of textile fabrics and prolong the period of their use. By means of the novel sonochemical method disclosed here, uniform deposition of metal oxide nanoparticles is achieved simply.
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[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/106,674 filed Oct. 20, 2008 and U.S. Provisional Patent Application Ser. No. 61/149,632 filed Feb. 3, 2009.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to systems and methods for cleaning the interior of tubular members. In particular aspects, the invention relates to methods and devices for scraping wellbore casing.
[0004] 2. Description of the Related Art
[0005] Wellbore cleaning devices include casing scrapers and brushing devices. These mechanisms are used to remove mud, cement sheath, perforation burrs, rust, scale, paraffin, and other debris from the internal surface of wellbore casing. The casing scraper or brush is typically attached to a drill string for operation. The drill string and cleaning device are then disposed within the casing members to be scraped, and rotated.
[0006] Typical casing scrapers include a central scraping body and one or more scraping blades that extend radially outwardly therefrom. Conventional casing scrapers generally fall into one of two categories: rotating and non-rotating. With a rotating scraper, the scraping body and the scraping blades are securely affixed to each other so that both rotate with the drill string. In applications where the drill string is rotated for long periods of time, rotating scrapers can cause serious wear and damage to the interior surface of casing. With a non-rotating scraper, only the scraping body rotates with the drill string. The scraper blades are not affixed to the central scraping body, but are urged radially outwardly from it by compression springs in order to provide a force for removal of debris. An example of this type of arrangement is found in U.S. Pat. No. 7,311,141 issued to Tulloch et al.
SUMMARY OF THE INVENTION
[0007] The invention provides methods and devices for cleaning the interior of tubular members, such as casing members. Exemplary non-rotating tubular cleaning devices are described which include a central tool mandrel with radially surrounding stabilizers and a cleaning member subassembly. The cleaning member subassembly includes one or more scraper blades that are secured around the tool mandrel. In one embodiment, a scraper device is described wherein each scraper blade of a scraper blade subassembly includes a blade housing having blade windows. Scraper blades are retained within the blade housing so that the scraper blades are biased radially outwardly through the windows. In another embodiment, a brush-type wellbore cleaning device is described wherein the cleaning member subassembly includes a brush attachment having a central collar with cleaning bristles.
[0008] A rotation interface is disposed between the cleaning member subassembly and stabilizers and ensures that the stabilizers and cleaning members can rotate with respect to the mandrel. In preferred embodiments, the interface includes sets of rotational bearings or bushings, and preferably roller bearings that enable the cleaning member subassembly to easily rotate with respect to the tool mandrel. Exemplary rotation interfaces feature annular indentations and split ring and split sleeve components that fit into the indentations to allow portions of the rotation interface to be recessed radially inwardly.
[0009] The construction of the cleaning devices permit these tools to have improved strength and resistance to axial and torsional forces within the work string within which the cleaning device is used. The threaded connection of the tool mandrel largely governs the strength of the tool overall. The use of annular indentations and inner bearing race and rotational sleeve components permits the diameter of the threaded portion of the tool mandrel to be radially enlarged relative to the indentations. As a result, the cleaning tools are stronger and more resistant to axial and torsional stresses and forces.
[0010] In other aspects, the invention relates to improved tools for cleaning the interior of a surrounding tubular and wherein the rotation interface permits the central mandrel to rotate within the cleaning members. In various embodiments, the cleaning members may be scraper blades or brushes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The advantages and further aspects of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
[0012] FIGS. 1A-1C are a side, cross-sectional view of an exemplary scraper device constructed in accordance with the present invention.
[0013] FIG. 2 is a side, external view of the scraper device shown in FIGS. 1A-1C .
[0014] FIG. 3 is a side, cross-sectional view of an exemplary split sleeve used in the scraper device of FIGS. 1A-1C and 2 , shown apart from the other components.
[0015] FIG. 4 is an axial cross-section taken along the lines 4 - 4 in FIG. 3 .
[0016] FIG. 5 is a side, cross-sectional view of an exemplary spacer used in the scraper device of FIGS. 1A-1C and 2 , shown apart from the other components.
[0017] FIG. 6 is an axial cross-section taken along the lines 6 - 6 in FIG. 5 .
[0018] FIG. 7 is a side, cross-sectional view of an exemplary scraper blade sleeve used in the scraper device of FIGS. 1A-1C and 2 , shown apart from the other components.
[0019] FIG. 8 is an axial cross-section taken along lines 8 - 8 in FIG. 7 .
[0020] FIG. 9 is a further enlarged view of lower portions of the scraper device shown in FIGS. 1A-1C and 2 .
[0021] FIG. 10 is an isometric view of an exemplary scraper blade used with the scraper device of FIGS. 1A-1C and 2 , shown apart from other components of the scraper device.
[0022] FIG. 11 is an end view of the scraper blade shown in FIG. 10 .
[0023] FIG. 12 is a cross-sectional view taken along the lines 12 - 12 in FIG. 11 .
[0024] FIG. 13 is an isometric detail view of an exemplary inner bearing race used with the scraper device shown in FIGS. 1A-1C and 2 .
[0025] FIG. 14 is an isometric view of an exemplary bearing used with the scraper device shown in FIGS. 1A-1C and 2 .
[0026] FIGS. 15A-15C present a side, cross-sectional view of an exemplary cleaning device in accordance with the present invention and incorporating a brush-type cleaning assembly.
[0027] FIG. 16 is an axial cross-section taken along lines 16 - 16 in FIG. 15A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] FIGS. 1A-1C and 2 illustrate a first exemplary wellbore cleaning device constructed in accordance with the present invention. The first cleaning device is in the form of an exemplary tubular scraper device or tool 10 that is useful for incorporation into a wellbore work string and disposed within a wellbore. The scraper device 10 includes a generally cylindrical tool mandrel, generally indicated at 12 . The tool mandrel 12 defines a central flowbore 14 along its length. The upper end of the tool mandrel 12 preferably includes a box-type threaded connection 16 so that the scraper device 10 may be secured to other portions of a wellbore work string (not shown). As shown in FIG. 1C , the lower to end of the tool mandrel 12 is secured by a threaded connection 18 to a bottom sub 20 .
[0029] The tool mandrel 12 presents an outer radial surface having a number of different diameter portions. There is an upper, enlarged-diameter portion 22 and a reduced diameter lower shaft, generally shown at 24 . The lower shaft 24 includes a plurality of annular indentations 26 , 28 , 30 , 32 , 34 , 36 , 38 which are preferably spaced apart from one another along the length of the lower shaft 24 . The indentations 26 , 28 , 30 , 32 , 34 , 36 , 38 have a diameter that is less than the diameter of the lower shaft 24 .
[0030] An upper wear ring 40 surrounds the lower shaft 24 immediately below the upper enlarged diameter portion 22 . An upper stabilizer 42 surrounds the lower shaft 24 below the wear ring 40 . A cleaning member subassembly or scraper blade subassembly, generally indicated at 44 , is located below the upper stabilizer 42 on the lower shaft 24 . Lower stabilizer 46 surrounds the lower shaft 24 below the scraper blade subassembly 44 . The upper and lower stabilizers 42 , 46 are of a type known in the art and function to centralize the scraper blade subassembly 44 within a surrounding casing member. Lower wear ring 48 is disposed below the lower stabilizer 46 and on the bottom sub 20 .
[0031] The scraper blade subassembly 44 includes an outer tubular cleaning member housing, or blade housing 50 which radially surrounds the lower shaft 24 of the tool mandrel 12 . The blade housing 50 defines a plurality of cleaning member windows, or blade windows 52 . The construction of the blade housing 50 may be better understood by further reference to FIGS. 7 and 8 , which show the blade housing 50 apart from the other components of the scraper device 10 . As shown there, the blade housing 50 includes a central axial bore 54 along its longitudinal length. The bore 54 includes an upper, enlarged diameter bearing chamber 56 and a reduced diameter engagement section 58 . The bearing chamber 56 has a smooth, cylindrical shape. However, the engagement section 58 preferably includes a plurality of radially inwardly directed engagement flats 60 . FIG. 8 shows the engagement section 58 having a hexagonal shape which provides six flats 60 . However, other suitable cross-sectional shapes may also be used (i.e., pentagon, square), and there may be more or fewer than six engagement flats 60 . In the exemplary embodiment shown in FIGS. 1A-1C and 7 , the bore 54 of the blade housing 50 also includes two radially-enlarged blade chambers 62 and 64 which are separated by a radially inwardly-projecting annular flange 66 . The blade chambers 62 , 64 contain the blade windows 52 . In addition, the bore 54 of the blade housing 50 contains a lower, enlarged diameter bearing chamber 68 .
[0032] Cleaning members in the form of scraper blades 70 are disposed radially within the blade housing 50 . FIGS. 10 , 11 and 12 depict an exemplary scraper blade 70 . Each scraper blade 70 includes a blade body 72 which presents radially outward-facing scraping surfaces 74 . The radially interior face 76 of the scraper body 72 is radially curved to generally match the curvature of the tool mandrel 12 . A spring-retaining recess 78 is formed within the interior face 76 (see FIG. 12 ). Retaining flanges 80 extend laterally outwardly from the blade body 72 . When a blade 70 is disposed within a window 52 of the blade housing 50 , the retaining flanges 80 prevent the blade 70 from falling radially outside of the window (see FIGS. 1A and 1B ). Compression springs 82 reside within the spring-retaining recess 78 of each blade 70 and bias the scraper blade 70 radially outwardly from the tool mandrel 12 . The configuration of the compression springs 82 are adapted to allow for the exertion of a symmetrical force between the scraper blade 70 and rotation sleeve 104 .
[0033] A rotation interface, generally indicated at 84 in FIGS. 1A-1C , is disposed radially between the lower shaft 24 and the surrounding stabilizers 42 , 46 and scraper blade subassembly 44 . The rotation interface 84 allows the stabilizers 42 , 46 and the scraper blade subassembly 44 to rotate freely around the lower shaft 24 . In one embodiment, the rotation interface 84 includes a plurality of rotational bearings that are in the form of roller bearing sets 86 . In the exemplary embodiment depicted in FIGS. 1A-1C , there are six roller bearing sets 86 . However, there may be more or fewer than six sets. Each of the roller bearing sets 86 is made up of an inner bearing race 88 , an outer bearing race 90 , and a plurality of rollers 92 that are disposed in between the inner and outer bearing races 88 , 90 . Alternatively, a bushing may be used in place of outer bearing race 90 , rollers 92 and spacer 116 . The rollers 92 are preferably cylindrically shaped members, as illustrated in FIG. 14 . However, spherical roller bearings might also be used. The inner bearing race 88 of each roller bearing set 86 is preferably made up of two halves 94 , 96 , as illustrated in FIG. 13 . Alternatively, if desired, an inner bearing race 88 could also be made up of three or more separate race portions which could be assembled within an indentation 26 , 28 , 30 , 34 , 36 , or 38 to make up a complete annular bearing race. When the roller bearing set 86 is assembled, the rollers 92 will rotate upon the outer radial surface 98 of the inner bearing race 88 and, due to rolling contact of the rollers 92 with both the inner and outer bearing races 88 , 90 , the bearing races 88 , 90 will easily rotate with respect to one another. The outer bearing races 90 of the roller bearing sets 86 are in contact with, and preferably secured to portions of either the scraper blade subassembly 44 or the stabilizers 42 , 46 . FIG. 9 shows, for example, that the outer bearing race 90 of the roller bearing set 86 that is mounted within indentation 34 is in contact with the surrounding scraper blade housing 50 and is secured in place against the scraper blade housing 50 by spacers 116 on each axial side. As a result, the scraper blade housing 50 will rotate about the tool mandrel 12 with the outer bearing race 90 . Similarly, the outer bearing races 90 of the roller bearing sets 86 that are located in indentations 36 and 38 are in contact with the lower stabilizer 46 so that the lower stabilizer 46 will rotate about the tool mandrel 12 with those outer bearing races 90 . Alternative cleaning elements may be used in place of scraper blades 70 , such as magnets or brushes. This may be achieved by removing outer bearing races 90 , rotation sleeve 104 and scraper blade subassembly 44 , and engaging the alternative cleaning element to the inner bearing race 88 .
[0034] FIGS. 15A-15C and 16 depict an alternative exemplary cleaning tool 10 ′ configured with an alternative cleaning member. The cleaning member of the cleaning tool 10 ′ is in the form of a brush 101 wherein cleaning brush bristles extend radially outwardly from a central collar. In this instance, the rotation interface includes bearing races 88 , which are disposed between the mandrel 12 and the brush 101 .
[0035] Referring once again to the scraper-type cleaning tool 10 shown in FIGS. 1A-1C and 2 - 14 , the rotation interface 84 also includes a split rotation sleeve 104 which underlies scraper blades 70 of the scraper device 10 . An exemplary rotation sleeve 104 is depicted in detail in FIGS. 3 and 4 wherein it can be seen that the sleeve 104 is preferably made up of two sleeve halves 106 , 108 . If desired, there may be more than two sleeve halves 106 , 108 which can be assembled about the lower shaft 24 to form a complete or substantially complete annular sleeve 104 . The rotation sleeve 104 preferably presents a smooth cylindrical outer radial surface 110 along most of its length. One axial end of the rotation sleeve 104 includes an outer interengagement surface 112 that presents engagement flats 114 . In the exemplary embodiment shown in FIG. 4 , there are six engagement flats 114 . However, there may be more or fewer than six, if desired. Alternatively, the interengagement surfaces 112 , 58 may comprise teeth as opposed to engagement flats, so long as both surfaces are complimentary to one another. The engagement flats 114 of the split sleeve 104 are shaped and sized to abut the engagement flats 60 of the blade housing 50 . This complimentary engagement permits the rotation sleeve and the blade housing 50 to rotate together without the need to affix them to one another with a fastener or otherwise. The rotation sleeve 104 halves 106 , 108 are placed radially around the shaft portion 24 of the tool mandrel 12 , and will readily rotate about the mandrel 12 .
[0036] In preferred embodiments, spacer rings 116 are located between roller bearing sets 86 under the stabilizers 42 , 46 . The spacer rings 116 serve to retain the roller bearing sets 86 in axial spaced relation to one another. FIGS. 5 and 6 illustrate an exemplary spacer ring 116 apart from the other components of the scraper device 10 .
[0037] As best seen in the enlarged view provided by FIG. 9 , roller bearing sets 86 are preferably abutted by elastomeric lip seals 122 of a type known in the art for creating a fluid seal against the bearing set 86 . In addition, the lip seals 122 will drag on the shaft portion 24 of the tool mandrel 12 to prevent the scraper blade subassembly 44 and stabilizers 42 , 46 from floating freely with respect to the tool mandrel 12 . The retaining ring 124 and spacer 116 mechanically secure the roller bearing set 86 in place axially. The fluid seal 122 prevents or limits the escape of lubricant from the bearing set 86 . In an alternative embodiment, the roller bearing sets 86 may be replaced by an annular bushing.
[0038] Removable pipe plugs 130 are preferably provided in each of the stabilizers 42 , 46 and the blade housing 50 . The pipe plugs 130 are preferably removably secured by threading and may be removed to allow lubricant to be supplied to the roller bearing sets 86 .
[0039] To assemble the scraper device 10 , the inner bearing races 88 for each of the roller bearing sets 86 are placed into the indentations 26 , 28 , 30 , 34 , 36 , 38 . This is possible because the inner bearing races 88 are each formed of multiple components (i.e. halves 94 , 96 ) which can be assembled within the indentations to form a complete annular bearing race 88 . Stabilizers are preassembled with lip seals 122 , outer bearing races 90 with rollers 92 , spacer ring 116 and retaining ring 124 . The upper stabilizer 42 is slid onto the shaft 24 to a position wherein it abuts the upper wear ring 40 . Springs 82 are installed in spring retaining recesses 78 . Spacer 116 , lip seals 122 and outer bearing race 90 with rollers or annular bushing 92 for blade housing 50 are slid onto shaft 24 . The rotation sleeve 104 is assembled around the shaft 24 in indentation 32 . The scraper blades 70 are disposed into the windows 52 of the blade housing 50 . Thereafter, the blades 70 , springs 82 , and blade housing 50 are slid onto the shaft 24 . The engagement section 58 of the blade housing 50 is positioned onto the outer surface 112 of the rotation sleeve 104 so that the engagement flats 114 of the split sleeve 104 are interengaged with the engagement flats 60 of the blade housing 50 . As a result of this interengagement, the blade housing 50 and split sleeve 104 will rotate as one about the shaft 24 of the tool mandrel 12 . Spacer 116 , lip seals 122 , and outer bearing race 90 with roller 92 are slid onto shaft 24 , and pushed inside of blade housing 50 . The lower stabilizer assembly 46 is then slid onto the shaft 24 . Thereafter, the wear ring 48 and bottom sub 20 are secured to the shaft 24 . It will be appreciated that the rotation interface 84 permits the stabilizers 42 , 46 and the scraper blade subassembly 44 to rotate freely about the tool mandrel 12 .
[0040] The internal diameters of the stabilizers 42 , 46 and the blade housing 50 are slightly larger than the external diameter of the threaded portion 18 of the tool mandrel shaft 24 . The internal diameters of the split bearing races 88 are smaller than the diameter of the threaded portion 18 . The use of split bearing races 88 reduces the amount of wear and frictional heat sustained on the surface of the mandrel 12 , when compared to the amount of wear and frictional heat a person of ordinary skill in the art would expect to occur if the stabilizers 42 , 46 and blade housing 50 were allowed to rotate on the surface of the mandrel 12 , by allowing for rotation about the split bearing races 88 . As FIG. 9 depicts, the outer diameter D 1 of each of the indentations (as illustrated at indentation 38 ) is less than the outer diameter D 2 of the shaft 24 at the point where the threaded connection 18 begins. Diameter D 2 is essentially the diameter of the shaft portion 24 where there are no indentations 26 , 28 , 30 , 32 , 34 , 36 and 38 . The inventors have determined that the strength of a scraper device within a work string and its resistance to damage from axial and torsional stresses is largely a function of the strength of the threaded connection 18 . The provision of split inner bearing races 88 and rotation sleeve 104 , which reside in a radially recessed manner within the indentations 26 , 28 , 30 , 32 , 34 , 36 and 38 , allows the threaded connection portion 18 of the shaft portion 24 to be provided with a larger diameter, thereby increasing the strength of the connection to bottom sub 20 , the overall strength of the tool 10 and the resistance to damage from applied forces within a wellbore. As a result, the threaded connection 18 substantially approximates full gauge (D 2 ) while at least a portion of the rotational interface is disposed upon the shaft portion 24 radially within the full gauge diameter D 2 by being recessed at less than full gauge (to the depth D 1 of the indentations 26 , 28 , 30 , 32 , 34 , 36 and 38 ).
[0041] The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention.
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Non-rotating tubular wellbore cleaning devices are described which include a central tool mandrel with radially surrounding stabilizers and a cleaning member subassembly. A rotational bearing is provided that is partially radially recessed, thereby improving the overall strength of the cleaning device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit of Korean Patent Application No. 10-2010-0093307, filed on Sep. 27, 2010, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field
One or more example embodiments of the present disclosure relate to a processor and an operating method of the processor, more particularly, a processor and an operating method of the processor supporting a coarse-grained array mode and a very long instruction word (VLIW) mode.
2. Description of the Related Art
Generally, in consideration of performance and cost, a data memory structure of a processor may be configured to incorporate an L1 memory having a small size and a relatively high speed within the processor, and to cause a memory having a larger size and a relatively low speed to use a source outside of (i.e., external to) the processor, such as a system dynamic random access memory (DRAM), and the like.
FIG. 1 illustrates a configuration of a processor 100 supporting a coarse-grained array mode and a very long instruction word (VLIW) mode according to conventional art.
Referring to FIG. 1 , the processor 100 supporting the coarse-grained array mode and the VLIW mode according to the conventional art may include a core 110 , a data memory controller 120 , and a scratch pad memory 130 .
The core 110 of the processor 100 according to the conventional art may have a structure disposing of a number of functional units (FUs) in a grid pattern, and may obtain enhanced performance by easily performing operations in parallel in the FUs through performing the coarse-grained array mode.
The processor 100 according to the conventional art may successively read a value in an input data array among software codes and perform an operation. When a reoccurring routine that is performed using a loop and that is in a form of using a result value in an output data array exists, the reoccurring routine may be processed through the coarse-grained array mode. Accordingly, a data memory access pattern in the coarse-grained array mode may usually correspond to a sequential access pattern. In a case of the sequential access pattern, a temporal/spatial locality may be low. Thus, when a cache memory is used as an L1 data memory, an area used for storage capacity may increase, a miss rate may increase, and a performance may deteriorate.
To enable the coarse-grained array mode to exhibit the best efficiency, the scratch pad memory 130 having a low area cost for unit capacity may be suitable for the data memory structure so that the input and output data array may be relatively large.
However, since the coarse-grained array mode may accelerate only a loop operation portion, a general routine other than the loop operation may be executed in the VLIW mode.
Since the VLIW mode may use only a portion of FUs among a plurality of FUs, performing the operation in parallel may result in poor performance. However, since the VLIW mode may perform a general software code, a function call, and the like in addition to the loop operation, the VLIW mode may be an essential function for the processor to fully execute a single software code.
Since a stack access, a global variable access, and the like may unrestrictedly occur during an execution of code in the VLIW mode, the data memory access pattern may have a relatively high temporal/spatial locality.
To enable the VLIW mode to exhibit the best efficiency, the cache memory, capable of enhancing performance using locality and reducing an external memory bandwidth, may be suitable for an L1 data memory structure.
The processor 100 according to a conventional art may include only the scratch pad memory 130 as the L1 memory. Thus, in the processor 100 according to a conventional art, both of a shared section in which a variable used in the coarse-grained array mode is stored and a local/stack section in which a variable used in the VLIW mode is stored may be included in the scratch pad memory 130 . In this instance, the core 110 according to a conventional art may access the scratch pad memory 130 through the data memory controller 120 based on an execution mode to be executed, that is, one of the coarse-grained array mode and the VLIW mode.
Thus, in the processor 100 according to the conventional art, the core 110 may access the scratch pad memory 130 at all times regardless of the execution mode of the core 110 . When external accesses simultaneously occur through a bus slave besides the core 110 with respect to the scratch pad memory 130 , an execution performance of the scratch pad memory 130 may deteriorate.
SUMMARY
The foregoing and/or other aspects are achieved by providing a processor supporting a coarse-grained array mode and a very long instruction word (VLIW) mode, including a core of the processor, a scratch pad memory including a shared section in which a variable used in the coarse-grained array mode is stored, a cache memory to cache a variable used in the VLIW mode, from a dynamic random access memory (DRAM) including a local/stack section in which the variable used in the VLIW mode is stored, and an address decoding unit to determine which section a memory access request received from the core is associated with, of the shared section and the local/stack section, based on a memory address corresponding to the memory access request received from the core. In an embodiment, when the memory address corresponds to the shared section, the core accesses the scratch pad memory, and when the memory address corresponds to the local/stack section, the core accesses the cache memory.
The foregoing and/or other aspects are achieved by providing an operating method of a processor supporting a coarse-grained array mode and a VLIW mode, including receiving a memory access request from a core of the processor, and determining which section the memory access request received from the core is associated with, of a shared section and a local/stack section, based on a memory address corresponding to the memory access request received from the core. In an embodiment, the scratch pad memory is accessed when the memory address corresponds to the shared section and the cache memory is accessed when the memory address corresponds to the local/stack section.
Additional aspects of embodiments will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects will become apparent and more readily appreciated from the following description of embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 illustrates a configuration of a processor supporting a coarse-grained array mode and a very long instruction word (VLIW) mode according to a conventional art;
FIG. 2 illustrates a configuration of a processor according to example embodiments; and
FIG. 3 illustrates an operating method of a processor according to example embodiments.
DETAILED DESCRIPTION
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. Embodiments are described below to explain the present disclosure by referring to the figures.
FIG. 2 illustrates a configuration of a processor 200 according to example embodiments.
Referring to FIG. 2 , a processor 200 supporting a coarse-grained array mode and a very long instruction word (VLIW) mode according to example embodiments may include, for example, a core 210 , an address decoding unit 220 , a cache memory 240 , and a scratch pad memory 250 .
The cache memory 240 may cache a variable used in the VLIW mode, from a dynamic random access memory (DRAM) 270 .
The DRAM 270 , according to example embodiments, may include a local/stack section in which the variable used in the VLIW mode is stored. In this instance, the DRAM 270 according to example embodiments may be located external to the processor 200 .
The scratch pad memory 250 may include a shared section in which a variable used in the coarse-grained array mode is stored.
According to an embodiment of the present disclosure when a programmer programs software and declares a global variable, the programmer may designate a data section, that is, the shared section or the local/stack section, as the section in which the global variable is located. For example, the programmer may declare that the variable used in the coarse-grained array mode is located in the shared section, and the variable used in the VLIW mode is located in the local/stack section.
A compiler may separately dispose the global variable in a predetermined address section for each data section in response to the declaration of the location.
Accordingly, the variable used in the coarse-grained array mode according to example embodiments may be disposed in a first memory address section set in response to the shared section. The variable used in the VLIW mode may be disposed in a second memory address set in response to the local/stack section.
For example, when an address range of 1 through 100 is set in response to the local/stack section, the compiler may separately dispose the global variable, declared to be located in the local/stack section, in the address range of 1 through 100. When an address range of 101 through 200 are set in response to the shared section, the compiler may separately dispose the global variable, declared to be located in the shared section, in one of the addresses in the address range of 101 through 200.
In this instance, when a memory access request occurs from the core 210 , the address decoding unit 220 may determine which of the shared section and the local/stack section the memory access request is associated with, based on a memory address corresponding to the memory access request.
For example, when the memory address of the memory access request corresponds to a memory address of the shared section, the address decoding unit 220 may determine that the memory access request is a memory access request associated with the shared section. In this instance, the core 210 may access the scratch pad memory 250 including the shared section.
When the memory address of the memory access request corresponds to a memory address of the local/stack section, the address decoding unit 220 may determine that the memory access request is a memory access request associated with the local/stack section. In this instance, the core 210 may access the cache memory 240 . When a cache miss occurs as a result of an access to the cache memory 240 , the core 210 may access the DRAM 270 including the local/stack section.
According to an embodiment of the present disclosure, the processor 200 may further include a data memory controller 260 .
The data memory controller 260 may control a memory access of the core 210 .
Depending on embodiments, when the memory access request of the core 210 is determined to be the memory access request with respect to the shared section, the core 210 may access the scratch pad memory 250 through the data memory controller 260 .
When the memory access request of the core 210 is determined to be the memory access request with respect to the local/stack section, and as a result of the access to the cache memory 240 of the core 210 the cache miss occurs, the core 210 may access the DRAM 270 through the data memory controller 260 .
When a memory access request with respect to an external section occurs from the core 210 , the core 210 may memory-access the external section through the data memory controller 260 .
The data memory controller, 260 according to an embodiment, may be connected to the core 210 . The cache memory 240 , according to an embodiment, may be connected to each of the data memory controller 260 and the address decoding unit 220 .
FIG. 3 illustrates an operating method of a processor according to example embodiments.
According to an embodiment of the present disclosure, when a programmer programs software and declares a global variable, the programmer may designate a data section, that is, the shared section or the local/stack section, as the section in which the global variable is located. For example, the programmer may declare that the variable used in the coarse-grained array mode is located in the shared section, and the variable used in the VLIW mode is located in the local/stack section.
A compiler may separately dispose the global variable in a predetermined address section for each data section in response to the declaration of the location.
Accordingly, the variable used in the coarse-grained array mode according to example embodiments may be disposed in a first memory address section set in response to the shared section. The variable used in the VLIW mode may be disposed in a second memory address section set in response to the local/stack section.
For example, when an address range of 1 through 100 is set in response to the local/stack section, the compiler may separately dispose the global variable, declared to be located in the local/stack section, in the address range of 1 through 100. When an address range of 101 through 200 is set in response to the shared section, the compiler may separately dispose the global variable, declared to be located in the shared section, in the address range of 101 through 200.
In the operating method of the processor supporting the coarse-grained array mode and the VLIW mode, in operation 310 , a core of the processor may generate a memory access request.
In operation 320 , one of the shared section and the local/stack section is determined to be associated with the memory access request, based on a memory address corresponding to the memory access request.
When the memory address of the memory access request corresponds to a memory address of the shared section, the operating method may determine that the memory access request is a memory access request associated with the shared section. In operation 330 , the operating method may access a scratch pad memory including the shared section.
The scratch pad memory, according to an embodiment, may include the shared section in which a variable used in the coarse-grained array mode is stored.
When the memory address of the memory access request corresponds to a memory address of the local/stack section, the operating method may determine that the memory access request is a memory access request associated with the local/stack section. In operation 340 , the operating method may access a cache memory.
The cache memory may cache a variable used in the VLIW mode, from a DRAM.
The DRAM according to an embodiment may include the local/stack section in which the variable used in the VLIW mode is stored. In this instance, the DRAM according to an embodiment may be located external to a processor.
When a cache miss occurs as a result of an access to the cache memory, the operating method may access the DRAM including the local/stack section in operation 350 .
The operating method of the processor according to the above-described embodiments may be recorded in non-transitory computer-readable media including program instructions to implement various operations embodied by a computer. The media may also include, alone or in combination with the program instructions, data files, data structures, and the like. Examples of non-transitory computer-readable media include magnetic media such as hard disks, floppy disks, and magnetic tape; optical media such as CD ROM disks and DVDs; magneto-optical media such as optical disks; and hardware devices that are specially configured to store and perform program instructions, such as read-only memory (ROM), random access memory (RAM), flash memory, and the like. Examples of program instructions include both machine code, such as produced by a compiler, and files containing higher level code that may be executed by the computer using an interpreter. The described hardware devices may be configured to act as one or more software modules in order to perform the operations of the above-described embodiments, or vice versa. Any one or more of the software modules described herein may be executed by a dedicated processor unique to that unit or by a processor common to one or more of the modules. The described methods may be executed on a general purpose computer or processor or may be executed on a particular machine such as the processor supporting a coarse-grained array mode and a very long instruction word (VLIW) mode described herein.
Although embodiments have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined by the claims and their equivalents.
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A processor and an operating method are described. By diversifying an L1 memory being accessed, based on an execution mode of the processor, an operating performance of the processor may be enhanced. By disposing a local/stack section in a system dynamic random access memory (DRAM) located external to the processor, a size of a scratch pad memory may be reduced without deteriorating a performance. While a core of the processor is performing in a very long instruction word (VLIW) mode, the core may data-access a cache memory and thus, a bottleneck may not occur with respect to the scratch pad memory even though a memory access occurs with respect to the scratch pad memory by an external component.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention concerns textile armatures used as products for reinforcing composite articles, i.e. articles based on resin (polyester or other resin) reinforced by a reinforcement textile armature.
[0002] Reinforcement textile armatures are known from the document EP 0 395 548 which describes the use of two textile reinforcement layers disposed on opposite sides of a central layer consisting of a mat based on fibers with permanent undulations. The reinforcement textile layers and the central layer are stitched/knitted together.
[0003] The document EP 0 694 643 for its part describes a textile armature used to produce composite articles and consisting of at least two reinforcement textile layers as such disposed on opposite sides of a central layer providing the thickness of said material, said layers being stitched/knitted together, which armature includes against at least one of its external faces a synthetic fiber veil, said veil being attached either by gluing it to the outside of the complex or by stitching the various layers together.
[0004] Stitching/knitting techniques are relatively slow and lead to slow fabrication rates, of the order of 3 to 5 meters per minute, that cannot be speeded up.
[0005] The textile armatures of the above documents also have non-uniform deformation capacities over their surface because of the use of stitching/knitting means to fasten the various textile layers to each other.
[0006] Also, the presence of stitching/knitting rows induces surface appearance defects in the finished part obtained after impregnating the textile armature with resin.
[0007] The document EP 0 659 922 discloses the use of two reinforcement textile layers disposed on opposite sides of a central layer consisting of a mat based on fibers with permanent undulations with, on at least one of the reinforcement textile layers, a fibrous veil based on chemical fibers with permanent crimping and with a linear density lower than that of the fibers of the central layer. The fibrous veil or veils, the reinforcement textile layers and the central layer are needle-punched together.
[0008] The needle-punching technique is still slow, leading to fabrication rates of the same order as the stitching/knitting technique. Also, the connection between the layers of the armature is often insufficient.
[0009] Furthermore, to ensure sufficient cohesion for the product to be handled, forceful needle-punching must be used, which breaks the glass fibers.
SUMMARY OF THE INVENTION
[0010] A first problem addressed by the invention is providing a textile armature that is of relatively low cost because it is quick to fabricate and that has good multidirectional deformation capacities when used to produce composite materials or parts.
[0011] At the same time, the present invention seeks to provide a textile armature that can be impregnated with resin easily and homogeneously when using press molding, injection molding or vacuum molding techniques.
[0012] Another aspect of the invention seeks to provide a textile armature of the above kind that can be easily cut without fraying.
[0013] To achieve the above and other objects, the invention proposes a textile armature usable for the production of composite materials or parts, comprising:
a central layer based on chopped fiber sections of a first type of synthetic material that have received before their formation into a layer a treatment conferring on them a permanent crimp, external layers disposed on opposite sides of the central layer,
[0016] wherein:
the external layers include chopped chemical fiber sections that have previously received a treatment communicating to them a permanent crimp and chopped reinforcement fiber sections, at least some of the chopped chemical fiber sections penetrate over a part of their length into the central layer, the chopped chemical fiber sections include at least first chopped chemical fiber sections including at least one surface layer of a thermoplastic material having a melting point lower than or equal to that of the chopped fiber sections of the central layer, the first chopped chemical fiber sections of the external layers adhere at least partly to each other and to the other chopped fiber sections of the textile armature.
[0021] Such a textile armature has good deformation capacities in a number of directions. More particularly, such an armature has no preferential deformation direction and no direction in which deformation is prevented. The textile armature of the invention has homogeneous cohesion between its various textile layers in all directions.
[0022] Because the chemical fibers adhere to the textile armature central layer fibers that they penetrate, it is possible to ensure efficacious interconnection of the armature layers by means of a relatively small number of such chemical fibers penetrating the central layer. The penetration of a relatively small number of chemical fibers can then be achieved using a preliminary needle-punching or light needle-punching technique, consisting of less dense needle-punching. Preliminary needle-punching is much faster than knitting/stitching and avoids breaking the reinforcement fibers, especially when they are glass fibers.
[0023] The permanent crimp of the chopped fiber sections of the central layer allows easy deformation of the textile armature when used in molding techniques. Moreover, the permanent crimp of the chopped fiber sections of the central layer preserves free spaces between the chopped fiber sections, thus conferring an aerated character on the armature, which encourages flow of resin when using press molding, injection molding or vacuum molding techniques.
[0024] The adhesion to each other of the chopped chemical fiber sections in the external layers efficiently limits the risk of fraying of the textile armature when cut. Avoided in particular is fraying of chopped glass fiber sections that reinforce the textile armature.
[0025] The chemical fibers have a permanent crimp enabling homogeneous external layers to be produced from a homogeneous mixture of chopped reinforcement fiber sections and chopped chemical fiber sections, for example. The crimp of the chemical fibers avoids “settling” of the mixture of fibers because of their different relative densities or sections. In a first embodiment, a homogeneous mixture can thus be obtained leading to the production of homogeneous external layers: in the external layers, the chemical fibers and the reinforcement fibers are then mixed in a generally homogeneous manner.
[0026] The reinforcement fibers can be glass fibers or plant (hemp, sisal, flax, etc.) fibers.
[0027] The chopped fiber sections of the central layer can preferably be of polypropylene, polyester or polyamide. This is because these fibers are very widely used in the textile industry, of relatively low cost, easy to spin and easy to shape to produce chopped fiber sections with an elastic permanent crimp.
[0028] For a more regular central layer, the chopped fiber sections of the central layer can have at least two different unitary linear densities.
[0029] The chopped chemical fiber sections present in the external layers advantageously have a cross section of smaller diameter than the chopped reinforcement fiber sections. This diameter difference encourages entrainment and penetration along at least part of the length of at least some of the chopped chemical fiber sections of the external layers into the central layer by a preliminary needle-punching process. During preliminary needle-punching, the needles chosen to entrain the chopped chemical fiber sections have a small cross section, so that they do not entrain the chopped reinforcement fiber sections much, if at all. This prevents breaking of the fragile chopped reinforcement fiber sections that reinforce the textile armature, specially in the case of reinforcing glass fibers.
[0030] The first chopped chemical fiber sections of the external layers can advantageously be of a thermoplastic material with a melting point lower than that of the chopped fiber sections of the central layer.
[0031] In one advantageous embodiment of the invention, the first chopped chemical fiber sections of the external layers can be of polyethylene.
[0032] Polyethylene is a material very widely used in the textile industry, of relatively low cost and having a low melting point. It provides thermal bonding at lower energy cost.
[0033] In another advantageous embodiment of the invention, it can be provided that:
the first chopped chemical fiber sections of the external layers are two-component chopped fiber sections having a central core of a first component and an external sheath of a second component, the melting point of the first component of the central core is higher than that of the second component of the external sheath.
[0036] The use of such two-component fibers produces a thermal bond to connect them to the central layer without risk of manifest or accidental damage to the external layers: only the external sheath of the two-component fibers is softened and participates in thermal bonding, their core remaining undamaged and retaining its mechanical properties.
[0037] In some cases, in particular in the case of reinforcement glass fibers, it can be relatively difficult to ensure sufficiently homogeneous mixing of the reinforcement fibers and the chemical fibers in the external layers. In this case, the external layers can advantageously be produced in a stratified form, comprising an external stratum essentially of chopped chemical fiber sections, an internal stratum essentially of chopped chemical fiber sections, and an intermediate stratum essentially of reinforcement fibers. The connection between the strata is provided by preliminary needle-punching followed by surface softening of the first chopped chemical fiber sections, some chemical fibers of the external stratum passing through the intermediate and internal strata of the external layer to penetrate into the central layer of the textile armature.
[0038] Another advantage of this embodiment is that the exterior surface of the textile armature consists essentially of chemical fibers. The thermoplastic material surface layers of these chemical fibers adhere to each other and thus oppose fraying of or damage to the reinforcement fibers upon subsequent handling of the textile armature when not yet embedded in resin.
[0039] The possibility of eliminating the chemical fiber internal stratum will be noted.
[0040] According to a first variant of both embodiments, the chopped chemical fiber sections of the external layers can include only first chopped chemical fiber sections.
[0041] Alternatively, according to a second variant of both embodiments, the chopped chemical fiber sections of the external layers can include a mixture of first chopped chemical fiber sections and second chopped chemical fiber sections. The second chopped chemical fiber sections are of a material having a melting point higher than the melting point of the thermoplastic material of the first chopped chemical fiber sections and a price very much lower than the price of the chemical fibers from which the first chopped chemical fiber sections are fabricated. For example, the chopped second chemical fiber sections are of polyamide or polyester.
[0042] Another aspect of the invention proposes a method of fabricating a textile armature usable for the production of composite materials or parts, including the following successive steps:
[0043] a) providing a central layer based on chopped fiber sections of a first type of synthetic material that have received before their formation into a layer a treatment communicating to them a permanent crimp,
[0044] b) disposing on opposite sides of the central layer an external layer including chopped reinforcement fiber sections and chopped chemical fiber sections with a permanent crimp including at least first chopped chemical fiber sections having at least one surface layer of a second type of thermoplastic synthetic material with a melting point lower than or equal to that of the first type of synthetic material,
[0045] c) effecting preliminary needle-punching to cause the chopped chemical fiber sections to penetrate into the central layer over part of their length,
[0046] d) heating the textile armature to soften at least superficially and to render adherent the chopped chemical fiber sections.
[0047] Such a fabrication process is easy to implement with technical means (machines, tooling, etc.) known and very widely used in the textile industry. The process is therefore of relatively low cost. The use of thermal bonding also allows a higher production rate than using bonding by stitching/knitting or by needle-punching.
[0048] During the step d), the heating can preferably be obtained by circulating hot air through the textile armature. This heating method provides thermal bonding of the fibers to each other as far as the heart of the textile armature and avoids intensive heating of the lower and upper faces of the textile armature on which are disposed the external layers including chopped chemical fiber sections. This therefore avoids excessive melting of the chopped chemical fiber sections of the external layers and the formation of a continuous layer of thermoplastic material after cooling, which continuous layer would compromise good impregnation of the textile armature by the resin on its use in press molding, injection molding or vacuum molding techniques.
[0049] Alternatively, during the step d), the heating can be effected by high-frequency microwave radiation or by infrared radiation of appropriate wavelength to soften the first chopped chemical fiber sections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] Other objects, features and advantages of the present invention will emerge from the following description of particular embodiments, which is given with reference to the appended figures, in which:
[0051] FIG. 1 is a diagrammatic view in longitudinal section of a textile armature of a first embodiment of the invention during its fabrication;
[0052] FIG. 2 is a diagrammatic view in longitudinal section of the FIG. 1 textile armature during a preliminary needle-punching operation;
[0053] FIG. 3 is a diagrammatic view in longitudinal section of the FIG. 2 textile armature during a heating operation;
[0054] FIG. 4 shows in perspective a chopped chemical fiber section of a two-component structure; and
[0055] FIG. 5 is a diagrammatic view in longitudinal section of a textile armature of a second embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] In a first embodiment shown in FIG. 1 , a textile armature 1 of the invention includes three successive textile layers 21 , 3 and 22 . The central layer 3 is based on chopped fiber sections 3 a of a first type of synthetic material. The chopped fiber sections 3 a have been treated to confer a permanent crimp on them before they are formed into a layer.
[0057] To guarantee increased durability of the elasticity of the crimped chopped fiber sections 3 a , the latter chopped fiber sections can advantageously be fabricated from single-strand fibers.
[0058] The chopped fiber sections 3 a can have the same unitary linear density. It is nevertheless possible for the chopped fiber sections 3 a to have at least two different unitary linear densities for greater regularity of the central layer 3 . Thus the central layer 3 can include chopped fiber sections 3 a of 110 dTex and chopped fiber sections 3 a of 70 dTex, for example.
[0059] On opposite sides of the central layer 3 are disposed external textile layers 21 and 22 . In this embodiment, the external textile layers 21 and 22 are based on a mixture of chopped reinforcement fiber sections 4 and chopped chemical fiber sections 7 .
[0060] The chopped chemical fiber sections 7 have been treated beforehand to confer a permanent crimp on them.
[0061] The external textile layers 21 and 22 are obtained from a homogeneous mixture of chopped chemical fiber sections 7 and chopped reinforcement fiber sections 4 such as glass fibers or plant fibers. Such a homogeneous mixture can be obtained by means of an appropriate cutter and then will be deposited by gravity onto the two faces of the central layer 3 .
[0062] The homogeneity of the mixture is also a result of the permanent crimp of the chopped chemical fiber sections 7 , which imparts a “grab” to the mixture and prevents a phenomenon known as “settling” caused by the different relative densities or sections of the chopped reinforcement fiber sections 4 and the chopped chemical fiber sections 7 .
[0063] Good results have been obtained with external layers 21 , 22 produced from a homogeneous mixture containing from 90% by weight of chopped glass fiber sections 4 and 10% by weight of chopped chemical fiber sections 7 .
[0064] The chopped chemical fiber sections 7 of the external textile layers 21 and 22 include at least first chopped chemical fiber sections 70 in a thermoplastic material having a melting point less than or equal to that of the chopped fiber sections 3 a of the central layer 3 . In the state represented in FIG. 1 , the textile armature 1 has no secure cohesion or connection allowing it to be transported.
[0065] Once provided with its three textile layers 21 , 3 and 22 , the textile armature 1 undergoes a preliminary needle-punching treatment shown in FIG. 2 . During this preliminary needle-punching operation, needles 8 cause at least some of the chopped chemical fiber sections 7 (including the first chopped chemical fiber sections 70 ) of each external textile layer 21 and 22 to penetrate over part of their length into the central layer 3 . The direction of movement of the textile armature 1 is indicated by the arrow 12 and the direction of movement of the needles is perpendicular to that direction 12 and to the surface of the textile armature 1 .
[0066] The needles 8 used have barbs 8 a of appropriate size for preferential entrainment of the chopped chemical fiber sections 7 , and in particular the first chopped chemical fiber sections 70 , and do not entrain the chopped reinforcement fiber sections 4 of the external textile layers 21 and 22 . In practice, the chopped chemical fiber sections 7 , in particular the first chopped chemical fiber sections 70 , have a smaller diameter than the chopped reinforcement fiber sections 4 . For example, chopped chemical fiber sections 7 of approximately 2 to 6 denier and chopped reinforcement fiber sections 4 of approximately 40 Tex minimum are used.
[0067] It is to be understood that the thicknesses and dimensions of the lines representing the chopped fiber sections 3 a , 4 , 7 and 70 in FIGS. 1 to 3 are not representative of the actual thicknesses and dimensions of the chopped fiber sections 3 a , 4 , 7 and 70 . The thicknesses and dimensions used in FIGS. 1 to 3 are merely intended to make it easier for the reader to appreciate the difference between the various fibers 3 a , 4 , 7 and 70 and textile layers 21 , 3 and 22 .
[0068] Preliminary needle-punching differs from needle-punching in that the textile armature 1 is passed between the needles 8 at a higher speed and the density of the needles 8 is lower. By way of illustration, standard needle-punching achieves a fabrication rate of at most approximately 4 meters per minute, whereas preliminary needle-punching achieves a rate of between approximately 8 meters per minute and approximately 20 meters per minute. Still by way of illustrative and indicative example, a needle-punching machine conventionally has a needle density per running meter between approximately 1600 and 32000, whereas a preliminary needle-punching machine has a needle density per running meter between approximately 900 and 1400.
[0069] The low needle density per running meter limits the risk of the chopped reinforcement fiber sections 4 of the textile layers 21 and 22 breaking when the needles 8 cause some of the chopped chemical fiber sections 7 to penetrate the external layers 21 and 22 in the central layer 3 , especially in the case of reinforcement glass fibers 4 .
[0070] The preliminary needle-punching is sufficient to ensure cohesion during transfer of the textile armature blank to the next workstation but insufficient to provide the final cohesion of the textile armature 1 , which is still not transportable to use as a reinforcing product following preliminary needle-punching.
[0071] After the preliminary needle-punching operation shown in FIG. 2 , the textile armature 1 is heated ( FIG. 3 ). During this heating step, the thermoplastic surface layer of the first chopped chemical fiber sections 70 of the external textile layers 21 and 22 is softened and renders the first chopped chemical fiber sections 70 adherent. The first chopped chemical fiber sections 70 that have been entrained by the preliminary needle-punching needles 8 adhere to the adjacent chopped reinforcement fiber sections 4 of the external textile layers 21 and 22 and adhere to the adjacent chopped fiber sections 3 a of the central layer 3 . After cooling, the various textile layers 21 , 3 and 22 of the textile armature 1 are thus interconnected by needle-punched and adhesively bonded fibers of the at least partly thermoplastic first chopped chemical fiber sections 70 . The textile armature 1 can then be transported. The adhesion of the at least partly thermoplastic first chopped chemical fiber sections 70 to the chopped reinforcement fiber sections 4 of the external textile layers 21 and 22 and to the chopped fiber sections 3 a of the central layer 3 compensates the inability of preliminary needle-punching to ensure sufficient cohesion of the textile armature 1 to render it transportable.
[0072] In one advantageous embodiment of the invention, the chopped fiber sections 3 a of the central layer 3 can be of polypropylene. Polypropylene is easy to spin and easy to shape to produce chopped fiber sections with permanent elastic crimp. Chopped fiber sections 3 a in polyester or in polyamide can equally be used.
[0073] In one embodiment of the invention, the chopped chemical fiber sections 7 include first chopped thermoplastic polyethylene fiber sections 70 . First thermoplastic chopped chemical fiber sections 70 of any other material having a melting point lower than that of the chopped fiber sections 3 a of the central layer 3 can equally be used.
[0074] Using polyethylene is advantageous because of its low melting point. The chopped polypropylene, polyester or polyamide fiber sections 3 a of the central layer 3 are not damaged much, if at all, by the heating operation and in this case retain all their physical and technical characteristics. On the other hand, the first chopped chemical fiber sections 70 of polyethylene drawn by preliminary needle-punching into the external textile layers 21 and 22 are softened by heating and adhere to the adjacent fibers of the textile layers 21 and 22 and to each other.
[0075] Heating is adjusted to soften and render the thermoplastic first chopped chemical fiber sections 70 adherent, but without melting them. This avoids the formation of uniform exterior layers on the upper and lower faces of the textile armature 1 that are impermeable to the resin. Such uniform and impermeable layers would compromise good impregnation of the textile armature 1 by the resin during a subsequent step of shaping by press molding, injection molding or vacuum molding.
[0076] In another advantageous embodiment of the invention, to avoid all risk of formation of exterior layers of low permeability to the resin, two-component thermoplastic fibers can be used as the first chopped chemical fiber sections 70 , as shown in FIG. 4 , having a central core 7 a and an external sheath 7 b , the melting point of the central core 7 a being higher than that of the external sheath 7 b.
[0077] The two-component first chopped chemical fiber sections 70 can include a polyamide, polyester or polypropylene central core 7 a and an external sheath 7 b of copolyester, polyethylene or any other material having a melting point less than that of the chopped fiber sections 3 a of the central layer 3 . In particular, good results have been obtained using a central core of polyester and an external sheath of copolyester or a central core of polypropylene and an external sheath of polyethylene. Other pairs of materials can be used in the form of coaxial two-component fibers: polypropylene and copolypropylene; polypropylene and ethyl vinyl acetate.
[0078] Because the central core 7 a has a higher melting point than the external sheath 7 b , the risk of accidental complete melting of the thermoplastic first chopped chemical fiber sections 70 of the external textile layers 21 and 22 during fabrication of the textile armature 1 is avoided.
[0079] This is also an effective way to limit the risk, during the heating step, of the thermoplastic first chopped chemical fiber sections 70 being completely melted by excessive or poorly controlled heating, forming uniform layers impermeable to the resin by spreading of their constituent material over the upper and lower faces of the textile armature 1 . The core of the two-component fibers is not damaged much, if at all: thus the external textile layers 21 and 22 are not damaged.
[0080] Furthermore, using two-component thermoplastic first chopped chemical fiber sections 70 with an external sheath 7 b and a central core 7 a reduces the polyolefin content of the textile armature 1 . This proves advantageous, the resin being not particularly compatible with polyolefins. In fact, the resin adheres badly to polyolefin fibers.
[0081] If two-component thermoplastic first chopped chemical fiber sections 70 are used, then the two-component thermoplastic first chopped chemical fiber sections 70 can advantageously have an external sheath 7 b of copolyester or polyethylene. The chopped polypropylene, polyester or polyamide fiber sections 3 a of the central layer 3 are thus not affected by heating. In fact, copolyester and polyethylene have melting points lower than those of polypropylene, polyester or polyamide. It is then possible to heat the textile armature 1 to a temperature just sufficient to soften the copolyester or polyethylene of the two-component thermoplastic first chopped chemical fiber sections 70 without softening or otherwise affecting the polypropylene, polyester or polyamide chopped fiber sections 3 a of the central layer 3 .
[0082] In a second embodiment, shown in FIG. 5 , a textile armature 1 of the invention again includes three textile layers 21 , 3 and 22 in succession. The central layer 3 has the same structure as the central layer 3 of the FIG. 1 embodiment described above.
[0083] In this second embodiment, shown in FIG. 5 , the difference lies in the structure of the external layers 21 and 22 . In this case, the external layers 21 and 22 are stratified layers each comprising a respective external stratum 21 c or 22 c , a respective internal stratum 21 a or 22 a and a respective intermediate stratum 21 b or 22 b.
[0084] The external strata 21 c and 22 c and the internal strata 21 a and 22 a consist essentially of chopped sections of chemical fibers such as the chemical fibers 7 of the FIG. 1 embodiment (which include at least first chopped chemical fiber sections 70 including at least one thermoplastic material surface layer).
[0085] The intermediate strata 21 b and 22 b consist essentially of reinforcement fibers such as the reinforcement fibers 4 of the FIG. 1 embodiment.
[0086] During preliminary needle-punching, chopped chemical fiber sections 7 , including first chopped chemical fiber sections 70 , are drawn through the strata by the needles until they penetrate into the central layer 3 . The subsequent heating bonds the first chopped chemical fiber sections 70 to the other fibers and connects the layers and strata.
[0087] In a variant of this second embodiment, an internal stratum 21 a , 22 a can be omitted.
[0088] The textile armature 1 of the invention can easily be fabricated at low cost by a method including the following steps in succession:
[0089] a) providing a central layer 3 based on chopped fiber sections 3 a of a first type of synthetic material that have received before their formation into a layer a treatment communicating to them a permanent crimp,
[0090] b) disposing on opposite sides of the central layer 3 a respective external layer 21 and 22 including chopped reinforcement fiber sections 4 and chopped chemical fiber sections 7 with a permanent crimp including at least first chopped chemical fiber sections 70 having at least one surface layer 7 b of a second type of thermoplastic synthetic material with a melting point lower than or equal to that of the first type of synthetic material,
[0091] c) effecting preliminary needle-punching ( FIG. 2 ) to cause the chopped chemical fiber sections 7 , in particular the first chopped chemical fiber sections 70 , of each external layer 21 and 22 to penetrate into the central layer 3 over part of their length,
[0092] d) heating the textile armature 1 ( FIG. 3 ) to soften at least superficially and to render adherent at least said first chopped chemical fiber sections 70 .
[0093] After the step d) of heating the textile armature 1 , there can advantageously follow a step e) of cold-rolling the textile armature 1 to give it a constant and homogeneous thickness. Rolling also encourages compacting of the fibers and bonding of the fibers to each other.
[0094] The chopped chemical fiber sections 7 of the external layers 21 and 22 , and in particular the first chopped chemical fiber sections 70 , can advantageously have a diameter less than that of the chopped reinforcement fiber sections 4 . The preliminary needle-punching of the step c) is then effected by means of needles 8 ( FIG. 2 ) that have barbs 8 a adapted to entrain preferentially the chopped chemical fiber sections 7 , including the first chopped chemical fiber sections 70 , but not to entrain significantly the greater diameter chopped reinforcement fiber sections 4 .
[0095] During the heating step d), the textile armature 1 enters a hot-air tunnel oven 9 . The hot-air tunnel oven 9 includes a conveyor belt 11 that moves the textile armature 1 through the oven 9 in the direction defined by the arrow 13 . The conveyor belt 11 is perforated. Hot air jets 14 are directed through the textile armature 1 to heat it throughout its thickness in order to cause the first chopped chemical fiber sections 70 which are at least in part of the thermoplastic type to adhere to the chopped fiber sections 3 a of the central layer 3 and to the chopped reinforcement fiber sections 4 of the external layers 21 and 22 .
[0096] To produce a textile armature 1 conforming to the embodiment of FIGS. 1 to 3 , a homogeneous mixture of chopped chemical fiber sections 7 and chopped reinforcement fiber sections 4 is obtained by means of a cutter during the step b) and deposited by gravity onto the two faces of the central layer 3 .
[0097] To produce a textile armature 1 conforming to the embodiment of FIG. 5 , the chemical fiber strata 21 a , 22 a , 21 c and 22 c are each produced by carding. The internal strata 21 a and 22 a , if any, are disposed on either side of the central layer 3 , after which the intermediate strata 21 b and 22 b of reinforcement fibers cut by a cutter are deposited by gravity, after which the external strata 21 c and 22 c are disposed on either side of the assembly formed in this way.
[0098] In a first variant of all the embodiments described above and shown in FIGS. 1 to 5 , the chopped chemical fiber sections 7 of the external layers 21 and 22 can consist only of first chopped chemical fiber sections 70 .
[0099] In a second variant of each of these embodiments, the chopped chemical fiber sections 7 of the external layers 21 and 22 can consist of a mixture of first chopped chemical fiber sections 70 and second chopped chemical fiber sections 71 .
[0100] The second chopped chemical fiber sections 71 are chosen to have a melting point higher than that of the first chopped chemical fiber sections 70 and are of a material less costly than the material of the first chopped chemical fiber sections 70 . Second chopped chemical fiber sections 71 of polyester or polyamide could be used, for example.
[0101] Firstly, using a mixture of first chopped chemical fiber sections 70 and second chopped chemical fiber sections 71 significantly reduces the fabrication cost of the textile armature of the invention. For example, a mixture containing approximately 50% to 70% by weight of second chopped chemical fiber sections 71 can be used.
[0102] Furthermore, using a mixture reduces the quantity of thermoplastic material in the external layers 21 and 22 to avoid, after the heating step, forming on the surface of the textile armature 1 an impermeable film of thermoplastic material preventing penetration of the resin, whilst conferring on the mixture, thanks to the second chopped chemical fiber sections 71 , sufficient density to be carded by a conventional carding device.
[0103] It should be noted that the textile armature 1 of the invention, in particular its variant with a mixture of first chopped chemical fiber sections 70 and second chopped chemical fiber sections 71 , has proven to be of remarkable benefit in so-called “pre-forming” techniques.
[0104] In this case, the textile armature 1 is heated during the step d) of the fabrication process that conforms it to a required shape. It is heated just sufficiently for the shape obtained to be able to be transported to a resin injection molding machine with a mold corresponding to the shape obtained and enabling the textile armature to be heated again, and slightly more strongly, before or during injection of the resin.
[0105] In the case of preforming a textile armature 1 with exterior layers 21 and 22 in a mixture of first chopped chemical fiber sections 70 and second chopped chemical fiber sections 71 , it has been found advantageous to use approximately 50% by weight or more of first chopped chemical fiber sections 70 .
Example
[0106] I) On a conventional carding device, a central layer 3 is produced of chopped crimped monofilament fiber sections 3 a of polypropylene with a unitary linear density of 110 dTex. The chopped fiber sections 3 a have a cut length of approximately 90 mm, a crimp of approximately two undulations per centimeter, and a melting point between approximately 170° C. and 180° C.
[0107] The central layer 3 has a mean thickness between approximately 4 and 5 mm and a weight of approximately 250 grams per square meter.
[0108] For greater regularity of the central layer 3 , chopped crimped monofilament polypropylene fiber sections 3 a with a unitary linear density of 70 dTex can be mixed in a proportion from 10% to 50% by weight with chopped fiber sections 3 a having a unitary linear density of 110 dTex.
[0109] II) There is deposited on each face of the central layer 3 an internal stratum 21 a and 22 a consisting of chopped chemical fiber sections 7 .
[0110] The chopped chemical fiber sections 7 consist of a mixture comprising 70% (by weight) of second chopped crimped chemical fiber sections 71 of polyester and 30% (by weight) of two-component first chopped chemical fiber sections 70 . The two-component first chopped chemical fiber sections 70 have a central core 7 a of polyester and a thermoplastic external sheath 7 b of copolyester. The thermoplastic copolyester external sheath 7 b has a melting point of approximately 110° C.
[0111] The second chopped crimped chemical fiber sections 71 of polyester have a unitary linear density between approximately 3 denier and approximately 6 denier, preferably chosen to be approximately 3.5 denier.
[0112] The two-component first chopped chemical fiber sections 70 have a unitary linear density between approximately 2 denier and 4 denier.
[0113] III) There is deposited on each internal stratum 21 a and 22 a an intermediate stratum 21 b and 22 b consisting of chopped reinforcement fiber sections 4 .
[0114] The chopped reinforcement fiber sections 4 are chopped glass fiber sections 4 having a unitary linear density of approximately 50 Tex and a cut length of approximately 50 mm.
[0115] The diameter of the elementary fibers of the chopped glass fiber sections 4 is approximately 14 microns.
[0116] The intermediate strata 21 b and 22 b have a density close to 450 g/m 2 .
[0117] IV) There is deposited on each intermediate stratum 21 b and 22 b an external stratum 21 c and 22 c of identical composition to the internal strata 21 a and 22 a.
[0118] V) The textile armature 1 is introduced by means of a conveyor belt 11 into a roller-type preliminary needle-puncher. The density of the needles is 4.6 per square centimeter, the separation of the rollers is 20 mm, and the depth of penetration of the needles is 12 mm. The belt moves at a speed of 10 meters per minute.
[0119] VI) After the preliminary needle-punching operation, the textile armature 1 is passed through a hot-air tunnel oven 9 having a heating portion 20 meters long at a speed of 10 meters per minute. The temperature of the hot-air tunnel oven 9 is approximately 120° C.
[0120] VII) On exit from the hot-air tunnel oven 9 , cold-rolling gives the textile armature 1 its final thickness, which is close to approximately 4 to 5 mm.
[0121] The present invention is not limited to the embodiments explicitly described and includes variants and generalizations thereof within the scope of the following claims.
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A textile armature that can be used for making composite materials or parts includes a central layer containing fiber segments of a first type of synthetic material previously submitted, before shaping it into a layer, to a process imparting a permanent crimp; outer layers including a mixture of segments of chemical fibers previously submitted to a process imparting a permanent crimping, and of segments of reinforcing fibers, at least some of the segments of chemical fibers of the outer layers penetrate along a portion of their length into the central layer. First segments of chemical fibers of the outer layers are bonded at least partially between them and to the other fiber segments of the textile armature.
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BACKGROUND OF THE INVENTION
The present invention is directed to articles of footwear, and in particularly, to footwear having relatively stiff upper shells mounted to a sole. Accordingly, the present invention has specific application in the ski and hiking boot industries.
The technology developed in the skiing industry in recent times has been quite fast paced, with improvements being made to skis, bindings and the boots. One area of interest has been the interrelationship between alpine, or "downhill", skiing and nordic, or "cross-country", sking. In alpine skiing, a rigid ski boot is locked into front and rear bindings on a relatively wide ski that is provided with cutting edges for permitting fast turns on steep downgrades. In alpine skiing, a typical ski boot has a completely rigid sole and a compeltely rigid upper shell that extends over the foot, around the ankle and over a portion of the lower leg. Such ski boots do not typically have the ability to flex so that the entire lower leg and foot of the human body is maintained in a relative unalterable configuration. Some ski boots, such as the boot shown in U.S. Pat. No. 4,461,103 issued July 24, 1984 to Annovi, provide a pivot between the foot shell and the ankle shell to allow limited relative movement. These boots often utilize resilient stiffening members so that resilient force may be applied by the skier to the toe portion of the foot by bending the knees forward against the resilient member.
On the other hand, in nordic skiing, it is important that a wide range of flexibility be maintained between the rear of the foot and the toe of the foot since nordic skiing has similarities to walking. In the past, typical nordic skiing boots or shoes have comprised a rather pliable leather article of footwear having a forward toe hinge that mounts in a front binding of a relatively narrow ski. The rear of the nordic boot is not secured to the ski so that the user may bend the boot along an area adjacent the ball of the foot. Indeed, for competent nordic skiing, it is necessary that the pivotal relationship between the toe and the heel of the foot exceed the typical range of flexing movement that takes place during walking.
One problem with nordic boots, however, has been their inability to resist torsional rotation about a longitudinal axis and their inability to resist lateral motion of the heel. This problem was recognized in U.S. Pat. No. 4,505,056 issued Mar. 19, 1985 to Beneteau. In the Beneteau patent, a cross-country ski boot is provided having a plurality of weakening ribs that extend adjacent the ball of the foot across the sides and top of thereof. To allow the boot to pivot, Beneteau encases his boot in a relatively stiff shell having a front toe portion and a rear heel portion separated and interconnected by a flat, flexing region of the rigid shell. The shell is then pivotally attached to a ski binding so as to prevent torsional rotation and lateral movement of the heel.
In addition to the prior art devices noted above, many other inventors have recognized the lack of comfort generated by an inflexible alpine boot when the skier removes the skis and attempts to walk from one location to another. To this end, there have been numerous developments of ski boots which flex slightly to allow greater ease in walking. One such prior art device is shown in U.S. Pat. No. 3,972,134 to Kastinger wherein a boot having a stiff sole and a rigid upper shell includes regions of reduced strength at a fore part of the foot to allow bending of the foot forwardly of the ankle, and pleats are provided at a forward part of the ankle to facilitate walking. U.S. Pat. No. 3,535,800, issued Oct. 27, 1970 to Stohr, shows a ski boot that flexes about a pivot on the ankle with this flexing accomplished by baffles extending forwardly and rearwardly of the boot at the ankle region. U.S. Pat. No. 3,953,930, issued May 4, 1976 to Ramer, also discloses a ski boot designed for greater ease in walking. In the Ramer structure, a flexible sole is provided to support a rigid shell defining a heel portion and a forward foot portion being telescopically inserted into a rigid shell defining a toe portion for the boot. As the skier walks in this boot, the toe portion and the heel/foot portion telescope with respect to one another. Limit stop means for preventing hyperextension of the floating toe portion is provided to limit relative movement between the toe portion and the heel portion.
Despite the improvements of these prior art patents over earlier ski and hiking boots, there remains the need for a boot that may be employed for both alpine skiing and for nordic skiing, which boot allows pivotal or rotational movement about the ball of the foot while at the same time remaining rigid against torsional rotation and lateral movement of the heel when the toe portion is secured to a front ski binding. There is further a need that allows greater flexibility of pivotal movement between the toe portion and heel portion so that nordic style skiers may implement telemark turns on relatively steep downgrades. There is further a need to provide a boot that can be used for nordic skiing, alpine skiing and for walking, which boot is acceptable in a wide variety of typical bindings.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a novel and useful article of footwear having independent toe and heel portions that are pivotally rotatable with respect to one another over a fairly large angular range.
It is a further object of the present invention to provide an article of footwear wherein independent toe and heel portions are pivotally connected to one another about the axis of the ball of the foot so as to allow relative ease in walking even when such boot is constructed of rigid materials.
Yet another object of the present invention is to provide a ski boot that may be used for nordic skiing, with such ski boot having a rigid toe portion that is pivotal with respect to a rigid heel portion about the function axis of the metatarsal phalangial joint articulation of the foot yet which boot prevents torsional rotation along its longitudinal axis and which prevents lateral movement of the heel portion when the toe portion is received in a ski binding.
A still further object of the present invention is to provide a ski boot having a pivot axis between a rigid toe portion and a rigid heel portion which axis is oriented at an angle with respect to the boot's longitude that corresponds to the axis of the ball of the foot.
It is still a further object of the present invention to provide a ski boot having an auxillary mounting plate so that such ski boot may be used for both nordic and alkpine skiing while, at the same time, being configured to be mountable into standard alpine bindings.
In order to accomplish these objects, the preferred embodiment of the present invention is directed to an article of footwear adapted to receive the human foot and operative to prevent torsional rotation of the foot while permitting bending movement about the ball of the foot. To this end, the broad form of the present invention includes a toe portion having a first sole portion and a relatively rigid first upper shell. The toe portion is configured to extend around and enclose a forward part of the human foot from a forward tip receiving the toes and rearwardly to a location just behind the ball of the foot. A heel portion includes a second sole portion and a relatively rigid second upper shell with the second upper shell having an access opening to permit insertion and removal of the foot. The second upper shell extends around the rear of the foot and forwardly to a location approximately the ball of the foot so that the second upper shell and the second sole portion encloses a rearward part of the foot between the heel and the ball thereof. A hinge means interconnects the toe portion and the heel portion to permit relative rotational movement about a fixed rotational axis with this rotational axis being in an axis plane generally parallel to the first sole portion. Preferably, the hinge means comprises a pair of oppositely projecting trunnion pins received in bearings with the trunnion pins and bearings interconnecting the toe and heel portions. The hinge permits pivotal movement between a flat position wherein the first and second sole portions are substantially oriented in parallel planes, and a second, flexed position, wherein the planes of the first and second sole portions are at an angle with respect to one another.
The relatively stiff upper shells prevent both torsional rotation and lateral movement of the heel portion when the toe portion is secured. When this article of footwear comprises a ski boot, this structure allows both alpine skiing and nordic skiing. When used in the nordic style, the rigidity of the upper shells permits substantial control over the nordic ski believed to be not heretofore obtained. When the footwear is used for skiing, a protective sheath or baffle extends between a wedge-shaped cut out between the upper shells of the toe and heel portions to prevent the ingress of snow or other unwanted materials. Similarly, in order to prevent hyperextension or over-flexing the boot, forward and rearward limit stops are provided. In some cases, it has been found desirable to resist the relative pivoting of the toe and heel portions, so that the present invention includes means to yieldably resist such rotation, in the form of either pistons, friction straps or stiff insert pads.
In one embodiment of the present invention, an auxillary sole plate is hingedly secured along the rotational axis so that the auxillary sole plate underlies the second sole portion. The auxillary sole plate terminates in a rear binding attachment element so that the boot may be worn in typical alpine bindings. A latch mechanism interconnects the heel portion and the auxillary sole plate so that, when released, the heel portion may pivot with respect to the sole plate yet, when affixed, the auxillary sole plate and sole portion are locked together. The auxillary sole plate may include openings to prevent excessive build-up of snow thereon; the heel portion of the footwear may then be provided with protrusions oriented to pass into the auxillary sole plate openings so as to eject any snow build-up.
These and other objects of the present invention will become more readily appreciated and understood from a consideration of the following detailed description of the preferred embodiment when taken together with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an article of footwear, in the form of a ski boot, according to the preferred embodiment of the present invention;
FIG. 2 is a side view in elevation of the ski boot shown in FIG. 1 shown in the flat position;
FIG. 3 is a cross-sectional view taken about lines 3--3 of FIG. 2;
FIG. 4 is a side view in elevation of the ski boot shown in FIG. 2, shown in the flexed position;
FIG. 5 is a bottom plan view of the ski boot shown in FIG. 2, in the flat position;
FIG. 6 is a side view in elevation of a first alternate embodiment of a ski boot according to the present invention, providing an auxillary sole plate and positioned in an alpine binding;
FIG. 7 is a side view in elevation of the ski boot shown in FIG. 6, in the flexed position, with the sole plate secured to heel portion of the ski boot;
FIG. 8 is a side view in elevation of the ski boot shown in FIG. 6, with the ski boot now being positioned in an alpine binding;
FIG. 9 is a top plan view of auxillary sole plate shown in FIG. 8;
FIG. 10 is a cross-sectional view taken about lines 10--10 of FIG. 9;
FIG. 11 is a side view in elevation of a second alternate embodiment of the present invention shown in the flat position;
FIG. 12 is a side view in elevation of the ski boot shown in FIG. 11 in the flexed position;
FIG. 13 is a side view in elevation of a third alternate embodiment of the present invention shown in the flat position;
FIG. 14 is a side view in elevation of the ski boot shown in FIG. 13 in the flexed position; and
FIG. 15 is a fourth alternate embodiment of the present invention, in the form of a hiking boot, in the flexed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to various articles of footwear which have relatively stiff upper shells which would normally limit the motion between the toes, foot and ankle. As such, the present invention has particular applicability to ski boots and hiking boots. However, it should be appreciated by one ordinarily skilled in the art that the many features described and claimed herein can extend to a variety of types of footwear in addition to those specifically mentioned.
In FIG. 1, a ski boot 10 is shown having a toe portion 12 and a heel portion 14 with heel portion 14 having an upward extension 16 adapted to encircle the lower leg of the wearer. Toe portion 12, heel portion 14 and upward extension 16 define a cavity to receive the human foot and lower leg through access opening 18. When received by boot 10, a forward part of the human foot including the toes and the portion of the foot generally known as the "ball" is recieved in toe portion 12. That part of the foot extending from the ball of the foot to the heel, and the lower leg and ankle area, is received in heel portion 14, including upper extension 16. Suitable fastening clamps 20, not forming part of this invention, are provided to fasten the ski boot 10 around the foot, as is known in the art.
The more detailed features of ski boot 10 are shown in FIGS. 2 and 3. In FIG. 2, toe portion 12 includes a first sole portion 22 that defines a first plane, and a sole portion 22 is secured to a relative rigid first upper shell 24. Toe portion 12 terminates in a rear edge 26 that extends from the top of the foot downwardly and rearwardly behind the ball of the foot. Heel portion 14 includes a second sole portion 28 that defines a second plane, and sole portion 28 is secured to a relatively rigid second upper shell 30 and terminates at a forward edge 32 that extends downwardly from the top of shell 30 and forwardly of the ball of the foot. Accordingly, heel portion 14 has a side wing on either side of boot 10, such as side wings 34 and 36 shown in FIG. 3. Forward edge 32 and rear edge 26 define a wedge-shaped cut out region 38 between toe portion 12 and heel portion 14, with this cut out region 38 being protected by a pleated baffle member or shield 40 that prevents ingress of unwanted material into the ski boot cavity.
It should be appreciated that toe portion 12 and heel portion 16 are structured independently of one another but are rotateably connected by hinge means about a rotational axis generally parallel to the first and second planes in a flat position, as is shown in FIGS. 2 and 3. In these figures, a pair of trunnion pins 42 and 44 extend laterally outwardly from side wings 34 and 36, respectively, and are rotateably recieved in bearings 46 and 48 mounted in suitable openings on the lateral sides of first upper shell 24 adjacent rear edge 26. Thus, trunnion pins 42, 44 and bearings 46, 48 are located on either side of the ball of the foot above the common plane of sole portion 22 and sole portion 28 when the sole portions are in the flat position shown in FIG. 2.
It should be understood, then, that toe portion 12 and heel portion 14 may rotate with respect to one another about the rotational axis defined by trunnion pins 42 and 44 to pivot with respect to one another. In order to prevent excessive pivotal motion, limit stop means are provided in the form of a first post 50 upwardly projecting from upper shell adjacent edge 26, and a second post 52 upwardly projecting from second upper shell 30 adjacent edge 32. A liner 54 is positioned within the cavity of the ski boot, as is common in the art, and a relatively stiff yet pliable pad 56 that underlies between liner 54 and sole portions 22 and 28. Pad 56 yieldably resists relative rotation of the toe and heel portions.
Referring now to FIGS. 2-4, it should be appreciated that toe portion 12 and heel portion 14 may be rotated between a flat position shown in FIG. 2, and a flexed position shown in FIG. 4 wherein the respective first and second planes of the toe and heel portions are at a large angle to one another. In the fixed position, the second sole portion preferably may pivot to a minimum angle within a range of 55° to 65° with respect to its plane when in its flat position as is shown by angle 0 shown in FIG. 4. As noted above, posts 50 and 52 provide limit stop means so that, as is shown in FIG. 4, when the boot 10 is placed in the flexed position, post 52 will abut post 50 to prevent further angular movement in the direction of arrow "A". In the flexed position, pleat shield 40 is squeezed together, in an accordion-like manner, but shield 40 is expanded in the flat position shown in FIG. 2.
It is further desirable to limit relative rotation of toe portion 12 and heel portion 14 in a direction from a flexed position past a flat position in order to avoid hyperextension of the foot. To this end, a downward limit stop means is provided to operate in conjunction with the forward limit stop means provided by posts 50 and 52. As is best shown in FIGS. 3, 4 and 5, a downward stop may be provided conveniently by means of a rigid plate 58, preferrably formed out of steel or other rigid metal, with plate 58 being affixed to one of first and second sole portions 22 and 28. In FIGS. 2-5, plate 58 is secured by means of a plurality of screws 60 to first sole portion 22 of toe portion 12. Plate 58 extends rearwardly from screws 60 to first sole portion 22 of toe portion 12. Plate 58 extends rearwardly from screws 60 across separation region 62 between toe and heel portions 22 and 28. Plate 58 then extends rearwardly along second sole portion 28. In the prefered embodiment, as is shown in FIG. 5, plate 58 is mounted in a first depression 64 in first sole portion 22, and extends in a second depression 66 formed at a forward part of second sole portion 28. Hence, when boot 10 is in the flat position, plate 58 is recessed with respect to bottom surface 68 of boot 10.
The operation of boot 10 may now be more readily appreciated and understood based on the foregoing description. In the flat position, toe portion 12 and heel portion 14 are rotated to receive the human foot in a normal, unflexed state so that sole portions 22 and 28 are substantially coplanar. Hyperextension is prevented by means of plate 58 which prevents relative rotation of the toe and heel portions past the flat position. In the flat position, ski boot 10 may be received in traditional alpine bindings and retained therein in a normal manner for control of the alpine ski. When the skier desires to walk, or use ski boot 10 for nordic skiing, toe portion 12 and heel portion 14, by virtue of the hinge means provided by the trunnion pins and bearings, is allowed to pivot forwardly as is shown in FIG. 4. For nordic skiing, toe portion 12 would of course be mounted in a standard nordic toe binding.
Since toe portion 12 and heel portion 14 are formed as rigid shells, and are attached at two points along axis F, ski boot 10 has torsional stability even when used for nordic skiing. Further, as is shown in FIG. 5 (wherein ski boot 10 is shown for a left foot) trunnion pin 42 lies forwardly of trunnion pin 44 so that axis F is located at an angle with respect to longitudinal axis L of ski boot 10. Further, as is shown in FIG. 2, rotational axis F is positioned somewhat midway between sole portions 22 and 28 and the top of upper shells 24 and 30 so that axis F is oriented generally at the center of the ball of the foot. Particularly, the hinging of toe portion 12 to heel portion 14 is contructed so that axis F generally extends along the functional axis of the metatarsal phalagial joint articulation between the proximal phalages and the metatarsals of the foot. Accordingly, axis F lies along the normal flex axis for the toes and the foot.
As noted above, pad 56 is relatively stiff, yet flexible, and is positioned between sole portions 22 and 28 and liner 54. When walking or using boot 10 for nordic skiing, the relative stiffness of pad 56 yieldingly resists the rotational movement of toe and heel portions 12 and 14, and thus the human foot placed in boot 10. Further, the resiliency of pad 56 tends to return boot 10 to the flat position. By selecting the stiffness and resiliency of pad 56, boot 10 may be customized for skiers of different weights and skiing abilities.
A first alternate embodiment of a ski boot according to the present invention is shown best in FIGS. 6-8. In these figures, ski boot 70 includes a toe portion 72 and a heel portion 74. Toe portion 72 has a first sole portion 76 which is hingeably secured by wing 78 of hinge 80 to a second sole portion 82 of heel portion 74. Second sole portion 82 is secured to hinge 80 by means of wing 84 so that toe and heel portion 72 and 74 may relatively rotate with respect to one another as described with respect to the preferred embodiment. Shield 128 prevents ingress of unwanted materials into boot 70.
An auxillary sole plate 86 is also affixed to hinge 80 by means of wing 88 so that toe portion 72, heel portion 78 and auxillary sole plate 86 may rotate with respect to one another about the rotational axis of hinge 80. Auxillary plate 88 may be realeaseably secured to heel portion 74 by means of mounting fingers 90 on plate 86 and releaseably clasps, such as clasp 92, on opposite sides of heel portion 74. Thus, heel portion 74 and auxillary plate 86 may be secured to one another, as is shown in FIG. 7, for common movement; alternately, auxillary sole plate 86 may be released from heel portion 74 for independent movement therewith, as is shown in FIG. 6. Sole plate 86 terminates, at a rear edge, in a binding mount 94 that is adapted to be secured in a standard alpine rear binding, such as rear binding 96 shown in FIG. 8.
An alternate structure is provided for the forward and rearward stop means, as is shown in FIGS. 6-8. In this alternate embodiment, an arcuate slot, such as slot 98 is formed near the front of heel portions 74, on opposite lateral sides of boot 70. A pair of side wings, such as side wing 100, are formed as an extension of rear edge 102 of toe portion 72 with side wings 102 projecting into the cavity defined by second upper shell 106 of heel portion 74. Each side wing, such as wing 102, is formed as an extension of first upper shell 104, and each carries a pin 108 that is received in each slot 98 so that pin 108 may move along slot 98 during the pivotal motion with the relative rotation of toe portion 72 and heel portion 74 being limited by the abutment of pin 108 against the ends of slot 98.
Sole plate 86 is best shown in FIGS. 9 and 10 where it should be appreciated that auxillary sole plate 86 has a pair of oppositely projecting fingers 90 and is provided with a plurality of openings 110 which function as described below. Since it is desirable that auxillary sole plate 86 be locked in a substantially planar relationship with first sole portion 76, a locking means as shown in FIG. 10, and in phantom FIG. 8. This locking means comprises a relatively flat locking bolt or plate 112 that is slideably received in bolt brackets 114 so that it may be slid from an unlocked position shown in FIG. 10 to a locked position shown in phantom in FIGS. 8 and 10. To this end, plate 112 may be received in a locking bolt bracket 116, shown in phantom in FIG. 8, to prevent auxillary sole plate 86 from pivoting with respect to sole portion 76. Naturally, this type of locking structure could be implemented on a two-piece boot, such as that shown in FIGS. 1-5. As is shown in FIGS. 7 and 8, auxillary sole plate 86 is oriented in a substantially spaced parallel relation to the bottom surface 118 of heel portion 74 so that an opening 120 is located therebetween. Space 120 is provided since snow tends to build up on the underside of the boot 70. For this reason, openings 110 are provided so that snow may be removed from space 120. To this end, also, the bottom of heel portion 74 is provided with a plurality of projections 122 which are oriented to pass within at least some of openings 110 to eject snow accumulating therein.
The operation of boot 70 may now be more fully appreciated. When it is desired to alpine ski, boot 70 is placed with toe portion 72 in a standard front binding 124 with binding mount 94 of plate 86 being received in rear binding 96 on ski 126. In this configuration, plate 86 is secured, by a respective clasp 92 to a respective finger 90. Locking plate 112 is slid to engage locking brackets 116. This boot may now be used for alpine skiing. Should the skier desire to nordic ski, the skier simply unfastens clasps 92 from fingers 90, as is shown in FIG. 6. In this position, heel portion 74 may be rotated with respect to toe portion 72 within the limits provided by pin 108 in slot 98. For walking, boot 70 is detached from the ski bindings, and plate 86 is again attached to heel portion 74 by clasps 92 and pins 90, and locking plate 112 is released.
A second alternate embodiment of the present invention is shown in FIGS. 11 and 12. Here, ski boot 14 includes toe portion 142 and heel portion 144 which are hinged together by means of hinge 146 in a manner similar to that described above. In this embodiment, though, a different means for yieldingly resisting the rotational movement of toe portion 142 and heel portion 144 as provided. Also, a different configuration for the forward and rearward limit stops are employed. In FIG. 11, a stiff but bendable strap 148 has a forward edge secured by means of screw 150 to first upper shell 152 of toe portion 142. Strap 148 has a free end 149 that extends rearwardly under a friction roller 154 along the upper surface of second shell portion 156 and upwardly slides through a guide bracket 158. A downward limit stop comprises a rib 160 formed on strap 148 in order to prevent hyperextension of the toe and heel portions. Similarly, the forward limit stop in the form of rib 162 is also provided on strap 148. Thus, strap 148 may slideably pass under roller 154. To this end, it should be appreciated that bracket 158 is provided wtih a slot to provide rib 160 to pass therethrough.
In order to adjust the force resisting the rotational movement, a threaded nut assembly 164 is attached to the side wall of heel portion 144 so that the support arm 166 of roller 154 may be drawn toward threaded nut assembly 164 so that roller 154 applies greater frictional pressure on strap 148.
A third alternate embodiment of the present invention is shown in FIGS. 13 and 14, with these figures showing a ski boot 170 having a construction similar to that described with respect to FIGS. 1-5. In FIGS. 13 and 14, though, a different means for resisting relative rotation is provided in the form of a pair of side mounted pistons, such as piston 172, extending between toe portion 174 and heel portion 176. Such pistons, such as piston 172, may be spring actuated as is shown by spring 178 to oridinarily increase the resistance to rotational force as the boot 170 moves from the flat position shown in FIG. 13 to the flexed position shown in FIG. 14. Pistons 172 could, if desired, be fluid actuated pistons, such as liquid shock absorbers or air cylinders. In any case, the limits of travel of the pistons will define the downward and forward limit stops.
Finally, a fourth alternate embodiment, in the form of hiking boot 180, is shown in FIG. 15. Here, again, toe portion 182 is secured to heel portion 184 by means of a sole mounted hinge 186 so that boot 180 is more comfortable for walking while maintaining its torsional stability.
Accordingly, the present invention has been described with some degree of particularity directed to the preferred embodiment of the present invention. It should be appreciated, though, that the present invention is defined by the following claims construed in light of the prior art so that modifications or changes may be made to the preferred embodiment of the present invention without departing from the inventive concepts contained herein.
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An article of footwear having independent toe and heel portions that are pivotally rotatable with respect to one another over a fairly large angular range. The independent toe and heel portions are pivotally hinged to each other about the axis of the ball of the foot so as to allow relative ease in walking even when the footwear is constructed of rigid material. The said footwear is a ski boot or a hiking boot.
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SPECIFIC DATA RELATED TO THE INVENTION
[0001] This invention claims the benefit of U.S. provisional application No. 60/675,790 filed Apr. 28, 2005.
BACKGROUND OF THE INVENTION
[0002] This present invention relates to disposable bottles and more particularly pertains to a disposable bottle for pre-packaged liquids that are sterilized, sealed and ready to use out of the package.
[0003] There are various problems and difficulties that have been encountered in providing people and animals of all age groups and, more specifically, babies with proper feeding by means of bottles, wherein bottles and their associated parts, as well as the contents should at all times be kept clean and sterilized. When a person or baby or animal is being fed at home or away from home the inherent problem is supplying liquid such as a food source or medication with the assurance that it is being administered from a sterile environment. Generally, the bottles are prepared and sterilized at home, which is time consuming and during which time the nipples and bottle parts are exposed to various contaminants both from being exposed to the environment and from the hands of the person that is preparing the bottle. Also, there is a possibility that not enough bottles have been prepared and the supply runs out when the bottle is needed the most, causing a chain reaction of events to happen such as a stop at the nearest restaurant without the time or facilities for sterilization thus potentially causing a biological disorder to occur such as projectile vomiting.
[0004] Even with the advent of disposable bottles, the problem of running out or the availability of sterilized milk or other sterilized liquids, such as formula or water, still exist. To the applicant's knowledge, there is no disposable baby bottle or any other type of disposable bottle available on the market today that can provide sterilized parts as well as sterilized food or liquids or medication in one package, where the bottle is pre-filled with any variety of liquids under ultimate, sterilized conditions, sealed as to not having to assemble any of the parts as described herein and being stored in such a way that maintains the integrity of being sterilized until the bottle as described herein is put into use.
[0005] Known prior art includes U.S. Pat. No. 4,678,092; U.S. Pat. No. 5,579,935; U.S. Pat. No. 3,777,025; U.S. Pat. No. 4,813,556; U.S. Pat. No. Des. 430,676; U.S. Pat. No. 6,737,091 B1. While these devices fulfill their respective, particular objectives and requirements, they do not disclose a new disposable bottle feeding device.
SUMMARY OF THE INVENTION
[0006] The present invention discloses a device for containing sterilized liquids including medication, water, protein, vitamins and liquid food sources of all types for adults and babies and animals of all age groups, such as the elderly and the impoverished in remote areas and in disaster areas where supplies containing sterile liquids are not available.
[0007] The present invention includes a sidewall that is all one piece or can be comprised of two or more pieces depending on the version used, having ventilation holes spaced throughout the sidewall for various reasons, and having a protective cap that is attached to the sidewall and can be removed when the disposable bottle is ready for use, having a nipple/liner that is manufactured as all one piece or is made separate, depending on the version used but with the overall intention as to act as one piece, the nipple/liner being installed inside the sidewall and or the nipple being part of the sidewall depending on the version of disposable bottle used but being leak-proof and sterilized, having a temperature strip mounted on the nipple/liner or sidewall to insure the proper temperature of the liquid inside the nipple/liner, and further includes sterile liquids being disposed in the nipple/liner or sidewall in the disposable bottle device, and covering all or part of the disposable bottle device is a protective covering that acts as a safety seal to insure the integrity of the contents. None of the prior art includes the combination of elements of the present invention.
[0008] It is understood that such disposable, pre-filled, sterile bottles as stated herein will be obtained at stores, in supermarkets, in vending machines, in fast food restaurants and anywhere food and beverages are available for purchase.
[0009] In this respect, before explaining the embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and or in the arrangements of the components set fourth in the following description of illustrated in the drawings. The invention is capable of other embodiments and is capable of being practiced and carried out in various ways depending on the application it is used in. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0010] It is the object of the present invention to provide a new disposable bottle device which has many of the advantages of the baby bottles mentioned in the prior art and many novel features that result in a new disposable bottle device which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art.
[0011] Still another object of the present invention is to provided a new disposable bottle device for ingesting prepackaged liquids of all types such as medication, vitamins, formula or foods regardless of their consistency including juices, water and milk for people of all age groups, babies and animals.
[0012] Still yet another object of the present invention is to provide a new disposable bottle device that is easy and convenient to use.
[0013] Even still another object of the present invention is to provide a new disposable bottle device that is completely pre-assembled and ready to use.
[0014] Another object of the present invention is to provide a new disposable bottle device where the nipple and liner act as one structure which insures that there is no possibility of mold, mildew or bacteria growing on the inside of the nipple/liner.
[0015] Still another object of the present invention is to provide a new disposable bottle device that can be administered to a recipient without ever touching the nipple with the hands or fingers, which insures a safe, clean, germ free liquid source.
[0016] These together with other objects of the invention, along with 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 the specific objects attained by its uses, reference should be made to the accompanying drawings and description which are illustrated by the preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will be better understood by the following detailed description taken in conjunction with the drawings in which:
[0018] FIG. 1 is a front cross-sectioned view of a new disposable bottle device according to the present invention;
[0019] FIG. 2 is a front cross-sectioned view of the disposable bottle with some liquid drawn out of the inner liner;
[0020] FIG. 3 is a front cross-sectioned view of the one-piece inner liner and nipple for the disposable bottle;
[0021] FIG. 4 is a front cross-sectioned view of a two-piece sidewall for the disposable bottle;
[0022] FIG. 5 is a front cross-sectioned view of a one-piece sidewall for the disposable bottle;
[0023] FIG. 6 is a front cross-sectioned view of a disposable bottle showing a different method of attaching the nipple to the liner; and
[0024] FIG. 7 is a front cross-sectioned view of a disposable bottle that is all one piece, having no inner liner where the sidewall and the nipple act as one in the same structure
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring to FIG. 1 , there is shown a front, cross-sectioned view of a disposable bottle device 10 according to one embodiment of the present invention. A thin layer of plastic or other pliable material 12 that can cover all parts of device 10 or just the protective cap 16 of the disposable bottle device functions as a protective safety wrap intended to be removed prior to use for the purpose of protecting the over-all integrity of the disposable bottle device and it's contents prior to purchase. A zipper-seal 14 in the same manner as a safety seal that is installed on a new bottle top on a common plastic disposable soda container can be used to insure the integrity of the disposable bottle and its contents while providing easy opening access. FIG. 1A is a front, cross-sectioned view of the protective cap 16 comprised of a single piece 32 or multiple pieces of ridged or pliable material such as plastic generally made using an injection mold, thus allowing close tolerances so that the protective cap would snap into place by means of ridges or extrusions 36 , or by a means that is determined by the manufacturer which would be suitable for this device when it is affixed to the device sidewall 18 for the purposes of preventing it from falling off the sidewall 18 when the disposable bottle is not being used. The cap 16 also protects the nipple 22 from damage and contact with germs, bacteria or any substance that would harm or be foreign to the user or contents of the disposable bottle. A protrusion 34 acts as a stopper when the protective cap 32 is installed on the sidewall 18 which in turn puts downward pressure on the feeding hole which is located at the top of the nipple as shown in FIG. 2 at 14 . When the protective cap 16 is put back on a partially used disposable bottle and snapped into place the nipple will not leak since the cap is pressed against the nipple top blocking hole 14 .
[0026] A two-piece sidewall 18 of material such as plastic, silicone, rubber, glass, aluminum, metal or any other pliable or rigid material that would be suitable for this invention including being made of a material that is determined by need, or environment, or regulation, or cost, or health issues forms a bottom support for the bottle or device 10 . The side wall 18 is joined for the purposes of this illustration at 19 but can be joined or separated at any location of the sidewall whether it be horizontally at the bottom or top or middle of sidewall 18 , or vertically down the middle from top to bottom of the sidewall which can be determined by the manufacturer or individual needs, but is intended to be joined together in a fixed fashion for the purpose of supporting and protecting the entire structure 10 from outside damage or contamination in the course of normal use, and for the purposes of housing the nipple/liner 22 before or after it is filled with prepackaged liquids 24 . Openings 20 in the sidewall 18 are located throughout the sidewall 18 but are not limited to any particular location or size or shape on the sidewall 18 and are intended to release any vacuum buildup that might be created when the bottle is being used including submerging the sidewall 18 in a liquid such as water for the purpose of heating or cooling the contents 24 that are inside the nipple/liner 22 thus allowing a liquid such as water to directly heat or cool the nipple/liner 22 and contents 24 . Openings 20 are also used when draining a liquid used to heat or cool contents 24 out of the sidewall 18 once the contents 24 and nipple/liner 22 have been heated or cooled to the preferred temperature. The nipple/liner 22 can be made of plastic or silicone or rubber or any other pliable material that is nontoxic, sterilized and suitable for this invention. Nipple/liner 22 is one continuous part that functions as a container to store liquids 24 of all types including medication, vitamins, formula or foods regardless of their consistency including juices, water and milk all of which are prepackaged in the nipple/liner 22 at the manufacture through the filler area 26 in the liner. Filler area 26 is not limited to this exact location on the liner as the opening could be installed anywhere on the nipple/liner 22 . Once the nipple/liner 22 has been filled with the desired liquid from the manufacturer to a capacity and volume that would minimize or eliminate any air that would be trapped inside the nipple/liner 22 , the opening in the nipple/liner 26 can be sealed with glue or heat or fusion or stamping or cauterization or clamping or tying or folding or pressure or any other type of adhesion that is suitable for this invention that will provide a leak proof environment for the liquid 24 that is stored inside the nipple/liner 22 to insure the integrity of the nipple/liner 22 as well as the overall use of the disposable bottle device 10 . Another use for the nipple/liner 22 is to form the nipple portion of the nipple/liner 22 which can be made from a different and thicker or thinner material other than the material of the liquid storing portion of the liner 22 . In such a case, the nipple material would be molded into the liner material and the liner material into the nipple material in such away that it would function as one piece. However, the nipple could be made of the same material and thickness as liner 22 depending on the application that the nipple/liner is being used for. A heat strip 28 is attached to the nipple/liner 22 either on the inside or outside of the nipple/liner, or to the inside or the outside of the sidewall 18 for the purpose of showing temperature of the liquid 24 . The strip 28 may be located at the general area 30 of the nipple/liner where 22 nipple/liner is attached to the sidewall 18 by means of adhesive or by glue or by heat or fusion or by snapping it or screwing it together in some way as to secure the nipple/liner 22 to the sidewall 18 when the device or bottle 10 is being used under normal conditions.
[0027] FIG. 2 illustrates how the nipple/liner 22 collapses when some of the liquid 24 has been extracted by suction applied via hole 14 . The liner 22 will fold, or gather, to roll upward as shown at 16 thus preventing air from getting into the liquid 24 and eliminating or greatly reducing excess air intake to the user ingesting the liquid 24 .
[0028] FIG. 3 illustrates a filled liner 22 in the inventive one piece nipple/liner configuration.
[0029] FIG. 4 illustrates one form of construction of the outer sidewall or support 18 .
[0030] FIG. 5 illustrates a one-piece sidewall 18 construction for the disposable bottle device which has the same overall function as the two-piece sidewall of FIG. 4 but is intended to allow the nipple/liner 22 to be inserted from the top of the sidewall as opposed to the bottom of the sidewall 10 .
[0031] FIG. 6 illustrates an alternate embodiment in which the nipple/liner 22 is formed as a nipple 42 attached at 46 to a liner 44 after filling the liner. The nipple and liner can be sealed together at 16 or other appropriate location with glue, heat, fusion, stamping, cauterization, clamping, tying, folding, pressure or any other type of adhesion that is suitable for this invention in a way as to be used as one structure, and in a way that will provide a leak proof environment for the liquid 24 that is stored inside the liner 44 .
[0032] FIG. 7 illustrates a further embodiment of the invention having some of the same characteristics as in FIG. 1 including cover 12 , the protective cap 16 and heat strip 28 , all having the same functions as those parts noted in FIG. 1 . The sidewall 18 has a nipple 42 built into it as part of the sidewall and made of the same or different material, and the nipple could be of a different thickness as the sidewall 18 but acting as one and the same structure, and could be attached or molded or glued or fused in such a way that would make the operation of the nipple function as one integral part of the sidewall, having no liner, meaning the liquid is placed inside the sidewall in a sterile environment and is drawn out of the disposable bottle through a hole at the top of the nipple, and having a filler hole 48 somewhere in the nipple/sidewall 18 so that liquid can be injected.
[0033] The invention and its advantages will be understood from the forgoing description and it will be apparent that various changes may be made in the form, construction and arrangement of the parts of the invention without departing from the spirit and scope thereof or sacrificing its material advantages, the arrangement hereinbefore described being merely by way of example, and I do not wish to be restricted to the specific form shown or uses mentioned, except as defined in the accompanying claims.
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This invention is a disposable bottle device intended to disperse all types of pre-packaged ready to use liquids to all age groups of people and to animals through a nipple located on the disposable bottle device. The disposable bottle device has a sidewall that is all one piece, having ventilation holes spaced throughout the sidewall, and having a protective cap that is attached to the sidewall, which can be removed when the disposable bottle is ready for use. The nipple and a liquid impermeable liner are manufactured as one piece that is leak-proof and sterilized. A temperature strip is attached in a location to insure the proper temperature of the liquid inside the nipple/liner. A protective covering over the device acts as a safety seal to insure the integrity of the contents before purchase.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to a sheet metal poly-V pulley having poly-V grooves formed at specified pitches in the peripheral wall of a cup-shaped blank, and a manufacturing method thereof.
2. Prior Art:
Conventionally, sheet metal poly-V pulleys of this type, that is, sheet metal made poly-V pulleys having a plurality of V-grooves, or so-called poly-V grooves, formed at specified pitches on the peripheral wall of a cup-shaped blank possessing bottom wall and peripheral wall formed by deep drawing of sheet metal blank, have been merchandized, and used widely as intermediate conduction poly-V pulleys in, for example, vehicles engine appliances.
Incidentally, this kind of sheet metal poly-V pulley, unlike the cast product, is very light in weight because a thin sheet metal blank is drawn, rolled and processed, and the rotation transmission efficiency to the belt to wind around is very high, so that the rotation may be properly transmitted to the belt if rotated at high speed. Aside from such advantages, more recently, the strength of the poly-V belt to be wound around the sheet metal poly-V pulley is extremely improved, and thanks to the enhancement of strength of this poly-V belt, the poly-V belt is not broken if the sheet metal poly-V pulley is rotated at a considerably high speed. That is, in order to rotate the poly-V belt at high speed, it must be wound around and engaged with the sheet metal poly-V pulley at a very high tension, and if rotated by winding and engaging at such high tension, the poly-V belt is not broken in the present situation.
However, as stated above, when rotated in engagement by winding the poly-V belt around the sheet metal poly-V pulley at high tension, since the poly-V pulley is made of a thin sheet metal blank, plastic deformation is likely to occur in the peripheral wall and bottom wall, or crossing parts of bottom wall and peripheral wall, and it is sometimes difficult to strengthen the pulleys as the strength of poly-V belts increases.
In this case, to prevent deformation of the sheet metal poly-V pulley, it may be possible to cope with the enhancement of strength of poly-V belt by using a considerably thick sheet metal blank, but it may result in a large increase in the material cost or difficulty in forming to manufacture a sheet metal poly-V pulley from a thick sheet metal blank, and also increase in the weight, which may finally sacrifice the advantages of the sheet metal poly-V pulley.
SUMMARY OF THE INVENTION
This invention is devised in the light of such circumstances, and it is hence a primary object of this invention to present a sheet metal poly-V pulley capable of effectively preventing plastic deformation against pushing pressure from the poly-V belt without causing increase of material cost, trouble of forming, and increase of weight.
In order to achieve the above object, the sheet metal poly-V pulley of this invention has a bent part projecting in a convex form toward the opening side of peripheral wall formed, in an annular form concentric with the axial center of the peripheral wall, in the bottom wall of a cup-shaped blank.
In such construction, if a large pushing pressure should be applied in an arbitrary period from the poly-V belt engaged with the poly-V grooves of a rotating peripheral wall, this bent part works as a shock absorber to effectively absorb this pushing pressure by following it up, so that the plastic deformation in the peripheral part and bottom wall, or crossing parts of peripheral wall and bottom wall may be effectively prevented. What is more, since it is only enough to form a bent part projecting in a convex form toward the opening side of the peripheral wall in an annular form concentric with the peripheral wall, in the bottom wall, the structure is simple and the manufacture is easy, while the increase of weight and cost may be effectively prevented. The effects are absolute and outstanding.
It is another object of this invention to present a method of mass-producing favorably sheet metal poly-V pulleys having said bent part in the bottom wall.
The foregoing object is achieved by providing a method comprising at least steps of:
forming a cup-shaped blank by deep-drawing a sheet metal blank to form a cup-shaped blank made of a bottom part and a rough peripheral wall part;
forming a stepped part by forming an inclined stepped part in said rough peripheral wall part and dividing the rough peripheral wall part into a poly-V groove forming part at the opening edge side and a preliminary forming part at the bottom side;
forming a rough preliminary forming blank by reversely drawing said preliminary forming part and substrate part to fold back inward, forming an inner peripheral side fold-back projected part projecting outward between said inclined stepped part and said preliminary forming part, and forming a bearing part from the preliminary forming part and an inverted substrate part from the bottom part;
forming a bent part by further reversely drawing inward said bearing part and inverted substrate part to form again, and forming an outer peripheral side fold-back projected part projecting outward between said poly-V groove forming part and inclined stepped part, and moderately curving inward in concave form the inclined stepped part between inner and outer peripheral side foldback projected parts; and
forming poly-V grooves having proper poly-V grooves formed in said poly-V groove forming part.
Other objects and features of this invention will become apparent in the course of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cut-away sectional view of a sheet metal poly-V to this invention;
FIGS. 2A to 2J partially cut-away sectional views showing principal manufacturing steps from the sheet metal blank to the product;
FIGS. 3A to 3N are partially cut-away sectional views showing further practical manufacturing steps of the method of manufacturing sheet metal poly-V pulley according to this invention; and
FIGS. 4 to 7 to are partially cut-away sectional views showing other embodiments of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, one of the embodiments of this invention is described below, in which numeral 1 is a sheet metal poly-V pulley possessing a bearing 91 and it has a tubular peripheral wall 2 integrally formed from the peripheral edge of a bottom wall 32, and poly-V grooves 61 are formed in said peripheral wall 2, while in the axial central part of the bottom wall 32, a bearing fitting part 81 integrally possessing a cylindrical part 42' projecting to the opening 22a side of the peripheral wall 2 and an annular flange 71 projecting inward from its end edge part is formed. A bearing 91 is press-fitted into said bearing fitting part 81, and the part of said cylindrical part 42' is crimped to the axial central side, so that said bearing 91 is planted in the bearing fitting part 81. A bent part 46 is formed in said bottom wall 32, a bent part 46 has a concave section projecting in a convex form toward the opening 22a side of the peripheral wall 2 in an annular form, concentric with the peripheral wall 2. The bent part 46 is used as a kind of shock absorber against the pushing pressure from the poly-V belt (not shown) which is engaged with the poly-V groves 61 of the peripheral wall 2.
An example of method of manufacturing the sheet metal poly-V pulley 1 possessing this bearing 91 is explained below while referring to FIG. 2 and FIG. 3.
FIGS. 2A to 2J are partially cut-away sectional views showing the principal manufacturing steps from the sheet metal blank to the product.
That is, in FIG. 2A, in the first place, a sheet metal blank of a specified thickness is deep-drawn, and a cup-shaped blank 11 consisting of a bottom part 21 and a rough peripheral wall part 22 having a flange 23 at the opening 22a side is formed;
in FIG. 2B, an inclined stepped part 31 is formed on the rough peripheral wall part 22 of said cup-shaped blank 11, and this rough peripheral wall part 22 is divided into a poly-V groove forming part 24 at the opening 22a side, and a preliminary forming part 25 at the bottom 21 side to obtain a stepped cup-shaped blank 12;
in FIG. 2C, the preliminary forming part 25 and bottom 21 side of said stepped cup-shaped blank 12 are reversely drawn and formed, and once folded back inward, and an inner peripheral side fold-back projected part 41 projecting outward is formed between said inclined stepped part 31 and preliminary forming part 25, and a rough preliminary forming blank 13a is obtained, using the preliminary forming part 25 as bearing supporting part 42 and the bottom part 21 as inverted substrate part 43;
in FIG. 2D, the bearing supporting part 42 and inverted substrate part 43 of said rough preliminary forming blank 13a are further drawn reversely inward to form again, and an outer peripheral side fold-back projected part 44 similarly projecting outward is formed between said V-groove forming part 24 and inclined stepped part 31, while the bottom wall part 32 between said bearing supporting part 42 and poly-V groove forming part 24 is drawn, and a convex projected part 45 projecting in curvature outward is formed;
in FIG. 2E, the flange 23 of the preliminary forming blank 13 obtained in the above preliminary forming blank forming step is cut off in a circle and removed, and at the poly-V groove forming part 24, with the end part 24a left over at said outer peripheral side fold-back projected part 44 side, a rough increased wall thickness forming blank 14a is obtained as an increased wall thickness peojected part 51 having said poly-V groove forming part 24a deflected outward by the portion corresponding to the increase of wall thickness;
in FIG. 2F, the increased wall thickness projected part 51 of said rough increased wall thickness forming blank 14a is flattened by pressure, and a poly-V groove forming part 52 increased in wall thickness corresponding to the degree of deflection is formed, and, at the same time, a reference groove part 62 for forming poly-V grooves is formed in part closer to said end part 24a, and an increased wall thickness forming blank 14 is obtained;
in FIG. 2G, with the molding reference point taken at said reference groove aprt 62, against the poly-V groove forming part 52 of said increased wall thickness forming blank 14, a poly-V grooved blank 15 forming a plurality of poly-V grooves 61 placed parallel to each other having rising lugs 63, 64 at both sides of said outer peripheral side fold-back projected part 44 and opening edge part 22b is obtained;
in FIG. 2H, said convex projected part 45 is drawn reversely inward, and a bent part 46 is formed in the bottom wall 32 by moderately curved and bulged in a concave form to the opening 22a side of the poly-V groove forming part 52 to obtain a bent part forming blank 16;
in FIG. 2I, the central part side of said inverted substrate 43 is cut off and removed, and a bearing fitting part 81 composed of cylindrical part 42' and annular flange 71 is formed, and a bearing forming blank 17 is obtained; and
in FIG. 2J, a prefabricated bearing 91 is press-fitted into the cylindrical part 42' which makes up the bearing fitting part 81 of said bearing forming blank 17 until abutting against the flange 71, and is further crimped and fixed in place.
After these steps, a desired sheet metal poly-V pulley 100 is manufactured, which possesses poly-V grooves 61 in the peripheral wall, possesses a bent part 46 bulging out in a convex form toward the opening 22a side on the bottom wall 32, and has the bearing 91 planted on the axial center.
FIGS. 3A to 3N are sectional explanatory drawings showing the further practical manufacturing steps of the same manufacturing method of said sheet metal poly-V pulley 100, and the details of each step are described below.
(1) Cup-shaped blank forming step (FIG. 2A):
In this cup-shaped blank forming step, as shown in FIG. 3A, a sheet metal blank of specified thickness and outside diameter is used as forming material, and it is deep-drawn into specified outside diameter and drawing depth by means of movable, fixed inner and outer drawing dies 111, 112, and holding die 113, and a cup-shaped blank 11 composed of bottom part 21 and rough peripheral wall part 22 is formed. At this time, at the opening edge of said rough peripheral wall part 22, a flange 34 due to excess material of drawing is left over.
(2) Stepped part forming step (FIG. 2B):
In this stepped part forming step, as shown in FIG. 3B, said cup-shaped blank 11 is fitted and held in the mutually overlaid inner holding dies 211, 212, and the part of the rough peripheral wall 22 at the bottom 21 side of the cup-shaped blank 11 is preliminarily rolled by a preliminary stepping roller 213, and an inclined stepped part 31 is formed in this part, and a stepped cup-shaped blank 12 is obtained.
That is, in this step, substantially, by forming the inclined stepped part 31 in the rough peripheral wall 22 of the cup-shaped blank 11, this rough peripheral wall part 22 is divided by the inclined stepped part 31 into the poly-V groove forming part 24 at the opening 22a side with increased diameter, and the preliminary forming part 25 at the bottom 21 side with decreased diameter.
(3) Rough preliminary forming blank forming step
(FIG. 2C):
In this rough preliminary forming blank forming step, as shown in FIG. 3C, said stepped cup-shaped blank 12 is fitted and held in the mutually overlaid inner holding dies 311, 312, and the preliminary forming part 25 and bottom part 21 of said stepped cup-shaped blank 12 are drawn reversely and formed into specified inside diameter and drawing depth by the inner drawing die 313, and are folded back inward, and an inner peripheral side fold-back projected part 41 projecting outward is formed between said inclined stepped part 31 and preliminary forming part 25, and a bearing supporting part 42 is formed from the preliminary forming part 25, and an inverted substrate part 43 from the substrate part 21.
In this step, finally, the inclined stepped part 31 and preliminary forming part 25 are formed in an acute angle in inverted state. In reverse drawing and forming in such a wide angle range, a strong internal stress occurs in the blank, but, in this step, since an inner peripheral side fold-back projected part 41 projecting outward is provided in this acute angle bent part, the generated internal stress is released smoothly because this part is bent at acute angle, and furthermore it can be concentrated into this fold-back projected part 41 which is composed as a kind of shock absorber, so that this forming may be done at higher precision and more easily.
(4) Preliminary forming blank forming step (FIG. 2D):
In this preliminary forming blank forming step, by pressing down while rotating the inner drawing die 313 with said stepped cup-shaped blank 13a fitted and held between the inner holding die 312 having an annular protuberance 312a formed at said inclined stepped aprt 31 side and the inner drawing die 313 having an annular concave part 313a formed at said inclined stepped part 31 side, as shown in FIG. 3D, an outer peripheral side fold-back projected part 44 similarly projecting outward is formed between the poly-V groove forming part 24 and inclined stepped part 31, while a preliminary forming blank 13 is obtained by forming a convex projected part 45 in the bottom wall 32 between both fold-back projected parts 41, 44.
In this step, since the convex projected part 45 is formed together with the outer peripheral side fold-back projected part 41 in such a manner as to open again the inner peripheral side fold-back projected part 41 once drawn into an acute angle in the preceding step, the internal residual stress concentrated in the inner peripheral side fold-back projected part 41 is moderately dispersed and released among the convex projected part 45 and fold-back projected part 44, and the fitting of the forming parts is improved, so that there is no risk of impeding the high precision forming.
(5) Increased wall thickness preliminary forming
step (FIG. 2E):
In this increased wall thickness preliminary forming step, first as shown in FIG. 3E, said preliminary forming blank 13 is held from both inside and outside by the outer holding die 411 and inner holding die 412 which runs along the contour of the inside of the preliminary forming blank 13, and said poly-V groove forming part 24 is cut from specified position by a shearing roller 413, and the flange 23 and excess material are removed in advance to shape neatly, and then, as shown in FIG. 3F, the blank is concentrically fitted and held by the inner and outer holding dies 414, 415, 416, while the end part 24a is tightly held by the inner and outer holding dies 415, 416 along the inner and outer shape of the preliminary forming blank 13, and the poly-V groove forming part 24 is deflected outward to the outer peripheral side by the portion corresponding to the increase of wall thickness stated below, by means of outer drawing and forming die 417, and an increased wall thickness projected part 51 is formed, and a rough increased wall thickness forming blank 14a is obtained.
(6) Increased wall thickness forming step (FIG. 2F):
In this increased wall thickness forming step, first as shown in FIG. 3G, said rough increased wall thickness forming blank 14a is held in a preliminary forming die 511, and the convex projected part 45 of said blank 14a, inner peripheral side fold-back projected part 41, bearing supporting part 42, and inverted substrate part 43 are concentrically held from outside by an outer holding die 512, while said increased wall thickness projected part 51 is supported by abutting its opening edge, that is, said opening edge 22b against the abutting stepped part 511a of the preliminary forming die 511.
In this state, by means of the poly-V groove preliminary forming roller 513 which also functions as wall thickness increasing roller, the bulging end part of the increased wall thickness projected part 51 is pressed, but since the opening edge 22b of the increased wall thickness projected part 51 is supported by abutting against the abutting stepped part 511a this increased wall thickness projected part 51 is gradually rolled and flattened by pressure by the roller surface 513a of this roller 513 to be formed in plastic fluidity so that an increase to specified wall thickness is attached in this part. At the same time, by the protruding forming plane 513b of this roller 513, the end part 24a brought closer to the increased wall thickness projected aprt 51, and also the outer peripheral side fold-back projected part 44 of the poly-V groove forming part 52 increased in wall thickness is drawn from the outer periphery to be rolled preliminarily, and a reference groove part 62 serving as the forming standard point is preliminarily formed in this part for poly-V groove forming, so that the increased wall thickness forming blank 14 is obtained.
In this case, rolling forming for increasing the wall thickness of poly-V groove forming part 52, and the simultaneous rolling forming of reference groove part 62 have the internal stress absorbed effectively by the presence of the outer peripheral fold-back projected part 44, so that the effect of this stress is not applied to other forming parts.
(7) Poly-V groove forming step (FIG. 2G):
In this poly-V groove forming step, first as shown in FIGS. 3H and 3I, in combining said preliminary forming die 511 and forming roller 513, it is sequentially replaced by the combination of the deviated first and second poly-V groove preliminary forming dies 515, 517 and forming rollers 516, 518, and while keeping the same holding state as above, said reference groove part 62 is used as one forming reference point for poly-V groove forming, and for this poly-V groove forming part 52 a plurality of preliminary poly-V grooves 61a, 61b placed parallel, as first and second preliminary rollings, are drawn in gradually, while rising lugs 63, 64 are formed to stand up gradually at the outer peripheral side fold-back projected part 44 side and opening edge 22b side.
That is, with respect to the poly-V groove forming part 52 increased in wall thickness, the reference groove part 62 serves as the forming reference point for poly-V groove forming, and, same as stated above, by the presence of the outer peripheral side fold-back projected part 44, the internal stress is effectively absorbed, and a plurality of preliminary poly-V grooves 61a, 61b as first and second preliminary rollings respectively are formed parallel easily and in accurate dimensional configuration in a sufficient wall thickness neither too less nor too much.
Afterwards, as shown in FIG. 3J, the combination of poly-V groove forming die and forming roller is replaced by the combination of deviated poly-V groove finishing forming die 519 and poly-V groove finishing forming roller 520, and here keeping the same holding state as above, too, a plurality of preliminary poly-V grooves 61b set parallel in said second preliminary rolling are drawn deep, finished and roller from outer periphery by the V-groove finishing forming roller 520, and the parallel plurality of poly-V grooves 61 are formed at high precision with respect to the poly-V groove forming part 52, so that a poly-V groove blank 15 is obtained.
Here, too, in preliminary rolling of this poly-V grooves 61 and finish-rolling, delicate actions of the internal stress are effectively absorbed by the outer peripheral fold-back projected part 44 and the convex projected part 45 bulging outside in contact with this part, and effects of forming stress and residual stress may not be applied to other forming parts.
(8) Bent part forming step (FIG. 2H):
In this bent part forming step, said poly-V grooved blank 15 is held in the inner holding die 611 as shown in FIG. 3K, and the poly-V grooves 61 of this blank 15 are held from outside by the holding die 612.
While rotating the reverse drawing roller 613, said convex projected part 45 is drawn reversely, and a bent part 46 having the convex projected part 45 bulging out to the opening 22a side is formed, and a bent part forming blank 16 is obtained.
In this step, too, when forming the bent part 46, delicate actions of the internal stress are effectively absorbed by the inner peripheral side fold-back projected part 41 and outer peripheral side fold-back projected part 44, so that effects of forming stress or residual stress may not be applied to other forming parts.
(9) Bearing part forming step (FIG. 2I):
In this bearing part forming step, first as shown in FIG. 3L, said bent part forming member 16 is firmly held, same as above, by the inner holding dies 614, 615, and outer holding die 616, and the bearing support part 41 of the bent part forming blank 16 is once shaped again by the shaping roll 617, and the dimensions and precision are corrected.
In this case, too, the internal stress applied at the time of shaping may be favorably absorbed by the inner peripheral side fold-back projected part 41 and bent part 46.
Next, as shown in FIG. 3M, the peripheral part 71 of the inverted substrate 43 communicating with the bent part 46 of said bent part forming blank 16 is firmly held by other inner holding die 618 and outer holding die 619, and the central side of this inverted substrate part 43 is cut off and removed, leaving only the part of the peripheral part 71 by means of shearing die 620, thereby forming a bearing fitting part 81 composed of cylindrical part 42 and annular flange part 71, so that a bearing forming member 17 is obtained.
(10) Bearing press-fitting, crimping step (FIG. 2J):
In this bearing press-fitting, crimping step, first as shown in FIG. 3N, the bent part 46 of said bearing forming member 17 is similarly held firmly as above by means of inner holding die 711 and outer holding die 712, and the outer base part of the cylindrical part 42' is held by the protruding end 711a of the inner holding die 711, and the annular flange part 71 by the inner holding die 713. In this state, using a push-in die 714, a prefabricated bearing 91 is press-fitted into the cylindrical part 42' to make up the bearing fitting part 81 until abutting against the flange part 71, while the outer upper part 42" of the cylindrical part 42' is crimped to set in place.
In this bearing press-fitting and crimping step, the outer base part of the cylindrical part 42' is stopped by the protruding end 711a of the inner holding die 711, and the flange part 71 is received by the inner holding die 13, so that press-fitting and crimping of the prefabricated bearing 91 may be very smooth and easy.
In this way, as intended by this embodiment, a sheet metal poly-V pulley 100 having poly-V grooves 71 in the peripheral wall 2, and having a bent part 46 which is annular and bulging out in convex form to the opening 22a side of the peripheral part, in the bottom wall 32, and also having a bearing 91 planted in the axial central part of the bottom wall 32 may be composed at high precision.
Incidentally, the bent part is not limited to the sectional shape shown in the embodiment, but it may be, for example as shown in FIG. 4, a bent part 46' moderately bulging in a concave form to the opening 22a side.
Similarly, the formation of the bent part is not limited to this embodiment in which it is once projected outward to the opposite side of the opening 22a side, and is then drawn reversely to bulge out in a convex form at the opening 22a side. Instead, for example, it may be bulged out to the opening 22a side from the beginning.
The sheet metal poly-V pulley of this invention is not limited to the sheet metal poly-V pulley having the bearing as shown in this embodiment, but this invention may be similarly applied to a sheet metal poly-V pulley without bearing or a sheet metal poly-V pulley having a stepped bottom wall 32' as shown in FIG. 5.
Furthermore, as the sheet metal poly-V pulleys to which this invention may be applied, a flat sheet metal poly-V pulley 100' not possessing grooves (or concave parts) in the inner side of the peripheral wall as shown in FIG. 6, or a sheet metal poly-V pulley 100" having V-shaped annular inner grooves 65 smaller than poly-V grooves 61 on the outer surface, positioned at the position corresponding to the apex of the partition wall of said poly-V grooves 61, in the inner side of the peripheral wall 2 as shown in FIG. 7 may be naturally acceptable.
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A sheet metal poly-V pulley and a method of manufacturing the same, having a tubular peripheral wall integrally formed from the peripheral edge of bottom wall and having poly-V grooves formed in said peripheral wall at specified pitches, in which a bent part is formed in said bottom wall in an annular form concentric with the axial center of the peripheral wall and bulging out in a convex form toward the opening side of the peripheral wall. The load from the poly-V belt which may cause plastic deformation of the sheet metal poly-V pulley is absorbed by this bent part, so that the increase of material cost, difficulty in forming, and increase of weight due to increase of the thickness of the blank of sheet metal poly-V pulley in order to enhance the strength may be avoided.
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BACKGROUND OF THE INVENTION
The present invention relates to a ceramic heater for use in an intake pipe heater of internal combustion engines or the like purposes and, more particularly, to a novel construction of a flexible ceramic heater which is adaptable to external force and less liable to be broken.
Recently, there is a tendency that ceramic heaters having positive temperature coefficient (PTC) characteristics are used for mixed air-fuel gas heating devices of internal combustion engines.
The ceramic heater is formed mainly of barium titanate by baking, and exhibits a low electric resistance at normal temperature but the electric resistance is drastically increased at a so-called Curie point which usually falls between 120° and 150° C. In general, this ceramic heater is shaped to have a form of a thin disc and is pressed at its one side with a metallic plate as a heating medium or adhered to the same by means of a conductive adhesive during the use. Usually, the metallic plate constitutes a part of the casing of the ceramic heater. In the ceramic heater of the type described above, the casing is often distorted by a pressure exerted on the outside of the casing. The ceramic heater itself, however, is very fragile and can be distorted only slightly. In consequence, the ceramic heater is broken by such an external force or, even if it is not broken, a small gap is undesirably formed between the ceramic heater and the casing to deteriorate the heat transfer characteristics.
This problem would be overcome if the ceramic heater itself has a certain flexibility. This, however, is extremely difficult to realize.
SUMMARY OF THE INVENTION
It is, therefore, a major object of the invention to overcome the above-described problems of the prior art by providing an improved ceramic heater.
To this end, according to the invention, there is provided a ceramic heater in which the disc-shaped or polygonal ceramic body is divided into a plurality of segments. These segments are connected to one another through a flexible and soft medium or, alternatively, arrayed and bonded to a common thin metallic plate, so that the PTC ceramics as a whole exhibit a flexibility at least partially.
This arrangement eliminates the breakage of the ceramics and keeps the close contact of the casing as the heating medium and the ceramic heater to ensure a good transfer of heat therebetween.
The above and other objects, as well as advantageous features of the invention will become clear from the following description of the preferred embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a ceramic heater of the invention attached, as a mixed air-fuel gas heating device, to an intake pipe of an internal combustion engine;
FIG. 2 is a sectional view of only a base portion of the casing of the mixed air-fuel gas heating device shown in FIG. 1;
FIG. 3 is a plan view of only a ceramic heater of the mixed air-fuel gas heating device shown in FIG. 1;
FIG. 4 is an enlarged sectional view of the ceramic heater taken along the line IV--IV in FIG. 3; and
FIG. 5 is an enlarged sectional view of a main part of the ceramic heater according to another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, a reference numeral 1 denotes an intake passage of an internal combustion engine at the upstream side portion of which disposed is a carburetor not shown. The fuel supplied through a fuel supplying opening to the venturi of the carburetor is mixed with the intake air and the mixture is supplied to the combustion chambers (not shown) of the engine through the intake passage 1 via a throttle valve 2. A circular bore 11 is formed at a so-called heat-riser portion immediately below the throttle valve 2, and a mixed air-fuel gas heating device generally represented by a symbol A is disposed at that portion.
The mixed air-fuel gas heating device A has a casing 3 which is constituted by a disc-shaped heating portion 31 formed integrally from a thin aluminum plate, a base portion 30 having three legs two of which are shown at 32, 33, extending from the periphery of the heating portion 31 and a heat insulating cover member 35 which covers the legs. In FIG. 1, two of the three legs are not shown because they are out of the section of FIG. 1. The heat insulating cover member 35 is made of a plastic or ceramic material and has a tubular form and constitutes together with the legs embedded therein a support for supporting the casing 3 within the opening 11.
As will be seen from FIG. 2 showing a section of the base portion 30, flanges 321, 331, etc. are formed at the ends of the legs 32, 33, etc. The bottom surfaces of these flanges are exposed from the bottom surface of a flange 351 formed at the edge of the heat insulating cover member 35, and both bottom surfaces are flush with each other.
A ceramic heater 4 according to the invention is bonded to the back side of the heating portion 31 by means of a conductive adhesive. In the illustrated embodiment, the upper and lower sides are positive and negative terminals, respectively.
A saucer-shaped electrode 5 made of a thin aluminum plate is pressed at its bottom side to the lower side of the heat generating member. Further, a stainless steel wool 6 is pressed to the lower side of the electrode 5. This stainless steel wool 6 is a cushioning member constituted by a braid of stainless steel wires each of which having a diameter of 0.1 mm or so. The stainless steel wool 6 is contacted at its lower side with a copper plate 7 which has a form of thin disc. The disc-shaped copper plate 7 is cut at its central portion and the cut piece is projected downwardly in the form of a claw 71. This claw 71 is electrically connected to the positive terminal of a series of batteries (not shown).
The copper plate 7 is supported at its lower face by a stay 8 made of an electrically insulating resinous material and having a comparatively large thickness. The stay 8 is pressed upward and supported by a circular clip 9 fitting in a groove formed in the inner peripheral surface of the cover member 35. The aforementioned claw 71 of the copper plate 7 extends through the central portion of the stay 8.
The heating portion 31 in the casing 3 of the mixed air-fuel gas heating device A constitutes a part of the wall of the intake pipe 10, and the cover member 35 having legs 32, 33, etc. embedded therein fits the opening 11 of the intake pipe. The cover member 35 is fixed to the intake pipe 10 by means of bolts 90a, 90b which penetrate the portions of the flange 351 in which the flanges 321, 331, etc. are embedded, so that the flanges 321, 331, etc. of the legs are electrically connected to the intake pipe 10 through the bolts 90a, 90b, etc. Between the flange 351 of the cover member 35 and the intake pipe 10, a gasket 12 is interposed. Also, the intake pipe 10 is provided with a water jacket 13 in which cooling water for cooling the engine is circulated.
Upon starting the cold engine, the temperature of the intake pipe 10 including its water jacket 13 is as low as the ambient air temperature. As the key switch is closed for starting the engine, the ceramic heater 4 is energized by the power supplied from the batteries. More specifically, the D.C. electric current flows from the positive electrode of the batteries to the negative electrode of the same via the claw 71 of the copper plate 7, stainless steel wool 6, saucer-shaped electrode 5, ceramic heater 4, heating portion 31 of the casing, legs 32, 33, etc. of the casing, bolts 90a, 90b, etc. and the intake pipe 10. In this closed electric circuit, only the ceramic heater 4 exhibits a substantial electric resistance. Thus, the ceramic heater 4 generates heat while consuming the electric power. Since the PTC ceramic heater exhibits a small resistance at the normal temperature, it is heated instantaneously up to the Curie point which falls between 120° and 150° C. and the generated heat is transferred to the heating portion 31.
The heat delivered to the heating portion 31 is transferred to three legs 321, 331, etc. but the heat transfer therefrom to the intake pipe 10 is made only through three bolts 90a, 90b, etc. because the intake pipe 10 and the legs are thermally insulated by the cover member 35. Thus, only small amount of heat is allowed to be transferred to the intake pipe 10. Also, the heat loss due to the radiation of heat from the legs 321, 331, etc. is suppressed because the legs are covered by the cover member 35. The legs embedded in the cover member 35 serve also as reinforcement core member of the latter to ensure a sufficiently high mechanical strength of the cover member 35.
It is possible to use a tubular leg instead of the illustrated plurality of legs. This, however, is not so recommendable because the heat transfer to the intake pipe is suppressed by limiting the area of path of the heat transfer when a plurality of comparatively thin legs are used as in the illustrated embodiment.
In consequence, the heating portion 31 shares almost the whole part of the heat generated by the ceramic heater 4 to efficiently promote the evaporation of the fuel. After operating the engine for several minutes subsequent to the start-up of the engine, the cooling water in the water jacket is heated up to a temperature of 80° C. or higher. Then, the power supply to the ceramic heater 4 may be stopped.
The detail of the ceramic heater 4 heretofore described will be explained with specific reference to FIGS. 3 and 4. FIG. 3 is a plan view of the ceramic heater 4. Although the ceramic heater 4 seems to have an integral disc-like form, it is actually divided into four segments by cross-like lines of division. In other words, the ceramic heater 4 is formed as an assembly of four sector segments 4a, 4b, 4c and 4d. These segments are jointed to one another not directly but through the medium of a cross-shaped band 41 (soft member) of a heat-resisting rubber such as fluororubber. The section of the jointing portion taken along the line IV--IV is shown in a larger scale in FIG. 4. Only the ceramic portion of the segment 4c is designated by a numeral 42c, while only the ceramic portion of the segment 4b is denoted by a numeral 42b. The ceramic pieces 42b, 42c are formed by baking mainly from barium titanate. The Curie point is adjusted by adding small amounts of lead (Pb), manganese (Mn) and so forth to fall within the range of between 120° to 150° C. As explained before, the electric resistance of these ceramics are drastically changed across this Curie point. More specifically, the ceramics exhibit a small electric resistance at normal temperature, but the electric resistance is increased to an extremely high level as the Curie point is exceeded. Nickel plating layers 43b, 44b are formed on both sides of the ceramic piece 42b, to serve as electrodes. The same applies also to other three segments. The electrode 43b contacting the stainless steel wool 6 constitutes the positive electrode, while the electrode 44b contacting the casing surface adjacent to the heating portion 31 constitutes the negative or grounding electrode.
The adjacent ceramic pieces, e.g. the ceramic pieces 42b, 42c, are bonded to each other through the band 41 of heat-resisting rubber. The band 41 has a rectangular cross-section and can withstand a temperature in excess of 150° C., and is shaped from a highly elastic material such as silicone rubber, fluororubber or the like. The band 41 is bonded to both ceramic pieces 42b, 42c, by means of an electrically non-conductive adhesive 45 such as silicon or epoxy resin adhesive.
The described ceramic heater constituted by the members 41 to 45 is adhered at its grounding-electrode side to the heating portion 31 of the casing by means of an electrically conductive adhesive 46. The adhesive 46 is of epoxy or silicon resin containing powders of silver (Ag) at a high density, and exhibits a high heat conductivity, as well as high electric conductivity.
During the operation of the internal combustion engine, the throttle valve 2 is maintained at a small opening except the case of the full load operation. In such a state, a highly reduced pressure (intake vacuum) which reaches 300 to 500 mmHg is established in the intake pipe 10. In consequence, the heating portion 31 of the casing 3 of the mixed air-fuel gas heating device A is sucked and lifted at its central portion to form a convex curved surface of a height of 30 to 100 microns, assuming that the heating portion 31 is made of an aluminum disc of 50 mm dia. and 1.2 mm thick. The ceramic heater 4, however, keeps the close contact with the heating portion 31, while absorbing the whole deflection by the rubber band 41.
FIG. 5 is an enlarged sectional view of another embodiment of the invention, showing the part corresponding to that of the first embodiment shown in FIG. 4.
As in the first embodiment, the ceramic heater of this embodiment is constituted mainly by four sector ceramic pieces 42a, 42b, 42c, 42d, although the sectional view in FIG. 5 shows only two 42b, 42c of these ceramic pieces. Nickel-plating layers 43b, 44b, 43c, 44c serving as electrodes are formed in both sides of the ceramic pieces 42b, 42c. The embodiment shown in FIG. 5 differs from the first embodiment in that the nickel-plating layers are not formed on the entire surfaces of the ceramic pieces 42b, 42c, but leave the peripheral portions of the ceramic pieces unplated. This applies also to the electrically conductive adhesives 46b and 46c for adhering the ceramic pieces to the heating portion 31.
The four ceramic pieces 42a, 42b, 42c and 42d are arrayed on and bonded to a plate 47 to form as a whole a disc. The adhesion is made by means of electrically conductive adhesive layers 46b', 46c'. As in the case of the nickel-plating layers, the adhesive layers 46b, 46c, 46b', 46c' are formed to leave the peripheries of the ceramic pieces 42b, 42c unplated. The plate 47 is made of a thin aluminum plate having a thickness of about 0.1 mm and carries four sector ceramic pieces thereon. The ceramic pieces are arrayed with a suitable gap between adjacent ones to form a cavity 48 as illustrated. This cavity 48 effectively absorbs the mechanical distortion of the heating portion 31. The cavity 48 may be filled with an electrically insulating and soft material. Also, it is possible to arrange such that the saucer-shaped electrode 5 serves also as the plate 47.
The embodiment shown in FIG. 5 offers the same advantage as the first embodiment: namely the absorption of the mechanical distortion of heating portion 31 and preservation of close contact between the ceramic pieces and the heating portion 31.
Although the invention has been described through its preferred forms, the described embodiments are not exclusive and various changes and modifications may be imparted thereto without departing from the scope of the invention.
For instance, although the ceramics are divided into four segments in the described embodiments, it is possible to divide the ceramics into 3 segments or even into 5 or 6 segments. The division need not always be made by diametrical or radial lines of division but be made by longitudinal and transverse lines of division.
In the embodiment shown in FIGS. 1 to 4, ceramic pieces may be bonded to one another by pouring a molten resin into the gap between adjacent ceramic pieces, instead of using the rubber band.
Furthermore, the ceramic heater and the heating portion of the casing may be simply pressed to each other although they are bonded to each other by an electrically conductive adhesive in the described embodiments.
As has been described, according to the invention, it is possible to obtain a flexible ceramic heater which is easy to assemble and to hold, by dividing the ceramics into a plurality of segments and jointing these segments to one another through the medium of flexible resin layers or by means of a thin metal plate on which the segments are arrayed and adhered, as if the segments are unitary with one another.
The flexible nature of the ceramic heater in turn offers advantages of durability of the ceramic heater against the external force and preservation of close contact between the ceramic heater and the heat transfer medium.
Further, by pressing and holding the thin ceramic plate by a cushioning member constituted by a braid of thin metal wires, all of the ceramic pieces are closely contacted to sufficiently perform their function.
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A flexible barium titanate ceramic PTC heater for use in, for example, an intake pipe of an internal combustion engine to heat the air-fuel gas mixture is formed as a thin disc-shaped ceramic sheet constituted by a plurality of individual coplanar ceramic segments having interior edges positioned in spaced side-by-side relationship. The juxtaposed edges of the ceramic segments are united to each other by a flexible, heat-resistant, electrically non-conductive rubber band disposed in the space between the segments and bonded thereto by an electrically non-conductive adhesive to form the segments into a thin disc-shaped sheet which can be flexed without causing flexing of any of the individual segments. The ceramic heater is positioned in a metallic casing with one planar face thereof bonded to the inner surface of the casing by an electrically conductive adhesive. A stainless steel wool cushioning member engages the other planar face of the ceramic heater to support the heater in the metallic casing.
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CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is in the field of equipment used in the production of fluids from, and injection of fluids into, oil and gas wells having multiple zones.
2. Background Art
Many oil or gas wells extend through multiple formations, resulting in the establishment of multiple zones at different depths in the well. It may be desirable to produce formation fluids such as gas or oil from different zones at different times, and to inject fluids such as water into different zones at different times, for the purpose of ultimately obtaining the maximum production from the well. Further, it may be desirable to produce formation fluids from one or more zones, while simultaneously injecting fluids into one or more other zones. Finally, it may be desirable to convert a particular zone from a production zone into an injection zone, after the zone is depleted.
Known equipment for these purposes usually requires pulling the completion assembly from the well, and changing or reconfiguring the equipment in the assembly, when it is desired to commence or cease production or injection in a particular zone. Further, known equipment is generally limited to the production of fluid or the injection of fluid at any given time, with simultaneous production and injection not being possible, or at least difficult. More specifically, known equipment is not capable of the simultaneous production from multiple zones and injection into multiple zones.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for selectively injecting into a given zone or multiple zones, or producing from a given zone or multiple zones, without pulling the equipment from the well. A completion unit is positioned next to each zone of the formation, with zones being segregated by packers. An injection sleeve and a production sleeve are provided in each completion unit. Each sleeve essentially bridges between the completion string and the production string, which is within the completion string. Each sleeve is shifted, such as by hydraulic, electrical, or mechanical operation, to selectively align a conduit through the sleeve with its associated port in the wall of the completion string. When aligned with the inlet port, the conduit in the production sleeve conducts formation fluid into a production fluid path in the production string. When aligned with the outlet port, the conduit in the injection sleeve conducts injection fluid from an injection fluid path into the formation. Regardless of sleeve position, both injection flow and production flow can be maintained through the completion unit to other completion units above or below.
By selectively shifting the sleeves, selected zones can be isolated, produced from, or injected into, as desired. One or more lower zones can be injected into while one or more upper zones are produced from, or vice versa. If desired, alternating zones can even be simultaneously produced from and injected into.
The novel features of this invention, as well as the invention itself, will be best understood from the attached drawings, taken along with the following description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a longitudinal section of a production unit as implemented in the present invention, with production flow from the zone isolated;
FIG. 2 is a transverse section of a production sleeve as used in the production unit of FIG. 1;
FIG. 3 is a longitudinal section of the production unit of FIG. 1, with production flow from the zone established;
FIG. 4 is a longitudinal section of an injection unit as implemented in the present invention, with injection flow into the zone isolated;
FIG. 5 is a transverse section of an injection sleeve as used in the injection unit of FIG. 4;
FIG. 6 is a longitudinal section of the injection unit of FIG. 4, with injection flow into the zone established;
FIG. 7 is a longitudinal section of a completion unit, showing production flow from the zone established, and showing an alternative configuration of the completion and production strings;
FIG. 8 is a longitudinal section of the completion unit of FIG. 7, showing production flow from the zone and injection flow into the zone both isolated; and
FIG. 9 is a longitudinal section of the completion unit of FIG. 7, showing injection flow into the zone established.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, a production unit 10 used as part of the present invention includes a completion string 12 of tubing or piping, a production string 14 of tubing or piping, one or more centralizing rings 16 , and a longitudinally shiftable production sleeve 18 . This production unit can be placed in a well bore, aligned with a selected zone of the downhole formation. The completion string 12 shown is flush joint piping, and the production string 14 can be flush joint piping. Other types of piping or tubing can also be used. The production string 14 is substantially coaxially located within the completion string 12 , centralized therein by the centralizing rings 16 . An upper end 19 and a lower end 21 of the production sleeve 18 are configured to slidably mount within production string fittings 23 , for shifting of the production sleeve 18 by means of longitudinal movement relative to the completion string 12 . It will be seen that shifting of the production sleeve 18 could be rotational relative to the completion string 12 , rather than longitudinal, if desired.
FIG. 2 shows a transverse section of the production sleeve 18 . One or more production fluid conduits 22 are arranged more or less radially from the center of the production sleeve 18 to its outer periphery. One or more injection fluid bypass channels 24 pass longitudinally through the production sleeve 18 , to ensure that injection fluid can bypass the production sleeve from an upper annulus to a lower annulus. A production fluid flow path 28 passes longitudinally through the production sleeve 18 , ensuring the production fluid from a lower zone can pass to an upper zone. The production fluid conduits 22 are also in fluid flow communication with the production fluid flow path 28 .
FIG. 1 shows only one of the production fluid conduits 22 , and only one of the bypass channels 24 . However, it can be seen that, regardless of the position of the production sleeve 18 , an injection fluid flow path exists through the production sleeve 18 as indicated by the arrow labeled IF. Further, the injection fluid flow path continues through bypass channels 26 in the centralizing rings 16 . This allows injection fluid pumped downhole in the annulus between the completion string 12 and the production string 14 to flow completely through the production unit 10 from an upper zone to a lower zone, regardless of the position of the production sleeve 18 .
It also can be seen that, regardless of the position of the production sleeve 18 , production fluid can flow through the production fluid flow path 28 in the production sleeve 18 as indicated by the arrow labeled PF. Further, production fluid can flow through the center of the centralizing rings 16 , in the production fluid flow path 28 in the production string 14 . This allows production fluid to flow completely through the production unit 10 from a lower zone to an upper zone, regardless of the position of the production sleeve 18 .
Shifting of the production sleeve 18 could be accomplished by several different means, such as hydraulically, mechanically, or electrically, or a combination thereof. FIG. 1 shows one embodiment of a hydraulic shifting means, including an upper hydraulic duct 30 , a lower hydraulic duct 32 , and a two directional hydraulic chamber 34 . A shoulder on the production sleeve 18 can be positioned in the hydraulic chamber 34 . When the upper duct 30 is pressurized, the production sleeve 18 is shifted downwardly, or to the right in the figure. When the lower duct 32 is pressurized, the production sleeve 18 is shifted upwardly, or to the left in the figure. A similar hydraulic assembly could be used to rotationally shift the production sleeve 18 , if preferred. Further, an electrical solenoid mechanism could accomplish either longitudinal or rotational shifting, if preferred. Still further, other known shifting mechanisms could be used to shift the production sleeve 18 .
A formation fluid inlet port 20 is formed through the wall of the completion string 12 . The production fluid conduit 22 in the production sleeve 18 does not align with the inlet port 20 , when the production sleeve 18 is in the upper position shown in FIG. 1 . This isolates the inlet port 20 , preventing flow of formation fluid through the inlet port 20 , through the production fluid conduit 22 , and into the production fluid flow path 28 . FIG. 3 illustrates that the production sleeve 18 can be selectively shifted downwardly when desired, to align the production fluid conduit 22 with the inlet port 20 . This establishes flow of formation fluid through the inlet port 20 , through the production fluid conduit 22 , and into the production fluid flow path 28 .
As shown in FIG. 4, an injection unit 40 used as part of the present invention includes the completion string 12 , the production string 14 , one or more centralizing rings 16 , and a longitudinally shiftable injection sleeve 42 . This injection unit also can be placed in a well bore, aligned with a selected zone of the downhole formation. As will be seen, the injection unit 40 can be associated with a production unit 10 for a particular zone of the formation, to facilitate selective production from, or injection into, the zone. An upper end 43 and a lower end 45 of the injection sleeve 42 are configured to slidably mount within production string fittings 23 , for shifting of the injection sleeve 42 by means of longitudinal movement relative to the completion string 12 . It will be seen that shifting of the injection sleeve 42 could be rotational relative to the completion string 12 , rather than longitudinal, if desired.
FIG. 5 shows a transverse section of the injection sleeve 42 . One or more injection fluid conduits 46 are arranged at several locations, connecting the upper side of the injection sleeve 42 to its outer periphery. One or more injection fluid bypass channels 56 pass longitudinally through the injection sleeve 42 , to ensure that injection fluid can bypass the injection sleeve from an upper annulus to a lower annulus. A production fluid flow path 28 passes longitudinally through the injection sleeve 42 , ensuring the production fluid from a lower zone can pass to an upper zone.
FIG. 4 shows only one of the injection fluid conduits 46 , and only one of the bypass channels 56 . However, it can be seen that, regardless of the position of the injection sleeve 42 , an injection fluid flow path exists through the injection sleeve 42 as indicated by the arrow labeled IF. Further, the injection fluid flow path continues through bypass channels 26 in the centralizing rings 16 . This allows injection fluid pumped downhole in the annulus between the completion string 12 and the production string 14 to flow completely through the injection unit 40 from an upper zone to a lower zone, regardless of the position of the injection sleeve 42 .
It also can be seen that, regardless of the position of the injection sleeve 42 , production fluid can flow through the production fluid flow path 28 in the injection sleeve 42 as indicated by the arrow labeled PF. Further, production fluid can flow through the center of the centralizing rings 16 , in the production fluid flow path 28 in the production string 14 . This allows production fluid to flow completely through the injection unit 40 from a lower zone to an upper zone, regardless of the position of the injection sleeve 42 .
Shifting of the injection sleeve 42 could be accomplished by several different means, such as hydraulically, mechanically, or electrically, or a combination thereof. FIG. 4 shows one embodiment of a hydraulic shifting means, including an upper hydraulic duct 50 , a lower hydraulic duct 52 , and a two directional hydraulic chamber 54 . A shoulder on the injection sleeve 42 can be positioned in the hydraulic chamber 54 . When the upper duct 50 is pressurized, the injection sleeve 42 is shifted downwardly, or to the right in the figure. When the lower duct 52 is pressurized, the injection sleeve 42 is shifted upwardly, or to the left in the figure. A similar hydraulic assembly could be used to rotationally shift the injection sleeve 42 , if preferred. Further, an electrical solenoid mechanism could accomplish either longitudinal or rotational shifting, if preferred. Still further, other known shifting mechanisms could be used to shift the injection sleeve 42 .
An injection fluid outlet port 44 is formed through the wall of the completion string 12 . The injection fluid conduit 46 in the injection sleeve 42 does not align with the outlet port 44 , when the injection sleeve 42 is in the upper position shown in FIG. 4 . This isolates the outlet port 44 , preventing flow of injection fluid through the injection fluid conduit 46 , through the outlet port 44 , and into the formation. FIG. 6 illustrates that the injection sleeve 42 can be selectively shifted downwardly when desired, to align the injection fluid conduit 46 with the outlet port 44 . This establishes flow of injection fluid through the injection fluid conduit 46 , through the outlet port 44 , and into the formation.
FIGS. 7, 8 , and 9 illustrate the pairing of a production unit 10 with an injection unit 40 to form a completion unit, which can be placed downhole in a well bore, aligned with a selected zone of the formation. Packers 58 can be used to isolate adjacent zones. FIGS. 7, 8 , and 9 also illustrate a variation of the configuration of the completion string and the production string, when it is desired to pump injection fluid into the annulus surrounding the completion string, rather than pumping injection fluid into an annulus between the completion string and the production string, as in the embodiments shown in FIGS. 1, 3 , 4 , and 6 . In either embodiment, however, production fluid flow and injection fluid flow can be controlled as shown in FIGS. 7, 8 , and 9 .
FIG. 7 shows the production sleeve 18 in its lower position, and the injection sleeve 42 in its upper position. This establishes flow of formation fluid from the zone into the production fluid flow path 28 , while preventing flow of injection fluid into the zone. FIG. 8 shows the production sleeve 18 in its upper position, and the injection sleeve 42 in its upper position. This prevents flow of formation fluid from the zone into the production fluid flow path 28 , while also preventing flow of injection fluid into the zone. FIG. 9 shows the production sleeve 18 in its upper position, and the injection sleeve 42 in its lower position. This prevents flow of formation fluid from the zone into the production fluid flow path 28 , while establishing flow of injection fluid into the zone.
It can be seen that, by selective shifting of the production sleeves 18 and the injection sleeves 42 in multiple zones, one or more zones can produce formation fluid, simultaneous with the injection of fluid into one or more other zones.
While the particular invention as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages hereinbefore stated, it is to be understood that this disclosure is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended other than as described in the appended claims.
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A method and apparatus for simultaneously producing fluid from one or more zones of an oil or gas well, while injecting fluid into one or more other zones of the well, and for converting a depleted production zone into an injection zone, by remotely shifting sleeves in the apparatus to selectively align inlet and outlet ports with production and injection flow paths, respectively. A production string is provided within a completion string; the completion string has inlet and outlet ports to the well bore. One or more production sleeves have production conduits which can be selectively aligned with inlet ports by shifting the production sleeves. One or more injection sleeves have injection conduits which can be selectively aligned with outlet ports by shifting the injection sleeves.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent application is a continuation-in-part of and claims the benefit of priority to U.S. patent application Ser. No. 13/152,919, filed Jun. 3, 2011, which in turn claims the benefit of priority to U.S. provisional patent application Ser. No. 61/351,503, filed Jun. 4, 2010. The disclosure of each of the aforementioned patent applications is incorporated by reference herein in its entirety for any purpose whatsoever.
BACKGROUND
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to a cosmetic applicator and in particular, relate to a cosmetic applicator comprising of at least two molded applicator parts that are interlinked such that a non-zero angle is formed at an interface of the two molded applicator parts with respect to a centerline of the applicator. The cosmetic applicator of present invention is able to imitate the twirl of the wrist during application and thereby provides a better application. The cosmetic applicator of the present invention may be used for cosmetic and care applications such as on skin or on keratinous fibers in the area of mascara application, lash care, nail care, mascara removal, lip application, hair coloring and hair repair etc.
[0004] 2. Description of the Related Art
[0005] Conventionally, applicators include a stem, at one end of which is connected an applicator head and at the other end is provided a handle for gripping. Cosmetic applicator such as a mascara applicator deposits and distributes the product i.e. mascara all over the lashes. As mascara, inherently, is a product that is difficult to apply because of the sensitive target area of application, it is desirable that no clumping of product occurs and the lashes are separated and combed evenly. However, all the desired effects are not possible with a single mascara brush. This is because the eyelashes are soft, flexible, delicate and in close proximity to very sensitive eye tissue. Further, a user requires twisting and/or turning his/her hands in a particular manner to achieve a particular desired effect on the lashes and not all users are adept in being able to gradually twist their wrist along with the outward stroke of application on the lashes. Continuous innovations in this area are being made to provide the user with an applicator that gives him/her a better application and makes the whole application effortless to the consumer.
[0006] Mascara brushes that rotate during application are known. U.S. Pat. No. 4,056,111 describes a motor-driven, rotatable mascara brush. U.S. Pat. No. 4,397,326 describes a non-motorized mascara brush, the head of which is free to rotate and does so when the brush head contacts the eyelashes during application. It is the act of brushing that causes the rotation. However, the usage of these applicators is cumbersome for the user and some users find it frightening to use the battery-powered applicators.
[0007] There have also been innovations in the area of mascara applicators wherein the applicator is made in two parts having two different kinds of tines. U.S. Pat. No. 7,231,926 to RND Group LLC discloses a mascara brush, wherein a single brush rod of the mascara brush is formed with both an application brush part with an application portion for applying a mascara liquid to the eyelashes and an arrangement brush part with a comb for arranging the eyelashes in order to simultaneously perform the application of the mascara liquid and arrangement of the eyelashes.
[0008] United States Patent Application No. 20090193602 to Dumler, Nobert, discloses a cosmetic brush that has a multiplicity of tines that project out from a main body. A portion of the tines forms first tines that are integrally connected to the main body, wherein the first tines consist of the same first plastic material as the main body. Another portion of the tines forms second tines that are connected to the main body differently than the first tines. The main body has a main body wall provided with through holes, and the second tines are integrally connected to each other by means of a connecting member disposed on the side of the main body wall facing away from the second tines, and extend through the through holes, wherein the main body and the connecting member are immediately adjacent to each other and adhesively connected to each other. The main body is designed in the form of a hollow cylinder and integrally connected to a handle extension piece. The second tines are softer than the first tines.
[0009] United States Patent Application No. 20100083979 to RND group discloses a mascara brush that includes a bristle part for applying mascara to eyelashes, and a comb part for tidying the eyelashes. The bristle part and the comb part are integrally formed with a brush body through an injection molding process, such that the tines of the bristle part are thin and the comb teeth of the comb part are relatively thick.
[0010] If the product is applied using the aforementioned applicators then during application on the lashes the application brush would be followed subsequently by the comb part or vice versa and the user is expected to gradually blend the application with multiple such strokes, however, this creates a stark application.
[0011] It is found by the inventors of the present invention that an applicator if capable of imitating the twirling action of the hand results in better application of the product and therefore the user is provided with an even application and in case of mascara application there occurs no clumping as well as better separation of lashes. Further, it is desirable that if the applicator is containing two different kinds of tines or application surfaces, then the application becomes much more easier and relieves the user of using two different applicator one after the other to get a desired application. Therefore, there is a need in the art for an applicator that is able to imitate the twirling action of the wrist of the user during application thereby giving the desired effect without the user having to put in any effort.
SUMMARY
[0012] The present invention generally relates to a cosmetic applicator. More particularly, the invention relates to a cosmetic applicator comprising of at least two applicator parts that are interlinked such that a non-zero angle is formed at an interface of the two molded applicator parts with respect to a centerline of the applicator wherein the at least two applicator parts comprise a base body.
[0013] According to yet another embodiment of the invention the cosmetic applicator imitates the twirl of the wrist during application and thereby provides an expert like application even by a novice at make-up skills.
[0014] According to yet another embodiment of the present invention, there is provided an applicator wherein the at least two applicator parts comprise of two different materials. As an exemplary embodiment, in a mascara applicator, the at least two applicator parts may comprise a hard comb part and a soft bristle part.
[0015] According to yet another embodiment of the invention the base body of one of the at least two applicator parts has a cavity into which is interlocked a complementary profiled base body of the other applicator part. The cavity is such that the central longitudinal axis of the cavity lies away at a non-zero angle from the central longitudinal axis of the base body. There is formed a non-zero angle X between the central longitudinal axis of the cavity of the at least one of the two applicator parts and the central longitudinal axis of the base body of the other applicator part interlocked into said cavity. Therefore, the at least two applicator parts are linked at a non-zero angle.
[0016] According to yet another embodiment of the invention the at least two applicator parts comprise an outer applicator part and an inner applicator part. The base body of the outer applicator part of a mascara applicator has a hollow cavity with the tines arranged on its circumference. The cavity is such that the central longitudinal axis of the cavity lies away at an angle from the central longitudinal axis of the base body. There is formed a non-zero angle X between the central longitudinal axis of the cavity of the outer applicator part and the central longitudinal axis of the base body of the inner applicator part. Further, the inner applicator part has a base body wherein the tines are arranged around the circumference of the base body and wherein the structure of the base body the inner applicator part is complimentary to the hollow cavity if the outer applicator part so that the inner applicator part fills the cavity of the outer applicator part thereby making a full applicator. Therefore, the two applicator parts are linked at a non-zero angle.
[0017] According to yet another embodiment of the invention there is provided a cosmetic applicator assembly comprising of a gripping member, a stem and an applicator as described above. The stem has a proximal end and a distal end. The proximal end of the stem is connected to the gripping member while the applicator is connected to the distal end of the stem.
[0018] In accordance with yet another embodiment of the invention the base body in a mascara applicator may have a plurality of tines extending from its circumference. According to an exemplary embodiment of the invention the tines on the base body of each part may extend out in parallel longitudinal rows. Alternatively the tines may extend radially parallel or in any other suitable arrangement. The at least two applicator parts comprise an outer applicator part and an inner applicator part. According to an embodiment of the invention the tines on the base body of the at least two applicator parts may be arranged in any suitable manner. Further, the tines may have any suitable length, width and density.
[0019] According to yet another embodiment of the present invention, during usage of the applicator due to the at least two applicator parts being interlinked at a non-zero angle, the set of tines from the two part applicator parts do not necessarily follow one behind the other on all the lashes at one go and the follow through is interspersed due to the twist, thus causing blending of the application by the two parts in the single stroke.
[0020] According to yet another embodiment of the invention the base body of said at least two applicator parts of the applicator is a doe foot. Cosmetic applicator of the present invention may be used for cosmetic and care applications on skin or on keratinous fibers such as for mascara application, hair coloring, lip application etc.
[0021] According to yet another embodiment of the present invention, an applicator for applying product is provided that includes a molded first applicator part having a first molded surface and a molded second applicator part having a second molded surface defined thereon. The molded second applicator part is coupled to the molded first applicator part to define at least a portion of an applicator tip. The first molded surface and the second molded surface of the molded first applicator part and the molded second applicator part respectively meets at an interface defined on an outer surface of the applicator tip. The interface has an orientation rotated about a center line extending axially through the applicator tip.
[0022] According to yet another embodiment of the present invention, an applicator for applying product is provided that includes a molded first applicator part having a first molded surface and a molded second applicator part having a second molded surface defined thereon. The molded second applicator part is coupled to the molded first applicator part to define at least a portion of an applicator tip. The coupling between the molded first and second applicator parts is such that a product delivery passageway is defined between said applicator parts via which the product or the composition can pass through. Further in the embodiment under consideration, the first molded surface and the second molded surface of the molded first and second applicator parts respectively meets at an interface defined on an outer surface of the applicator tip, wherein the interface has an orientation rotated about a center line extending axially through the applicator tip.
[0023] According to yet another embodiment of the present invention, an applicator for applying product is provided that includes a molded first applicator part having a first molded surface and a molded second applicator part having a second molded surface defined thereon. The molded second applicator part is coupled to the first applicator part to define at least a portion of an applicator tip. The first molded surface and the second molded surface of the molded first and the second applicator parts respectively meets at an interface defined on an outer surface of the applicator tip. Further in the embodiment under consideration, an aperture is formed through at the interface to define a product delivery passageway via which the product/composition can pass through the applicator. The interface has as an orientation rotated about a center line extending axially through the applicator tip.
[0024] According to yet another embodiment of the present invention, an applicator for applying product is provided that includes a molded first applicator part having a first molded surface and a molded second applicator part having a second molded surface defined thereon. The molded second applicator part is coupled to the molded first applicator part to define at least a portion of an applicator tip. The first molded surface and the second molded surface of the molded first and the second applicator parts respectively meets at an interface defined on an outer surface of the applicator tip and at least one projection is formed on the interface of the first molded surface and the second molded surface. The at least one projection on the interface is partially made of a projection molded out from the first molded surface and partially made of a projection molded out from the second molded surface. Accordingly, the at least one projection on the interface is partially made of a material of the first molded surface of the outer applicator part and partially made of a material of the second molded surface of the inner applicator part. According to a preferred embodiment of the present invention, a row of projections is formed at the interface of the first molded surface and second molded surface such that each projection in said row is partially made of the material of the first molded surface of the outer applicator part and partially made of the material of the second molded surface of the inner applicator part. The first and second molded surfaces may be molded from different materials. The different materials of the first and second molded surfaces may have properties that are attractive and non-attractive to mascara, have different hardness, have different tactile feel, have different color, have different chemical nature, have different magnetic property, have different temperature property and/or other property.
[0025] According to yet another embodiment of the present invention, an applicator for applying product is provided that includes a molded first applicator part having a first molded surface and a molded second applicator part having a second molded surface defined thereon. The molded second applicator part is coupled to the molded first applicator part to define at least a portion of an applicator tip. The first molded surface and the second molded surface of the molded first and the second applicator parts respectively meets at an interface defined on an outer surface of the applicator tip. Further in the embodiment under consideration, the applicator tip comprises at least one longitudinal groove extending from a distal end of the applicator tip to proximal end of the applicator tip. Preferably, the applicator tip comprises a plurality of longitudinal grooves extending from a distal end of the applicator tip to proximal end of the applicator tip. The applicator tip may have a cross section such as a truncated star cross section or plus-sign shaped cross-section and the like. The first molded surface and the second molded surface are aligned such that the outer surface comprises a longitudinal groove at the interface of the first molded surface and the second molded surface. Further, each of the first and second molded surfaces may have at least one longitudinal groove defined thereon. According to an embodiment of the present invention, the plurality of longitudinal grooves of the applicator may be V-shaped or U-shaped. The plurality of longitudinal grooves may be arranged in a symmetrical or asymmetrical configuration on the applicator tip. In yet another embodiment, the applicator tip may comprise the at least one longitudinal groove only at the interface of the first molded surface and the second molded surface. Further, the applicator tip is provided with a plurality of projections arranged in longitudinal rows. Preferably, the projections from the first molded surface are alternately disposed to form at least one longitudinal row of projections on the outer applicator part. Similarly, the projections from the second molded surface are alternately disposed to form at least one longitudinal row of projections on the inner applicator part. The projections from the first molded surface are integrally molded with the first molded surface and projections from the second molded surface are integrally molded with the second molded surface. The projections from the first molded surface have the same material property as the first molded surface and projections from the second molded surface have the same material property as the second molded surface.
[0026] According to yet another embodiment of the present invention, an applicator for applying product is provided that includes a molded first applicator part having a first molded surface and a molded second applicator part having a second molded surface defined thereon. The molded second applicator part is coupled to the molded first applicator part to define at least a portion of an applicator tip. The first molded surface and the second molded surface of the molded first and the second applicator parts respectively meets at an interface defined on an outer surface of the applicator tip. The applicator tip includes at least one row of projections consisting of alternately disposed projections at the interface of the two molded surfaces such that projections from the first molded surface alternate with the projections from the second molded surface in the row of projections at the interface. The projections from the first molded surface are integrally molded with the first molded surface and projections from the second molded surface are integrally molded with the second molded surface. The outer and inner applicator parts may be molded from different materials. The different materials of the first and second molded surfaces may have properties that are attractive and non-attractive to mascara, have different hardness, have different tactile feel, have different color, have different chemical nature, have different magnetic property, have different temperature property and/or other property.
[0027] In yet another embodiment of the invention, an applicator assembly is provided that includes an applicator coupled to a gripping member by a stem. The applicator includes at least two molded applicator parts that are interlinked such that a non-zero angle is formed at an interface of the two applicator parts with respect to a centerline of the applicator.
[0028] These and further aspects which will be apparent to the expert of the art are attained by a cosmetic applicator in accordance with the main claim.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0030] FIG. 1 illustrates an isometric view of the applicator according to one embodiment of the invention.
[0031] FIG. 2 illustrates a front view of the applicator of FIG. 1 .
[0032] FIG. 3 illustrates a sectional view of the applicator of FIG. 2 .
[0033] FIG. 4 illustrates a sectional view of the applicator of FIG. 2 taken along section line 4 - 4 of FIGS. 2 , 3 .
[0034] FIG. 5 illustrates the outer applicator part of the applicator of FIG. 1 .
[0035] FIG. 6 illustrates the inner applicator part of the applicator of FIG. 1 .
[0036] FIG. 7 illustrates the isometric view of an applicator assembly comprising the applicator according to an embodiment of the present invention.
[0037] FIG. 8 illustrates a sectional view of the applicator according to another embodiment of the present invention.
[0038] FIG. 9 illustrates a sectional view of the applicator according to yet another embodiment of the present invention.
[0039] FIG. 10 illustrates a sectional view of an applicator according to yet another embodiment of the present invention.
[0040] FIG. 11A illustrates a front view of an applicator according to yet another embodiment of the present invention.
[0041] FIG. 11B illustrates a sectional view of the applicator of FIG. 11A .
[0042] FIG. 12 illustrates a sectional view of the applicator of FIG. 11A taken along line A-A.
[0043] FIG. 13A illustrates a front view of the outer applicator part of the applicator of FIG. 11A .
[0044] FIG. 13B illustrates a perspective view of the outer applicator part of the applicator of FIG. 11A .
[0045] FIG. 14A illustrates a front view of the inner applicator part of the applicator of FIG. 11A .
[0046] FIG. 14B illustrates a perspective view of the inner applicator part of the applicator of FIG. 11A .
[0047] FIG. 15 illustrates a sectional view of an applicator according to yet another embodiment of the present invention.
[0048] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the Figures. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION
[0049] The applicator according to one embodiment of the present invention is shown in FIGS. 1 to 6 .
[0050] FIG. 1 is one embodiment of the present invention showing an isometric view of a molded applicator 100 . The applicator 100 is elongated along a center line 102 (e.g., the centre longitudinal axis), extending from proximate end 104 to a distal end 106 . The applicator 100 includes an applicator tip 108 separated by a base 110 from a mounting portion 112 . A portion of the center line 102 extending through the base 110 and mounting portion 112 may be linear, while a portion of the center line 102 extending through the applicator tip 108 may be linear, curved or have another geometry. In the embodiment depicted in FIG. 1 , the center line 102 passes linearly through the base 110 , applicator tip 108 and mounting portion 112 .
[0051] FIG. 2 is a front view of the applicator 100 illustrating the applicator tip 108 in greater detail. The applicator tip 108 is elongated (in the y-direction) and extends from the base 110 to the distal end 106 of the applicator 100 . The shape of the elongated applicator tip 108 may be substantially cylindrical in form, but may optionally have a sectional profile (in the z/x plane) which is other than circular, for example, oval or polygonal, among other shapes. In the embodiment depicted in FIG. 2 , the elongated applicator tip 108 has a cylindrical form.
[0052] The applicator tip 108 has an outer surface 202 that is formed from at least two surfaces formed from molded materials, shown in FIG. 2 as a first molded surface 206 and a second molded surface 208 . The first and second molded surfaces 206 , 208 may be aligned such that the outer surface 202 is substantially smooth and contiguous across an interface 204 of the surfaces 206 , 208 . The interface 204 of the surfaces 206 , 208 is elongated (in the y-direction) and is rotated about the center line 102 of the applicator tip 108 . The rotated interface 204 of the surfaces 206 , 208 may define a twist, helix or other non-linear form. For example, at least one of the first and second molded surfaces 206 , 208 rotate in the z/x plane as the surfaces 206 , 208 extend from the base 110 toward the distal end 106 . In this manner, at least one of the first and second molded surfaces 206 , 208 has a helical form about the center line 102 . In the embodiment depicted in FIG. 2 , both surfaces 206 , 208 have a congruent helical form about the center line 102 such that the interface 204 of the surfaces 206 , 208 form a non-zero angle (shown by reference numeral 214 ) relative to the center line 102 . In one embodiment, the non-zero angle 214 is about 55 to about 65 degrees, such as about 60 degrees. In other embodiments, the non-zero angle 214 may be greater than or less than 60 degrees. Alternatively, the molded surfaces 206 , 208 may be elongated polygons such that the interface 204 , although linear, still rotates about the centerline 102 .
[0053] The first and second molded surfaces 206 , 208 may also be fabricated from materials having different properties. The first molded surface 206 is fabricated from a material which is softer than a material from which the second molded surface 208 is fabricated. In one embodiment, the first molded surface 206 is fabricated from a material having a hardness of less than about 80 Shore D scale (ShD). In another embodiment, the second molded surface 208 is fabricated from a material having a hardness of greater than about 20 Shore D scale (ShD). It is also contemplated that the material of the first molded surface 206 may be harder than the material of the second molded surface 208 . The different materials of the first and second molded surfaces 206 , 208 may have properties that are attractive and non-attractive to mascara, have different stiffness, have different tactile feel, have different color, have different chemical nature, have different magnetic property, have different temperature property and/or other property. The combination of the different materials utilized for the first and second molded surfaces 206 , 208 , along with the rotational or twisting orientation of the surfaces 206 , 208 , allow the applicator 100 to mimic the twirl of the wrist during mascara application and thereby provides an expert like application even by a novice at make-up skills. Moreover, the hard material has been found to provide separation of the lashes during the application of mascara, while the softer material provides lift and volume. Thus, the unique twist of the hard and soft surfaces allows the softer surface to be followed by the harder surface so that mascara is applied to the lash in a manner that separates lifts and volumizes without expert manipulation of the applicator 100 .
[0054] The first and second molded surfaces 206 , 208 may also include a plurality of projections 216 . The projections 216 may be attractive projections, and non-attractive projections, discs, and brush tines, among other properties and geometries. The projections 216 , when present, may extend radially outward from the outer surface 202 . In one embodiment, the projections 216 extend radially outward in a direction perpendicular to the outer surface 202 .
[0055] In the embodiment depicted in FIG. 2 , projections 216 from the first molded surface 206 form at least one longitudinal (i.e., substantially aligned with the center line 102 ) row of first brushes 210 while projections 216 from the second molded surface 208 form at least one longitudinal row of second brushes 212 . The projections 216 forming the row of first brushes 210 may be integrally molded with the first molded surface 206 , such that the rows of first brushes 210 have the same material property as the first molded surface 206 . Likewise, the projections 216 forming the row of second brushes 212 may be integrally molded with the second molded surface 208 , such that the rows of second brushes 212 have the same material property as the second molded surface 208 . In this configuration, a substantially linear movement of the applicator 100 even without substantial rotation will engage the lash with rows of brushes 210 , 212 having alternating physical properties, thereby enhancing the mimic of the twirl of the wrist during application. It is also contemplated that the material of the projections 216 may be different between rows, different within a row, and/or different than the material of the surface 206 , 208 from which the projections 216 extend.
[0056] In one embodiment, the projections 216 forming each row of brushes 210 , 212 are aligned and extend substantially perpendicular to the outer surface 202 . The projections 216 forming the first row of brushes 210 may be congruent to the projections 216 forming the second row of brushes 212 . In the embodiment depicted in FIG. 2 , the first molded surface 206 includes projections 216 forming the two congruent helical rows of defining two first rows of brushes 210 , while the second molded surface 208 includes projections 216 forming the two congruent helical rows of defining two second rows of brushes 212 , wherein the rows of brushes extending from the first molded surface 206 are congruent with the rows of brushes extending from the second molded surface 208 . Thus, the rows of brushes 210 , 212 may define congruent rows orient at a non-zero angle relative to the center line 102 of the applicator 100 , for example as illustrated by the angle 214 shown in FIG. 2 .
[0057] FIGS. 3-4 are sectional views of the applicator 100 . The applicator 100 includes an outer applicator part 302 and an inner applicator part 304 . The applicator parts 302 , 304 are molded from different polymers or two polymers having different physical properties. The materials suitable for forming the applicator parts 302 , 304 (i.e., and consequently the surfaces 206 , 208 ) include porous rubber, non-porous rubber, fabric mesh, felt material, foamed polymers, sponge material, thermoplastic, thermoplastic elastomer (TPE), metal and its composites, ceramic, nylon, or any other suitable material.
[0058] The outer applicator part 302 comprises of a base body 306 that has a hollow cavity 308 , and on the outer circumference of the base body 306 is defined by the first molded surface 206 , which in one embodiment, include projections 216 arranged as a plurality of tines 310 extending out from said base body 306 . The base body 306 includes at least one elongated window 316 that exposes the hollow cavity 308 through the first molded surface 206 .
[0059] The inner applicator part 304 has a base body 312 which is complimentary and snug fits within the hollow cavity 308 of the outer applicator part 302 . The base body 312 of the inner applicator part 304 has an outer circumference defined by the second molded surface 208 , which in one embodiment include projections 216 arranged as a plurality of tines 314 extending out from said base body 312 . The second molded surface 208 of the base body 312 extends through the window 316 of the base body 306 such that the first molded surface 206 and second molded surface 208 align to define the outer surface 202 of the applicator 100 .
[0060] Further, the applicator parts 302 , 304 may be suitably connected with each other to expose the rows of projections 216 of each of the applicator parts in a suitable arrangement. As shown, the applicator parts 302 , 304 are so arranged to expose the projections 216 of each of the applicator parts 302 , 304 in a common x-z plane. Alternatively, adjacent projections 216 in each of the applicator parts 302 , 304 may be in different x-z planes.
[0061] FIG. 5 is a front view of one embodiment of the outer applicator part 302 . In the embodiment of FIG. 5 , the outer applicator part 302 includes two elongated windows 316 arranged in a congruent helical orientation about the center line 102 . Thus, the two windows 316 may be congruent helixes and be oriented at a non-zero angle relative to the center line 102 of the applicator 100 , for example as illustrated by the angle 214 shown in FIG. 2 .
[0062] The outer applicator part 302 also includes one or more engagement features 502 , such as a groove or ridge, extending outward from the base body 306 to facilitate coupling the applicator 100 to a stem of an applicator assembly, as discussed further below.
[0063] FIG. 6 is a perspective view of the inner applicator part 304 . In the embodiment of FIG. 6 , the base body 312 includes two ridges 602 extending radially from a central rod 604 . The two ridges 602 twist about the central rod 604 in a helical orientation that mates with and extends through the helical windows 316 of the outer applicator part 302 as shown in FIG. 4 . Thus, the two ridges 602 match the orientation of the windows 316 and are thereby oriented a non-zero angle relative to the center line 102 of the applicator 100 , for example as illustrated by the angle 214 shown in FIG. 2 . It is contemplated that the number of windows 316 and mating ridges 602 may vary.
[0064] The central rod 604 ends in a barb 606 like feature that is axially spaced from the ridges 602 . The barb 606 is orientated to allow the central rod 604 to pass through the hollow cavity 308 and exit the outer applicator part 302 at the proximate end 104 of the applicator 100 to lock the inner applicator part 304 within the outer applicator part 302 .
[0065] Returning to FIG. 2 and as discussed above, the plurality of projections 216 may be made of different materials so as to give multiple effects in a single application of mascara. The projections 216 extending from a respective surface 206 , 208 may be made of soft and hard materials or vice versa. Further, the projections 216 may be arranged on the surfaces 206 , 208 and inner applicator part 304 respectively in any suitable manner. Further, the projections 216 may have any suitable length, width/thickness and density.
[0066] FIG. 7 illustrates another embodiment of the present invention. As shown in the FIG. 7 , an applicator assembly 700 includes an applicator 100 as described above, a stem 702 and a gripping member 704 . The stem 702 has a proximal end 706 and a distal end 708 . The proximal end 706 of the stem 702 is connected to the gripping member 704 , while the applicator 100 is connected to the distal end 708 of the stem 702 . Although the applicator 100 may be connected to the distal end 708 of the stem 702 in any suitable manner, in the embodiment depicted in FIG. 7 the distal end 708 of the stem 702 includes a hollow bore 710 which receives the mounting portion 112 of the applicator 100 . The hollow bore 710 includes one or more undercuts or grooves 712 which engage with the engagement features 502 of the outer applicator part 302 to secure the applicator 100 to the stem 702 . Alternatively, the applicator 100 may be connected to the distal end 708 utilizing plastic welding techniques, adhesives or other suitable fastening technique.
[0067] FIG. 8 illustrates another embodiment of the present invention. The applicator 800 is substantially similar to the applicator 100 described above, expect in that a product delivery passage/channel 802 is defined within the inner applicator part 304 of the applicator 800 via which the product/composition can pass through. Alternatively, the channel 802 in the applicator 800 via which the product can pass through may be defined within the outer applicator part 302 of the applicator 800 .
[0068] FIG. 9 illustrates another embodiment of an applicator 900 . The applicator 900 is substantially similar to the applicator 100 described above, except in that at least one aperture 902 is formed through the outer surface 202 of the applicator tip 108 that is formed from at least two surfaces formed from molded materials, as a first molded surface 206 and a second molded surface 208 . The first and second molded surfaces 206 , 208 may be aligned such that the outer surface 202 is substantially smooth and contiguous across an interface 204 of the surfaces 206 , 208 . The aperture 902 formed through at the outer surface 202 allows the product/composition to pass through the applicator 900 . It is also contemplated that a hole, a slot, and the like may be formed through at the outer surface 202 of the first and second molded surfaces 206 , 208 .
[0069] FIG. 10 illustrates a sectional view of an applicator 1000 according to yet another embodiment of the present invention. The applicator 1000 is substantially similar to the applicator 100 described above, except that, at least one projection 216 is formed on the interface 204 of the first molded surface 206 and the second molded surface 208 . According to a preferred embodiment of the present invention, a row 222 of projections 216 is formed at the interface 204 of the two molded surfaces 206 , 208 such that each projection 216 in the row 222 is a combination of a projection 216 a molded out from the first molded surface 206 and a projection 216 b molded out from the second molded surface 208 . Accordingly, each projection 216 in the row 222 is partially made of the material of the first molded surface 206 of the outer applicator part 302 and partially made of the material of the second molded surface 208 of the inner applicator part 304 . The projection 216 a molded out from the first molded surface 206 makes up 1-99% of each projection 216 in the row 222 and the projection 216 b molded out from the second molded surface 208 makes up the rest 99-1% of each projection 216 in the row 222 or vice versa. Further, all projections 216 in the row 222 are fabricated such that all of the projections 216 have same ratio of material of the first molded surface 206 to material of the second molded surface 208 . In an alternate embodiment of the present invention, the projections 216 in the row 222 may vary in their ratio of material of the first molded surface 206 to material of the second molded surface 208 . The first and second molded surfaces 206 , 208 may be fabricated from materials having different properties. In one embodiment, the first molded surface 206 is fabricated from a material which is softer than a material from which the second molded surface 208 is fabricated. In another embodiment, the first molded surface 206 is fabricated from a material which is harder than a material from which the second molded surface 208 is fabricated. The different materials of the first and second molded surfaces 206 , 208 may have properties that are attractive and non-attractive to mascara, have different stiffness, have different tactile feel, have different color, have different chemical nature, have different magnetic property, have different temperature property and/or other property.
[0070] FIG. 11A and FIG. 11B illustrates a front view and a sectional view of an applicator 1200 according to yet another embodiment of the present invention. FIG. 12 illustrates the sectional view of the applicator 1200 taken along line A-A of the applicator 1200 . As seen in FIGS. 11A to 12 , the applicator 1200 includes an outer applicator part 1210 having a first molded surface 1220 defined thereon; and an inner applicator part 1230 coupled to the outer applicator part 1210 to define at least a portion of an applicator tip 1250 . The inner applicator part 1230 has a second molded surface 1240 defined thereon. As seen in FIGS. 11A and 12 , the first molded surface 1220 and the second molded surface 1240 meet at an interface 1260 defined on an outer surface 1270 of the applicator tip 1250 . The interface 1260 of the first molded surface 1220 and the second molded surface 1240 have an orientation rotated about a center line 1020 extending axially through the applicator tip 1250 . The applicator tip 1250 includes at least one longitudinal groove, more preferably, a plurality of longitudinal grooves extending from a distal end of the applicator tip 1250 to proximal end of the applicator tip 1250 . The applicator tip 1250 has a truncated star cross section. The first molded surface 1220 has at least one longitudinal groove 1280 a formed thereon. Likewise, the second molded surface 1240 has at least one longitudinal groove 1280 b formed thereon. The first molded surface 1220 and the second molded surface 1240 are aligned such that the outer surface 1270 comprises a longitudinal groove 1280 c at the interface 1260 of the first molded surface 1220 and the second molded surface 1240 . In another embodiment, the applicator tip 1250 may comprise the longitudinal groove 1280 c only at the interface 1260 of the first molded surface 1220 and the second molded part 1240 . Further, the applicator tip 1250 includes a plurality of projections 1290 a , 1290 b arranged in longitudinal rows. The projections 1290 a from the first molded surface 1220 are alternately disposed to form at least one longitudinal (i.e., substantially aligned with the center line 1020 ) row 1310 of projections 1290 a on the outer applicator part 1210 . Similarly, the projections 1290 b from the second molded surface 1240 are alternately disposed to form at least one longitudinal row 1320 of projections 1290 b on the inner applicator part 1240 . The projections 1290 a forming the row 1310 are integrally molded with the first molded surface 1220 , such that the row 1310 of projections 1290 a have the same material property as the first molded surface 1220 . Likewise, the projections 1290 b forming the row 1320 are integrally molded with the second molded surface 1240 , such that the row 1320 of projections 1290 b have the same material property as the second molded surface 1240 .
[0071] In alternate embodiments, the applicator tip 1250 may have a cross section other than a truncated star cross section, such as plus-sign shaped cross-section and the like.
[0072] In alternate embodiments of the present invention, the longitudinal grooves 1280 a , 1280 b , 1280 c may be arranged in a symmetrical or asymmetrical configuration on the applicator tip 1250 .
[0073] In alternate embodiments of the present invention, the longitudinal grooves 1280 a , 1280 b , 1280 c may extend in the applicator tip over a longitudinal segment of the applicator tip.
[0074] In alternate embodiments of the present invention, the longitudinal grooves 1280 a , 1280 b , 1280 c may be of U-shape, V-shaped and the like.
[0075] In yet another alternate embodiment of the present invention, the at least one longitudinal groove 1280 a , 1280 b or 1280 c of the applicator tip 1250 may have at least one projection disposed therein, more preferably, may have a row of projections disposed therein.
[0076] FIG. 13A is a front view of the outer applicator part 1210 of the applicator 1200 and FIG. 13B is a perspective view of the outer applicator part 1210 of the applicator 1200 . The outer applicator part 1210 comprises of a base body 1330 that has a hollow cavity 1340 , and the outer surface of the base body 1330 is defined by the first molded surface 1220 . The base body 1330 includes at least one elongated window 1350 , more preferably, two elongated windows 1350 arranged in a congruent helical orientation about the center line 1020 and the windows 1350 expose the hollow cavity 1340 through the first molded surface 1220 . The two windows 1350 are oriented at a non-zero angle relative to the center line 1020 . The outer applicator part 1210 includes at least one longitudinal groove 1280 a on the first molded surface 1220 . Further, the first molded surface 1220 include a plurality of alternately disposed projections 1290 a forming a longitudinal row 1310 of projections 1290 a.
[0077] FIG. 14A is a front view of the inner applicator part 1230 of the applicator 1200 and FIG. 14B is a perspective view of the inner applicator part 1230 of the applicator 1200 . The inner applicator part 1230 has a base body 1360 which is complimentary and snug fits within the hollow cavity 1340 of the outer applicator part 1210 (as seen in FIG. 11B ). The base body 1360 of the inner applicator part 1230 has an outer circumference defined by the second molded surface 1240 . The base body 1360 of applicator 1200 includes at least one ridge, more preferably two ridges 1370 that extend radially from a central rod 1380 . The two ridges 1370 twist about the central rod 1380 in a helical orientation that mates with and extends through the helical windows 1350 of the outer applicator part 1210 (as shown in FIG. 12 ). Thus, the two ridges 1370 match the orientation of the windows 1350 of the outer applicator part 1210 and are thereby oriented at a non-zero angle relative to the center line 1020 of the applicator 1200 . The inner applicator part 1230 includes at least one longitudinal groove 1280 b on the second molded surface 1240 . Further, the second molded surface 1240 include a plurality of alternately disposed projections 1290 b forming a longitudinal row 1320 of projections 1290 b.
[0078] FIG. 15 is sectional view of an applicator 1300 according to yet another embodiment of the present invention. The applicator 1300 includes an outer applicator part 1210 having a first molded surface 1220 defined thereon; and an inner applicator part 1230 coupled to the outer applicator part 1210 . The inner applicator part 1230 has a second molded surface 1240 defined thereon. The applicator 1300 like applicator 1200 includes plurality of longitudinal grooves 1280 a and 1280 b on the first and second molded surfaces 1220 and 1240 respectively but does not include any longitudinal groove 1280 c at the interface 1260 of the two molded surfaces 1220 , 1240 . The applicator 1300 comprises at least one row 1310 having alternately disposed projections 1290 a on the first molded surface 1220 , at least one row 1320 having alternately disposed projections 1290 b on the second molded surface 1240 . Further, the applicator 1300 comprises at least one row 1330 having alternately disposed projections 1290 a , 1290 b at the interface 1260 of the two molded surfaces 1220 , 1240 such that projections 1290 a from the first molded surface 1220 alternate with the projections 1290 b from the second molded surface 1240 in the row 1330 at the interface 1260 . The projections 1290 a from the first molded surface 1220 are integrally molded with the first molded surface 1220 . Similarly, the projections 1290 b from the second molded surface 1240 are integrally molded with the second molded surface 1240 . The first and second molded surfaces 1220 , 1240 may be fabricated from materials having different properties. In one embodiment, the first molded surface 1220 is fabricated from a material which is softer than a material from which the second molded surface 1240 is fabricated. In another embodiment, the first molded surface 1220 is fabricated from a material which is harder than a material from which the second molded surface 1240 is fabricated. The different materials of the first and second molded surfaces 1220 , 1240 may have properties that are attractive and non-attractive to mascara, have different stiffness, have different tactile feel, have different color, have different chemical nature, have different magnetic property, have different temperature property and/or other property.
[0079] In one embodiment the first molded surface 206 , 1220 and second molded surface 208 , 1240 are separately molded, then assembled. In another embodiment, the first molded surface 206 , 1220 may be over molded on the second molded surface 208 , 1240 . It is contemplated that the applicator 100 , 800 , 900 , 1000 , 1200 , 1300 can be made by other fabrication techniques such as bi-injection, co-injection or sandwich molding technique and the like may be utilized.
[0080] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. Accordingly, the appended claims should be construed to encompass not only those forms and embodiments of the invention specifically described above, but to such other forms and embodiments as may be devised by those skilled in the art without departing from its true spirit and scope.
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The present invention generally relates to a cosmetic applicator and in particular, relate to a cosmetic applicator comprising of at least two molded applicator parts that are interlinked such that a non-zero angle is formed at an interface of the at least two molded applicator parts with respect to a centerline of the applicator. The cosmetic applicator of present invention imitates the twirl of the wrist during application and thereby provides a better application. The cosmetic applicator of the present invention may be used for cosmetic and care applications such as mascara application, hair coloring, lip application, etc.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority benefit of Taiwan application Ser. No. 87113032, filed Aug. 7, 1998, the full disclosure of which in incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and a structure of manufacturing an inductor in an monolithic circuit, and more particularly to a method and a structure of manufacturing an inductor with a high-quality factor and an air trench.
2. Description of the Related Art
The continuous miniaturization of integrated circuits (ICs) is a main trend in the semiconductor industry for the purpose of not only obtaining smaller sizes and lighter weights but also reducing manufacturing costs. Today, many digital circuits and analog circuits, such as complicated microprocessors and operational amplifiers, have been successfully mass produced into ICs by very large scale integrated (VLSI) technology. In general, the above-mentioned circuits include active devices, such as bipolar junction transistors (BJTs), field effect transistors (FETs) and diodes, and passive devices, such as resistors and capacitors.
However, miniaturization techniques have not been completely developed yet for certain circuits applied in specific areas, including, for example, radio frequency (FR) circuits, which are applied in communication equipment, such as cellular telephones (i.e., mobile telephones), cordless telephones, wireless modems and so on. Miniaturization of the RF circuits hinges on the ability to manufacture inductors with an appropriately high quality factor. Currently, the quality factor of inductors manufactured by semiconductor technology is less than 5 , which does not meet desirable requirements. Although certain low-resistance metals, such as gold, can be used to increase the quality factor, it cannot be implemented by the current semiconductor technology.
It is well know that the quality factor represents the qualities of produced inductors. It can be estimated by the following formula: Q = K ω L R s
wherein ω is angle frequency, L is inductance, and R S is series resistance. Under an ideal condition, the quality factor Q of a non-loss inductor ( that is, R=0) is approximately infinite. Even though it is impossible to manufacture the ideal inductor in the real world, an inductor with a high quality factor can be definitely obtained by decreasing the energy losses thereof.
Referring to FIG. 1, an equivalent circuit of a real inductor is shown. It can be considered that the real inductor consists of an ideal inductor L, a resistor R S and a capacitor C d , wherein the ideal inductor L and the resistor R S are connected to each other in series and then are coupled to the capacitor C d in parallel. Generally, the resistor R s of a spiral metal line used for forming the real inductor is considered to be a main factor in reducing the quality factor thereof. One way to resolve this problem is to widen the metal line. However, this increased the area occupied by the metal line and the parasitic capacitance C d that follows. It is obvious that the increased area is opposed to the miniaturization of the inductor. The parasitic capacitance decreases the self-resonance frequency of the inductor, which, as a result, limits the range of the operating frequency thereof. On the other hand, the quality factor Q is directly proportional to the angle frequency and is inversely proportional to the series resistor, so the metal line cannot be optionally widened.
SUMMARY OF THE INVENTION
In view of the above, an object of the invention is to provide a method and a structure of manufacturing an inductor with a high quality factor and an air trench in a monolithic circuit. The inductor manufactured by the invention has lower series resistance and a lower parasitic capacitance. Therefore, the inductor of the invention has lower energy losses, a higher quality factor and a higher operating frequency.
To attain the above-stated object, an inductor in a monolithic circuit according to the invention has the following structure. A plurality of spiral metal lines formed over a substrate. A plurality of dielectric layers, each of which is formed between two adjacent spiral metal lines. A plurality of via plugs formed in the dielectric layers to connect two adjacent spiral metal lines to each other. A spiral air trench formed along the spacing of the spiral metal lines in the dielectric layers. In such a structure having a plurality of spiral metal lines stacked on each other with the via plugs therebetween, the series resistance thereof is greatly decreased without widening the inductor. Moveover, air contained in the spiral air trench with a lower dielectric constant can efficiently reduce the parasitic capacitance of the inductor. Hence, the inductor manufactured based on the structure has a higher quality factor.
A method of manufacturing an inductor according to the invention comprises the following steps. A plurality of spiral metal lines aligned with each other is formed over a substrate. A plurality of dielectric layers, each of which is located between two adjacent spiral metal lines, is formed over the substrate. A via plug is formed in each dielectric layer to connect two adjacent spiral metal lines. An upper dielectric layer is formed over the spiral metal lines. A spiral air trench is formed in the dielectric layers along the spacing of the of the spiral metal lines.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood from the detailed description given hereinbelow and the accompanying drawings, which are given by way of illustration only, and thus do not limit the present invention, and wherein:
FIG. 1 is a schematic circuit diagram illustrating an equivalent circuit of a real inductor;
FIG. 2 is top view illustrating an inductor manufactured by a preferred embodiment of the invention;
FIGS. 3A-3H are cross-sectional views illustrating a method of manufacturing an inductor according to the preferred embodiment of the invention;
FIGS. 4A-4C are cross-sectional views illustrating another method of forming a spiral air trench after the step shown in FIG. 3E; and
FIGS. 5A-5C are cross-sectional views illustrating a further method of forming a spiral air trench after the step shown in FIG. 3 E.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 2 is a top view of an inductor manufactured by a preferred embodiment of the invention. In FIG. 2, an inductor 20 formed on a semiconductor substrate includes a spiral conductive line 22 . One end of the spiral conductive line 22 is electrically connected to a first bonding pad 26 via a first connective line 24 while the other end thereof is electrically connected to a second bonding pad 29 via a second connective line 28 . The bonding pads 26 and 29 are used to electrically connect other circuits. A spiral air trench 23 (indicated by a dash line) is formed along the gap of the spiral conductive line 22 to reduce the parasitic capacitance thereof and increase the quality factor thereof.
Referring to FIGS 3 A- 3 H, a method of manufacturing an inductor according to a preferred embodiment of the invention is shown. In FIG. 3A, a lower metal line 34 , such as an aluminum line is formed by sputtering and photolithography on an insulator 32 , such as a silicon oxide layer, which is deposited on a substrate 30 , such as a silicon substrate. The lower metal line 34 serves as a first connective line.
Referring to FIG. 3B, a lower dielectric layer 36 , such as a silicon oxide layer, is formed on the insulator 32 and the lower metal line 34 by, for example, chemical vapor deposition (CVD). It is then planarized by, for example, etch back or chemical mechanical polishing (CMP) to facilitate subsequent photolithography. The lower dielectric layer 36 is patterned to form via holes (not shown) by, for example, photolithography and etching until portions of the surface of the lower metal line 34 are exposed. Next, a metal layer (not shown), such as a tungsten layers, is formed over the substrate 30 by, for example, chemical vapor deposition; it completely fills the via holes to electrically connect the lower metal line 34 ( which serves as the first connective line). Then, part of the metal layer above the level of the lower dielectric layer 36 is removed by planarization form first via plugs 38 , such as tungsten plugs, by, for example, chemical mechanical polishing of etch back.
Referring to FIG. 3C, a first spiral metal line 40 a and a first metal line 40 b , such as a square spiral aluminum line and an aluminum line, are formed on the lower dielectric layer 36 by, for example sputtering and photolithography. As shown in FIG 3 C, the first metal line 40 b and the inner end of the spiral metal line 40 a are connected to the lower metal line 34 (i.e., the first connective line) via the first via plugs 38 .
Referring to FIG. 3D, a first dielectric layer 42 , such as a silicon oxide layer, is formed on the spiral metal line 40 a , the first metal line 40 b and the lower dielectric layer 36 by, for example, chemical vapor deposition. It is then planarized by, for example, etch back or chemical mechanical polishing to facilitate subsequent photolithography. Next, the first dielectric layer 42 is patterned to form via holes (not shown) by, for example, photolithography and etching, until the first spiral metal line 40 a and the first metal line 40 b are exposed. A metal layer (not shown), such as a tungsten layer, is formed over the substrate 30 and completely fills the via holes by, for example, chemical vapor deposition. Part of the metal layer above the level of the first dielectric layer 42 is removed to form second via plugs 44 and a third via plug 44 ′, such as tungsten plugs, in the via holes by, for example, chemical mechanical polishing or etch back, thereby connecting the spiral-shaped metal line 40 a and the first metal line 40 b , respectively.
Referring to FIG. 3E, the steps shown in FIGS. 3C and 3D are repeated to form a second spiral metal line 46 a on the second via holes 44 , a second metal line 46 b on the third via plug 44 ′, a second dielectric layer 48 on the first dielectric layer 42 , the second spiral metal line 46 a and the second metal line 46 b , fourth via plugs 50 on the second spiral metal line 46 b and a fifth via plug 50 ′ on the second spiral metal line 46 a . Therefore, a third spiral sluminum line 52 a , such as a square spiral metal line, is formed on the fourth via plugs 50 ; a third metal line 52 b , such as an aluminum layer is formed on the fifth via plug 50 ′; and a second connective line 52 c , such as an aluminum layer, is formed on the fourth via plug 50 just above the outer end of the second spiral metal line 46 a by, for example, sputtering, photolithography and etching. Moreover, the third metal line 52 b electrically connects the lower metal line 34 (i.e., the first connective line) and the first bonding pad 26 as shown in FIG. 2, while the second connective line 52 c is electrically connected to the second bonding pad 29 as shown in FIG. 2 .
Referring to FIG 3 F, an upper dielectric layer, consisting, for example, of a silicon oxide layer 54 and a silicon nitrite layer 56 , is formed on the third spiral metal line 52 b , the third metal line 52 b and the second connective line 52 c by, for example, chemical vapor deposition. Then, a positive photoresit 58 having a trench 60 just above the third metal line 52 b is formed on the silicon nitrite layer 56 by photolithography. Parts of the silicon oxide layer 54 and the silicon nitrite layer 56 just below the trench 60 are removed to expose the third metal line 52 b by etching for subsequently bonding.
Referring to FIG. 3G, the positive photresist 58 is removed. Next a positive photoresit 62 , having a spiral trench 64 aligned with the gaps of the third spiral metal line 52 a , the third metal line 52 b and the second connective line 52 c , is formed on the silicon nitrite layer 56 and the third metal line 52 b . The spiral trench 62 keeps an appropriate distance from the third spiral metal line 52 a by using an original mask for the formations of the spiral metal lines 40 a , 46 a and 52 a and by adjusting its exposure dose to create a photo bias during development. This step can save a one-mask cost. Referring to FIG. 3H, parts of the silicon nitrite layer 56 , the silicon oxide layer 54 and the dielectric layers 48 and 42 uncovered by the positive photoresist 62 are removed to expose the lower dielectric layer 36 by etching, thereby forming a spiral air trench 66 . Thus, the inductor according to the invention is completely manufactured.
Although the third metal line 52 b is first exposed, and then the spiral air trench 66 is formed, it is obvious, for those skilled in the art that the order of the above-stated two steps is exchangeable. That is, the spiral air trench 66 can be first formed before the third metal line 52 b is exposed. Moreover, to protect the sidewalls of the spiral air trench 66 , another silicon nitrite layer (not shown) can be formed on the inner surfaces thereof.
FIGS. 4A-4C show another method of forming an air trench after the step shown in FIG. 3 E. Referring to FIG 4 A, an oxide layer 68 is formed on the third spiral metal line 52 a , the third metal line 52 b , the second connective line 52 c and the second dielectric layer 48 by, for example chemical vapor deposition. Thereafter, a positive photoresist 70 , having a spiral trench 72 aligned with the spaced of the third spiral metal line 52 a , the third metal line 52 b and the second connective line 52 c ,is formed on the oxide layer 68 by photolithography. The spiral trench 72 keeps an appropriate distance from the third spiral metal line 52 a by using the original mask for the formations of the spiral metal line 40 a , 46 a and 52 a and by adjusting its exposure does to create a photo bias during development.
Referring to FIG. 4B, using the positive photoresist 70 as a mask, a spiral air trench 74 is formed in the oxide layer 68 and the dielectric layers 42 and 48 by etching. Then, a silicon nitride layer 76 , serving as a passivation, is formed on the oxide layer 68 and the inner surfaces of the spiral air trench 74 . Referring to FIG. 4C, pasts of the silicon nitride layer 76 and the oxide layer 68 just above the third metal line 52 b are removed to form a trench 78 and to expose the third metal line 52 b for subsequent bonding, by photolithography and etching. Thus an inductor of the invention is completely manufactured.
FIGS. 5A-5C show a further method of forming an air trench after the step of FIG. 3 E. Referring to FIG 5 A, an upper dielectric layer, consisting, for example, of a silicon oxide layer 80 and a silicon nitride layer 82 , is formed on the third spiral metal line 52 a , the third metal line 52 b and the second connective line 52 c by, for example, chemical vapor deposition. Then, a positive photoresist 84 , having a spiral trench 86 aligned with the spacing of the third spiral metal line 52 a , the third metal line 52 b and the second connective line 52 c , is formed on the silicon nitride layer 82 by photolithography. The spiral trench 86 keeps an appropriate distance from the third spiral metal line 52 a by using the original mask for the formations of the spiral metal lines 40 a , 46 a and 52 a and by adjusting its exposure does to create a photo bias during development.
Referring to FIG. 5B, with the photoresist 84 serving as a mask, an etching process is performed to form a spiral air trench 88 . The photoresist 84 is removed. Next, a silicon nitride layer 90 , serving as a passivation, is formed on the silicon nitride layer 82 and the inner surfaces of the spiral air trench 88 . Referring to FIG 5 C, parts of the silicon nitride layer 90 , silicon oxide layer 82 and silicon nitride layer 80 just above the third metal line 52 b are removed to form a trench 92 , thereby exposing the third metal line 52 b for subsequently bonding. Thus, an inductor according to the invention is completely manufactured.
As can been seen from FIG. 3H, 4 C or 5 C, an inductor with an air trench according to the invention at least comprises the substrate 30 ; the spiral metal lines 40 a , 46 a and 52 a , and the dielectric layers including the insulator 32 , the lower dielectric layer 36 , the dielectric layers 42 and 48 and the upper dielectric layer. Furthermore, a plurality of via plugs 38 , 44 , and 50 are formed in the lower dielectric layer 36 and the dielectric layers 42 and 48 respectively, to connect the metal lines 34 , 40 a , 46 a , and 52 a to each other. The spiral air trench 66 , 74 , or 88 is formed in the dielectric layers 42 and 48 . In addition, the inductor, which mainly includes the spiral metal line 40 a , 46 a and 52 a , has the first connective line 34 and the second connective line 52 c . A silicon nitride layer, serving as a passivation, is formed on the inner surfaces of the spiral air trench. Although the inductor is formed by 4 metal lines (including 3 spiral metal lines) and a plurality of via plug, wherein there are only 3 turns for each spiral metal line, it is well known by those skilled in the art that the number of metal lines of the inductor and the number of the turns for each spiral metal line are not limited by the embodiment at all.
Since the inductor according to the invention includes 3 spiral metal lines and a plurality of via plugs, the cross-sectional area of the inductor is increased, resulting in a decrease in the resistance thereof. Moreover, because no additional area is taken by the structure, it is much better for integration. The spiral air trench filled with air which has a lower dielectric constant (≅1) can efficiently reduce the parasitic capacitance of the inductor created. As a result, the inductor of the invention, suitable for RF circuits operating at a higher frequency, has a higher quality factor.
While the invention has been described by way of example and in terms of the preferred embodiment, it is to be understood that the invention in not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so at to encompass all such modifications and similar arrangements.
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The structure of high-Q inductor applied in a monolithic circuit according to the invention comprises a plurality of spiral metal lines and a plurality of dielectric layers, each dielectric layer formed between two adjacent spiral metal lines. Furthermore, via plugs are formed in each dielectric layer to electrically connect two adjacent spiral metal lines. A spiral air trench is formed along the spacing of the spiral metal lines in the dielectric layers. Therefore, 3D-structure of the inductor of the invention can greatly reduce the series resistance thereof without widening the spiral metal lines. In addition, the spiral air trench, filled with air which has a lower dielectric constant, can efficiently reduce the parasitic capacitance between the spacing of the spiral metal lines. As a result, the inductor of the invention has a higher quality factor at a proper RF operating frequency region.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 13/450,661 filed on Apr. 19, 2012, which is a continuation of U.S. patent application Ser. No. 12/975,544 filed on Dec. 22, 2010 (now abandoned), which is a continuation of U.S. patent application Ser. No. 12/489,036 filed on Jun. 22, 2009 (now abandoned), which is a continuation of U.S. patent application Ser. No. 11/158,608 filed on Jun. 22, 2005 (now abandoned), all of which are incorporated in their entirety herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to the fields of mechanical engineering and child safety. More particularly, the invention relates to a keyless lock for doors.
BACKGROUND
[0003] All too often parents have discovered that their small children are able to unlock and open a door to the outside of the home or a door at the top of a stairway. To avoid devastating accidents that can occur when children open doors that are not to be opened by them, parents have resorted to installing a lock on the inside surface of the door that requires the use of a key to unlock and open the door. This presents a significant inconvenience to everyone in the home who uses the door, as the key to the lock can be easily misplaced. Such a lock also presents a safety hazard in the case of fire, for example, when the lock key is not readily available and the occupants of the home, possibly panicked, are obstructed or prevented from exiting the home. A need exists for a door lock that allows adults and older children to easily operate the lock while precluding small children from doing so.
SUMMARY OF THE INVENTION
[0004] What has been developed is a keyless lock for doors that prevents young children from opening doors their parents or caretakers do not wish them to open. An exemplary keyless lock of the invention is a dead-bolt type lock having no keyed lock access side to it, but rather, a knob or handle on one or both sides of the door that when turned, locks or unlocks the door. The lock is positioned within the door at a height that is unreachable by small children (e.g., at least about 1.5 meters). The keyless lock can be used to lock hinged and sliding doors. The lock is compatible for doors for interior rooms of a home as well as for doors that provide access to the exterior of the home and therefore access for small children to leave the premises of the home without supervision. Adults and older children, however, are not locked in or out of the room or house as no key is required for operating the lock, merely the turning of a knob.
[0005] Accordingly, the invention features a door having a keyless lock. This keyless lock includes a first means for locking and unlocking the lock and a second means for locking and unlocking the lock, the first means positioned on the interior surface of the door and the second means positioned on the exterior surface of the door. The first and second means are positioned on the door at a distance from the bottom of the door of at least about 1.5 meters. The first and second means for locking and unlocking the lock can include a knob and a handle. The door can be a hinged door as well as a sliding door.
[0006] In another aspect, the invention features a kit for locking a door. This kit includes (a) a keyless lock including a first means for locking and unlocking the door and a second means for locking and unlocking the lock that when installed in the door, the first means is positioned on the interior surface of the door and the second means is positioned on the exterior surface of the door, and (b) printed instructions for installing the keyless lock in the door at a distance from the bottom of the door of at least about 1.5 meters. The first and second means for locking and unlocking the lock can include a knob and a handle. The door can be a hinged door as well as a sliding door. The kit might also include a keyless lock installation device which can be a U-shaped device that can be reversibly mounted to a door (e.g., using a fastener such as two blunt-ended screws with twist handles) and can include guide holes which can be used as a stencil-like guide for precisely drilling holes into the door. The components of the kit can be included within a single packaging unit.
[0007] Also within the invention is a method for locking a door. This method includes the steps of: (a) providing a door, (b) providing a keyless lock installed within the door, the keyless lock including a first means for locking and unlocking the lock and a second means for locking and unlocking the lock, the first means positioned on the interior surface of the door and the second means positioned on the exterior surface of the door, and (c) manipulating the first or the second means for locking and unlocking the lock. The first and second means for locking and unlocking the lock can include a knob and a handle. The door can be a hinged door as well as a sliding door.
[0008] Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although systems, materials and devices similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable systems, materials, and devices are described below. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the systems, materials, and devices are illustrative only and not intended to be limiting. Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective front view of a door having a keyless lock of the invention.
[0010] FIG. 2 is an exploded view of a first embodiment of a keyless lock.
[0011] FIG. 3 is a cross-sectional view of the embodiment of FIG. 2 , the lock being in an unlocked position.
[0012] FIG. 4 is a cross-sectional view of the embodiment of FIG. 2 , the lock being in a locked position.
[0013] FIG. 5 is an exploded view of a second embodiment of a keyless lock.
[0014] FIG. 6 is a front view of the keyless lock of FIG. 5 in a locked position.
[0015] FIG. 7 is a front view of the keyless lock of FIG. 5 in an unlocked position.
[0016] FIG. 8 is a perspective view of a sliding door having the keyless lock of FIGS. 5-7 mounted thereon.
[0017] FIG. 9 is a perspective front view of a third embodiment of a keyless lock.
[0018] FIG. 10 is a perspective view of a sliding door having the keyless lock of FIG. 9 mounted thereon.
[0019] FIG. 11 is a perspective view of a keyless lock installation device.
[0020] FIG. 12 is a perspective view of the keyless lock installation device of FIG. 11 fastened to a door.
DETAILED DESCRIPTION
[0021] In brief overview, referring to FIG. 1 , a first exemplary embodiment of a keyless door lock 20 is shown mounted in a hinged door 10 . An operator locks and unlocks the door by manipulating a means for locking and unlocking the lock. The means for locking and unlocking the lock can be any graspable implement, such as a handle or a knob. In the embodiment shown in FIGS. 1-10 , the means for locking and unlocking the lock is knob 25 , and to lock and unlock the door, one simply grasps the knob 25 and turns it in the appropriate direction. The lock 20 can include one means for locking and unlocking the lock (e.g., knob 25 ) mounted to one side of the door 10 , but preferably includes a first and a second means for unlocking the lock (e.g., two knobs 25 ), the first means mounted to the interior surface of the door and the second means mounted to the exterior surface of the door 10 . Having first and second means for unlocking and locking the lock is preferable because this allows the lock 20 to be operated from either side of the door 10 . The knob 25 can be any type of graspable implement but is preferably one that is easy to grasp and turn. The knob 25 can be made of any suitably rigid material, including metal, metal alloy, plastic, and composite materials thereof. The lock 20 is positioned at an adequate distance 22 from the ground such that a small child cannot reach the lock 20 . An adequate distance 22 from the ground is at least about 1.5 meters (e.g., 1.4, 1.45, 1.5, 1.55, 1.6, 1.65, 1.7, 1.75, 1.8, 1.83, 1.9, 2.0, 2.1, 2.2 meters).
[0022] As shown in FIG. 2 , one embodiment of a keyless lock 20 includes several components for mounting and operating the lock 20 . Mounted inside the door 10 is a locking bolt housing 60 having an aperture 65 for receiving a connecting means 55 . A locking bolt 70 is disposed within the locking bolt housing 60 when the lock 20 is in a locked position but moves at least partially out of the locking bolt housing 60 when the lock 20 is in a locked position. The locking bolt 70 is moved in and out of the locking bolt housing 60 via a connecting means 55 and a knob 25 . The locking bolt 70 and knob 25 are operably connected by the connecting means 55 . In this embodiment, the connecting means 55 is shown as a ribbed connecting rod 55 . Any suitable device or component for operably connecting the knob 25 to the locking bolt 70 , however, can be used. The connecting rod 55 has a first end that is attached to the knob 25 and a second end that protrudes through the aperture 65 in the locking bolt housing 60 . In the embodiment shown in FIG. 2 , the knob 25 is attached to the first end of the connecting rod 55 by screws 35 that are screwed into screw holes 30 of the knob 25 . A decorative plate 50 is preferably installed between the connecting rod 55 and the knob 25 in order to conceal any hole made in the door 10 by the installation of the connecting rod 55 . The decorative plate 50 has a central aperture 40 through which the first end of the connecting rod 55 is disposed so that it can be attached to the knob 25 . The decorative plate 50 can be attached to the door 10 by any suitable means but in the embodiment shown in FIG. 2 , the plate 50 is attached to the door 10 via two screw holes 45 and screws that are driven therethrough.
[0023] The locking bolt 70 shown in FIG. 2 has a cavity at one end which features a series of teeth 75 for engaging the ribbed connecting rod 55 . The locking bolt 70 also includes a chamber housing a spring 73 that is positioned mostly interior to the chamber when the locking bolt 70 is positioned within the locking bolt housing 60 but that is urged out of the chamber when the locking bolt 70 is moved from the locking bolt housing 60 . When the locking bolt 70 is disposed within the locking bolt housing 60 , the spring 73 is positioned slightly out of the chamber and contacting the interior wall of the locking bolt housing 60 such that the spring 73 seats the locking bolt 70 firmly within the locking bolt housing 60 .
[0024] When the locking bolt 70 is moved from inside the locking bolt housing 60 it moves towards the portion of the door frame 15 (or door jamb or wall) that is disposed opposite to the keyless lock 20 . A mounting plate 85 having a central bore 80 therein is rigidly mounted to this portion of the door frame 15 (or door jamb or wall) for receiving the locking bolt 70 . The mounting plate 85 is rigidly mounted to the door frame 15 (or door jamb or wall) via any suitable mounting means (e.g., screw holes 90 and screws driven therethrough).
[0025] The mechanism by which the keyless lock 20 of FIGS. 1 and 2 operates is illustrated in the cross-sectional views of FIGS. 3 and 4 . FIG. 3 illustrates a keyless lock 20 in an unlocked position in which the locking bolt 70 is disposed entirely within the locking bolt housing 60 . The second end of the connecting rod 55 is shown positioned within the locking bolt 70 cavity having a series of teeth 75 . The ribs of the ribbed connecting rod 55 mate with the spaces between the teeth 75 , thereby forming a gear in which the movement of the locking bolt 70 is caused by rotating the ribbed connecting rod 55 . The connecting rod 55 is rotated via manipulation of the knob 25 , i.e., turning the knob from a resting position. When the connecting rod 55 is rotated in the direction of the arrow in FIG. 3 , the ribs of the connecting rod 55 grip the teeth 75 of the locking bolt 70 and the connecting rod 55 moves in the direction of the arrow while it urges the locking bolt 70 out of the locking bolt housing 60 . As the locking bolt 70 is urged from the locking bolt housing 60 , the locking bolt 70 is urged into the central bore 80 of the mounting plate 85 ( FIG. 4 ), thereby locking the door. To unlock the door, the connecting rod 55 is rotated in the opposite direction and the movement of the locking bolt 70 is reversed, disposing the locking bolt 70 within the locking bolt housing 60 . In addition to the dead bolt-type lock described above, any bolt mechanism (e.g., spring-loaded or other mechanism) can be used in a keyless lock of the invention. In addition to the mounting plate for receiving the locking bolt described above, a keyless lock of the invention can be mounted to a door, door frame, or door jamb by any suitable mounting means.
[0026] Another exemplary embodiment of a keyless lock 20 is shown in FIG. 5 . The keyless lock 20 of FIG. 5 is preferred for use with a sliding door, including, for example, sliding glass doors that are often found at the rear side of houses having swimming pools. The keyless lock 20 is shown mounted in a sliding door 100 in FIG. 8 . In this embodiment, the keyless lock 20 includes a housing 120 mounted within the door 100 . The housing 120 is operably connected to a latching means 105 having a body 113 , an aperture 115 having multiple grooves, the aperture 115 central to the body 113 , and a hook-shaped arm 110 via a connecting means 55 . The latching means 113 is rotated back and forth between a locked position and an unlocked position via a knob 25 and the connecting means 55 . In this embodiment, the connecting means 55 is shown as a ribbed connecting rod 55 . Any suitable device or component for connecting the knob 25 to the latching means 105 , however, can be used. The connecting rod 55 has a first end that is attached to the knob 25 and a second end that protrudes through the multi-grooved aperture 115 of the latching means 105 and into the housing 120 . The knob 25 is attached to the first end of the connecting rod 55 by any suitable means (e.g., screws 35 that are screwed into screw holes 30 of the knob 25 ).
[0027] The keyless lock 20 shown in FIG. 6 also has a securing means 125 having a body 130 and a member 140 extending from the body 130 for securing the hook-shaped arm 110 of the latching means 105 . The securing means 125 is rigidly mounted to the appropriate portion of the door frame 15 (or door jamb or wall) disposed opposite to the keyless lock. The securing means 125 is rigidly mounted to the door frame 15 (or door jamb or wall) via any suitable means (e.g., screw holes 135 and screws 145 driven therethrough). The lock 20 is positioned at an adequate distance 22 from the ground (e.g., 1.5 meters) such that a small child cannot reach the lock 20 . The lock 20 can include one means for locking and unlocking the lock (e.g., knob 25 ) mounted to one side of the door 10 , but preferably includes a first and a second means for unlocking the lock (e.g., two knobs 25 ), the first means mounted to the interior surface of the door and the second means mounted to the exterior surface of the door 10 . Having first and second means for unlocking and locking the lock is preferable because this allows the lock 20 to be operated from either side of the door 10 . The knob 25 can be any type of graspable implement but is preferably one that is easy to grasp and turn. The knob 25 can be made of any suitably rigid material, including metal, metal alloy, plastic, and composite materials thereof.
[0028] Operation of the keyless lock 20 shown in FIGS. 5 and 8 is illustrated in FIGS. 6 and 7 . FIG. 6 illustrates a keyless lock 20 in a locked position in which the hook-shaped arm 110 of the latching means 105 is disposed on the member 140 extending from the body 130 of the securing means 125 . The first end of the connecting rod 55 is shown positioned within the multi-grooved aperture 115 central to the body 113 of the latching means 105 . In this embodiment, the ribs of the ribbed connecting rod 55 mate with the grooves of the aperture 115 , thereby forming a gear in which the rotation of the latching means 105 is coupled to the rotation of the ribbed connecting rod 55 . The connecting rod 55 and latching means 105 are rotated via manipulation of the knob 25 , i.e., turning the knob from a resting position. When the connecting rod 55 is rotated clockwise, the ribs of the connecting rod 55 catch in the grooves of the aperture 115 of the body 113 of the latching means 105 and lift the hook-shaped arm 110 away from the member 140 ( FIG. 7 ) so that the hook-shaped arm 110 is no longer secured to the securing means 125 , thereby unlocking the door. To lock the door, the knob 25 is rotated in a counter-clockwise direction, thereby securing the hook-shaped arm 110 to the member 140 extending from the body 130 of the securing means 125 .
[0029] A variation of the keyless lock of FIGS. 5-8 is illustrated in FIG. 9 . In this embodiment, the keyless lock 20 includes a housing 120 mounted within a door. The housing 120 is operably connected to a knob 25 and a latching means 105 having a body 113 with a central aperture 115 , and a hook-shaped arm 110 . A portion of the knob 25 is passed through the aperture of the latching means 105 and protrudes into the housing 120 . The knob 25 , latching means 105 , and housing 120 are all securely connected such that rotating the knob 25 also rotates the latching means 105 and the housing 120 . The keyless lock 20 shown in FIG. 9 also has a securing means 125 having a body 130 and a member 150 extending from the body 130 for receiving the arm 110 of the latching means 105 . The securing means 125 is rigidly mounted to a portion of the door frame (or door jamb or wall) disposed at essentially the same distance from the ground as the knob 25 . The securing means 125 is rigidly mounted to the door frame (or door jamb or wall) by any suitable means. The latching means 105 is rotated back and forth between a locked position and an unlocked position via turning of the knob 25 . By rotating the knob 25 such that the arm 110 of the latching means 105 is disposed within the 150 member for receiving the arm 110 of the latching means 105 , the lock 20 is engaged and the door cannot be opened.
[0030] FIG. 10 illustrates another embodiment of the keyless lock 20 of FIG. 9 mounted in a sliding door 100 . In this embodiment, the securing means 125 is rigidly mounted to the portion of the door frame 15 (or door jamb) as shown.
[0031] FIGS. 11 and 12 show a keyless lock installation device 200 which can be a U-shaped bracket 201 that can be reversibly mounted to a hinged door 210 (e.g., using a fastener such as two blunt-ended screws 202 a and 202 b with twist handles 203 a and 203 b wherein the screws 202 a and 202 b can be threaded through holes 204 a and 204 b as shown in FIG. 11 ) that can include side guide holes 205 a , 205 b and center guide hole 206 which can be used as a stencil-like guide for precisely drilling holes into the door. The side guide holes 205 a , 205 b and center guide hole 206 can be of any dimensions suitable for use with the components of the keyless lock 20 , e.g., side guide holes 205 a , 205 b can have a diameter of 0.8 cm +/− 0.1, 0.2, 0.3, or 0.4 cm and center guide hole 206 can have a diameter of 1.3 cm +/− 0.1, 0.2, 0.3, 0.4, 0.5, or 0.6 cm. The U-shaped bracket 201 can be reversibly fastened to the door 210 at the location where it is desired to install the keyless lock 20 (e.g., at a distance from the bottom of the door of at least about 1.5 meters) by adjusting screws 202 a and 202 b . Once secured to the door 210 , the installer can use a drill to insert into the side guide holes 205 a , 205 b and center guide hole 206 to make holes in the door 210 . The depth of the hole made using the center guide hole 206 can be about 7 cm +/− 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, or 4 cm. The hole made using the side guide holes 205 a , 205 b can be through the entire width of the door 210 . The two holes can intersect to create a single T- or cross-shaped lumen with 3 holes. After the holes have been drilled, the keyless lock installation device 200 can be removed from the door 210 and the components of the keyless lock 20 can then be installed using these 3 holes (see FIG. 1 ).
[0032] A keyless lock of the invention is used to lock a door without requiring a key and without allowing small children to operate the lock. The invention thus provides a kit and a method for locking a door. An exemplary kit of the invention includes a first means for locking and unlocking the lock and a second means for locking and unlocking the lock that when installed in the door, the first means is positioned on the interior surface of the door and the second means is positioned on the exterior surface of the door. The kit also includes printed instructions for installing the keyless lock in the door at a distance from the bottom of the door of at least about 1.5 meters, and/or a keyless lock installation device such as that described above and in FIGS. 11 and 12 . An exemplary method of locking a door includes the steps of: (a) providing a door, (b) providing a keyless lock installed within the door, the keyless lock comprising a first means for locking and unlocking the lock and a second means for locking and unlocking the lock, the first means positioned on the interior surface of the door and the second means positioned on the exterior surface of the door, and (c) manipulating the first or the second means for locking and unlocking the lock.
[0033] From the foregoing, it can be appreciated that the keyless lock of the invention provides a system for preventing young children from opening doors while providing unfettered access to older children and adults. While the above specification contains many specifics, these should not be construed as limitations on the scope of the invention, but rather as examples of preferred embodiments thereof. Many other variations are possible. For example, the means for locking and unlocking the lock can be any suitable device in addition to a knob, including a handle or other graspable implement. As other examples, the knob may have a different shape, the connecting means can have a different shape, the locking bolt may have a different means for engaging the connecting means, and the spring may have a range of tensions. Different movements may be required to engage the means for locking and unlocking the lock (e.g., knob) and different movements of the means for locking and unlocking the lock (e.g., knob) may be required to cause the retraction of the locking bolt. Also, different securing and mounting arrangements can be used. Different techniques may be used to connect various components to one another. Such techniques may include, for example, molding, welding, use of adhesives, and press fitting. Furthermore, the general shapes and relative sizes of the various components may vary. Many different materials may be considered suitable for manufacturing the components described herein.
[0034] Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
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A keyless door lock that prevents young children from opening doors. The lock is a bolting mechanism type lock or a latching type lock having no keyed lock access side to it, but rather, a means for locking and unlocking the lock, such as a knob, on one or both sides of the door that when turned, unlocks the door. The lock is positioned within the door at a height that is unreachable by small children. The lock can lock doors internal to the home (e.g., doors to medicine closets, cleaning supply closets, garage doors, doors at the top of stairs) and doors that provide access to the exterior of the home, thus access to leave the home without supervision. Adults and older children, however, are never locked in or out of the room or house as merely the turning of a knob is required for operating the lock.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
A mechanical magnetic pin setter for facilitating the positioning and retaining of dowel pins in the production of cast replicas of teeth and mouth to aid in the production of crowns and bridges for dental restoration.
2. Description of the Prior Art
Various mechanical devices have been developed and patented for performing functions in the area of this invention. One device utilizing permanent magnets in its construction is U.S. Pat. to Kestler, No. 3,650,032. The arrangement of the magnets and the related structure of Kestler, however, substantially varies from the combination of this invention. Several wholly mechanical devices not utilizing magnets have been developed and patented for the retention of dowel pins in position.
SUMMARY OF THE INVENTION
The device of this invention is designed to be supported on a desk or work bench to facilitate the dentist or technician in producing castings of the teeth as a procedure to assist the dentist in restoration procedures. The device generally comprises a rectangular base which may be constructed of formica or other suitable materials. Projecting upward from the base are two support rods which terminate in their upper extremity in two flat iron or steel metallic sheets comprising horizontal plates. Positioned below these horizontal plates substantially midway between the two vertical support rods is an adjustable work table. This work table is adjustable as to angle or tilt and elevation. The top of the work table has an adjustable plastic top supported by a ball and socket joint with the base of the work table securely attached to the base of the device. A ratchet shaft projects upward from the elevator base and is attached to the plastic top through the ball and socket interconnector. Knurled knobs connected to pinion drive shaft permits the elevation or lowering of the plastic top of the work table throughout a range of approximately 2 inches. The foregoing structure may be assembled from components presently commercially available; perhaps with the exception of the horizontal plates at the upper extremity of the support rods.
The most novel structure of this device perhaps resides in two interconnected permanent horseshoe magnets retained by a non-magnetic interconnecting yoke. The magnetic poles of the magnets are positioned and retained in the yoke in a 90° configuration or normal to the corresponding magnet. This pair of magnets with the interconnecting yoke formed the support structure from the horizontal plates to the metallic metal dowel support rods which retain the brass dowel pins at the exact desired position in the impression carried in the impression tray. The dowel pins are adjusted prior to casting exactly in the center of the tooth to be restored. The work table is then lowered by means of the pinion knurled knobs; the first pour of the castings is deposited in the impression carried by the impression tray and the work table returned to its previous position which is determined by the referenced pointer. The device is left in position until the casting sets. The first casting may be coated with a release agent and a second pour deposited to facilitate working with and separating of the cast impression. When the combined castings have solidified the individual tooth may be cut from the impression together with its dowel pin and worked with in preparation of crowns and bridges.
For a more detailed description of the construction and operation of the device reference is made to the attached drawings, the description of the preferred embodiment and the claims. Identical reference characters are utilized throughout the several drawings and detailed description to refer to identical or equivalent components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation perspective view of the composite device simulating its use.
FIG. 2 is a top view taken on line 2--2 of FIG. 1 looking in the direction of the arrows illustrating dowel pins in positions in an impression for casting.
FIG. 3 is a fragmented view of the permanent magnets and their interconnecting yoke.
FIG. 4 is a fragmented view of the magnets rotated 90°.
FIG. 5 is a dowel support rod and brass dowel retained by the support rod.
FIG. 6 is an exploded view of a final casting with a single tooth and dowel pin removed.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment utilized a rectangular formica base 10 which was 11/2 inches thick, 7 inches wide and 11 inches long. Equally spaced from each end of base 10 was a first support rod 11 and a second support rod 12. These rods 11 and 12 were 1/2 inch OD and 91/2 inches long. The bottom portion was threaded and secured to the base 10 with rod securing nuts 13. The apertures in the base 10 receiving the support rods 11 and 12 were positioned 2 inches inward from each end of the base 10. At the upper extremity of each support rod 11 and 12 was welded a first horizontal support plate 14 and a second horizontal support plate 15. These plates 14 and 15 might be of various configurations; however, in the preferred embodiment the plates were approximately 3 inches by 51/2 inches having generally an arcuate configuration. It is desirable in the construction to mount a reference pointer 16 on one of the support rods 11 and 12. Reference pointer 16 had a 21/2 inch elongated pointer projecting from a plastic pointer base 17 which was 3/4 inch wide and 21/2 inches long. The pointer base 17 is secured in position on support rod 11 or 12 by means of a pointer set screw 18.
Positioned approximately midway of base 10 slightly off center from the support rods 11 and 12 is an adjustable work table 19 having a plastic top 20 which is approximately 41/2 inches by 5 inches and 1/4 inch thick. Its support stem 21 projects downward from the plastic top. The stem has a circular 1 inch base and a stem approximately 1 inch long. The stem terminates in a ball 22 approximately 1/2 inch in diameter which fits into a socket 23 resulting in a ball and socket joint which permits a tilting and adjusting of the plastic top 20 of the work table 19. Rotatably mounted beneath socket 23 was ball set screw 24 which is adapted to rotate and secure the ball and socket joint in position. Bottom portion of work table 19 is a cylindrical structure securely screwed to base 10 which comprises elevator base 25. This elevator base 25 is approximately 13/4 inches in diameter and is approximately 23/4 inches in length. The ratchet shaft 26 projects through elevator base 25 in such a fashion as to permit the raising or lowering of plastic top 20 of the work table. Projecting outward on one side of ratchet shaft 26 was a threaded rack 27 approximately 2 inches in length providing a range of lowering and elevation of the ratchet shaft 26 of approximately 2 inches. Engaging rack 27 was the pinion gear 28 which was secured on a pinion drive shaft 29 having pinion knurled knobs 30 at each end. Pinion drive shaft 29 was approximately 23/4 inches in length having 3/4 inch knurled knobs 30 at each end.
A magnetic structure of novel design was developed for utilization in conjunction with the horizontal plates 14 and 15 mounted at the upper extremity of support rods 11 and 12. The magnetic structure comprises a horizontal horseshoe magnet 33 approximately 5/16 inch thick having a length from its arc to its poles of approximately 13/16 inch with the width of the contact polar surface of 14/16 inch securely interconnected to a somewhat larger vertical horseshoe magnet 34. This vertical horseshoe magnet 34 was 3/4 inch thick also having a length from its arc to its place of approximately 13/16 inch with a contact surface at the poles of approximately 1 inch. Interconnecting these two magnets in a right angle configuration was a non-metallic plastic magnet connecting yoke 35. This yoke 35 maintained the horizontal magnet 33 and the vertical magnet 34 in a space relationship of approximately 1/4 inch with the poles of the respective magnets forming a 90° angle. In utilizing this combined magnetic structure the horizontal horsehoe magnet 33 contacts horizontal plate 14 or 15 supporting and retaining vertical horseshoe magnet 34 in a position substantially perpendicular to base 10. This configuration permits the positioning of the iron or steel dowel support rods 36 in both the vertical and horizontal plane to be retained in the established position. These dowel support rods are 1/3 inch in diameter and 3 inches long. Brass dowel pins 37 are retained frictionally in position by dowel pin recesses 38 formed in the end of the dowel support rods 36.
In utilization of the device of this invention in producing a cast for replica of the individual teeth a portion of quick set plaster 40 is placed in the center of plastic top 20 of work table 19. The quick set plaster 40 is covered with a thin plastic membrane 41 after which impression tray 42 carrying the impression 43 is placed on the plastic membrane 41. The impression tray 42 is permitted to settle into the quick set plaster 40 forming a stable support. The procedures are delayed sufficiently to permit the quick set plaster 40 to harden or arrive at a stable configuration.
OPERATION OF THE DEVICE
At this stage of the procedure the combination of this invention becomes particulrly self-evident to a dentist or skilled technician. In the following casting procedures, replicas of the individual teeth may be accurately produced. To accomplish this individual brass dowel pins 37 must be precisely positioned in the center of a tooth indentation 44 which is to be subjected to restoration procedures. Horizontal horseshoe magnet 33 is placed on first horizontal plate 19 with vertical horseshoe magnet 34 projecting over tooth indentation 44. Dowel support rod 36 carrying brass dowel pin 37 is placed in contact with vertical horseshoe magnet 34 and the magnets 33 and 34 shifted in position to the point wherein dowel support rod 36 is exactly in the center of tooth indentation 44. Dowel support rod 36 may be moved laterally, elevated or lowered to precisely place the brass dowel pin 37 in the center of the tooth indentation 44.
For an illustration of the flexibility afforded in positioning dowel pins utilizing the device, reference is particularly made to FIG. 1. In positioning the dowel support rod 36 carrying the brass dowel pin 37, it is rather self-evident that horizontal, horseshoe magnet 33 may be slid across and placed in any desired position on the face of the first horizontal plate 14. Dowel support rod 36 can be tilted at any desired angle from the vertical along the face of vertical, horseshoe magnet 34. The shifting of horizontal horseshoe magnet 33 on first horizontal plate 14 in combination with this shifting of dowel support rod 36 along the face of vertical horseshoe magnet 34 allows considerable latitude of positioning and angular adjustment. From the illustration of FIG. 1, it appears that it is quite possible to place dowel support rod 36 on the side of vertical, horseshoe magnet 34, thereby permitting a tilting of dowel support rod along the side of magnet 34. This selectively of positioning of dowel support rod 36 along the face or side of vertical horseshoe magnet 34 permits extensive latitude in laterally, vertically, and angularly positioning of the brass dowel pins 37 in the operation of the device of this invention. By the utilization of additional magnets and additional dowel support rods 36 other castings of individual teeth may be accomplished. With the dowel support rods 36 carrying the brass dowel pins 37 in the exact desired position the adjustable work table 19 is lowered to its bottom position and a first mix of stone 45 partially filling impression 43 is poured into position. Once this is accomplished the work table 19 is elevated to its exact former position by means of rotating the pinion knurled knobs 30 until reference pointer 16 contacts the upper surface of plastic top 20 which returns each component to the identical position the components were at the time the dowel support rods 36 and the brass dowel pins were adjusted into position. This first mix of stone 45 is permitted to set at which time it is coated with a releasing lubricant 46. At this point in the procedure the impression tray 42 carrying the impression 43 and the soldified first mix of stone 45 may be removed from the work table 19. The added second mix of stone 47 is placed on the impression 43 in the impression tray 42 forming the desired configuration for facility in handling and permitting to solidify. When the setting or curing process is completed the cast impression may be removed from the impression tray. The individual teeth which are to be the subject of restoration are separated from the remainder of the casting by saw cuts 48. With a saw cut 48 separating the individual tooth a tapping on the tip of dowel pin 37 will release the individual tooth from the casting. In pouring the second mix of stone 47 a slightly exposed tip 49 of the dowel pin 37 should remain visible. A tapping of this exposed tip 49 should release the individual tooth.
The procedures followed in the utilization of the device of this invention, although perhaps containing some degree of novelty when specifically applicable to the novel mechanical features of this invention, are not specifically claimed. The appended claims are mechanical in scope. What is desired to be claimed is all adaptations and modifications of the novel features of this invention not departing from the scope of equivalents of the invention as defined in the appended claims.
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A magnetic pin setter useful in constructing replicas of teeth for production of crowns and bridges. The device employs two support rods mounted on a base, each supporting a horizontal plate at its upper extremity. Mounted on the base between the two support rods is an adjustable work table. In producing castings for restoration work including crowns and bridges, dowel pins must be positioned for the casting and removal of individual tooth models to be restored. Small horseshoe magnets are magnetically attached to the horizontal plates and the second magnet interconnected to the first magnet holds a vertical support rod in position. The rods retain the dowel pins in position in the center of the individual teeth for the casting process.
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BACKGROUND AND SUMMARY OF THE INVENTION
The subject matter of U.S. Pat. No. 5,709,784 is incorporated by reference herein.
The present invention is directed on a tool with a tool body and a wear resistant layer system, wherein the layer system comprises at least one layer of MeX, wherein
Me comprises titanium and aluminum,
X is at least one of nitrogen and of carbon.
Definition
The term Q I is defined as the ratio of the diffraction intensities I(200) to I(111), assigned respectively to the (200) and (111) plains in the X ray diffraction of a material using the θ-2θ method. Thus, there is valid Q I =I(200)/I(111). The intensity values were measured with the following equipment and with the following settings:
Siemens Diffractometer D500
Power:
Operating voltage: 30 kV
Operating current: 25 mA
Aperture Diaphragms:
Diaphragm position I: 1°
Diaphragm position II: 0.1°
Detector Diaphragm: Soller slit
Time constant: 4 s
2θ angular speed: 0.05°/min
Radiation: Cu-Kα(0.15406 nm)
When we refer to "measured according to MS" we refer to this equipment and to these settings. Thereby, all quantitative results for Q I and I throughout this application have been measured by MS.
We understand by "tool body" the uncoated tool.
We understand under "hard material" a material with which tools which are mechanically and thermally highly loaded in operation are coated for wear resistance. Preferred examples of such materials are referred to below as MeX materials.
It is well-known in the tool-protecting art to provide wear resistant layer systems which comprise at least one layer of a hard material, as defined by MeX.
The present invention has the object of significantly improving the lifetime of such tools. This is resolved by selecting for said at least one layer a Q I value, for which there is valid
Q.sub.I ≧1
and wherein the tool body is made of high speed steel (HSS) or of cemented carbide, whereby said tool is not a solid carbide end mill or a solid carbide ball nose mill. Further, the value of I(200) is higher by a factor of at least 20 than the intensity noise average level as measured according to MS.
According to the present invention it has been recognised that the Q I values as specified lead to an astonishingly high improvement of wear resistance, and thus of lifetime of a tool, if such a tool is of the kind as specified.
Up to now, application of a wear resistant layer systems of MeX hard material was done irrespective of interaction between tool body material and the mechanical and thermal load the tool is subjected to in operation. The present invention thus resides on the fact that it has been recognised that an astonishing improvement of wear resistance is realised when selectively combining the specified Q I value with the specified kind of tools, thereby realising a value of I(200) higher by a factor of at least 20 than the average noise intensity level, both measured with MS.
With respect to inventively coating cemented carbide tool bodies, it has further been recognised that a significant improvement in lifetime is reached if such cemented carbide tools are inserts, drills or gear cutting tools, as e.g. hobs or shaper cutters, whereby the improvement is especially pronounced for such inserts or drills.
The inventively reached improvement is even increased if Q I is selected to be at least 2, and an even further improvement is realised by selecting Q I to be at least 5. The largest improvement are reached if Q I is at least 10. It must be stated that Q I may increase towards infinite, if the layer material is realised with a unique crystal orientation according to a diffraction intensity I(200) at a vanishing diffraction intensity I(111). Therefore, there is not set any upper limit for Q I which is only set by practicability.
As is known to the skilled artisan, there exists a correlation between hardness of a layer and stress therein. The higher the stress, the higher the hardness.
Nevertheless, with rising stress, the adhesion to the tool body tends to diminish. For the tool according to the present invention, a high adhesion is rather more important than the highest possible hardness. Therefore, the stress in the MeX layer is advantageously selected rather at the lower end of the stress range given below.
These considerations limit in practice the Q I value exploitable.
In a preferred embodiment of the inventive tool, the MeX material of the tool is titanium aluminum nitride, titanium aluminum carbonitride or titanium aluminum boron nitride, whereby the two materials first mentioned are today preferred over titanium aluminum boron nitride.
In a further form of realisation of the inventive tool, Me of the layer material MeX may additionally comprise at least one of the elements boron, zirconium, hafnium, yttrium, silicon, tungsten, chromium, whereby, out of this group, it is preferred to use yttrium and/or silicon and/or boron. Such additional element to titanium and aluminum is introduced in the layer material, preferably with a content i, for which there is valid
0.05 at. %≦i≦60 at. %,
taken Me as 100 at %.
A still further improvement in all different embodiments of the at least one MeX layer is reached by introducing an additional layer of titanium nitride between the MeX layer and the tool body with a thickness d, for which there is valid
0.05 μm≦d≦5 μm.
In view of the general object of the present invention, which is to propose the inventive tool to be manufacturable at lowest possible costs and thus most economically, there is further proposed that the tool has only one MeX material layer and the additional layer which is deposited between the MeX layer and the tool body.
Further, the stress σ in the MeX is preferably selected to be
1 GPa≦σ≦4 GPa, thereby most preferably
within the range
1.5 GPa≦σ≦2.5 GPa.
The content x of titanium in the Me component of the MeX layer is preferably selected to be
70 at %≧x≧40 at %, thereby in a further
preferred embodiment within the range
65 at %≧x≧55 at %.
On the other hand, the content y of aluminum in the Me component of the MeX material is preferably selected to be
30 at %≦y≦60 at %, in a further preferred embodiment even to be
35 at %≦y≦45 at %.
In a still further preferred embodiment, both these ranges, i.e. with respect to titanium and with respect to aluminum are fulfilled.
The deposition, especially of the MeX layer, may be done by any known vacuum deposition technique, especially by a reactive PVD coating technique, as e.g. reactive cathodic arc evaporation or reactive sputtering. By appropriately controlling the process parameters, which influence the growth of the coating, the inventively exploited Q I range is realised.
To achieve excellent and reproducible adhesion of the layers to the tool body a plasma etching technology was used, as a preparatory step, based on an Argon plasma as described in U.S. Pat. No. 5,709,784.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the relationship between nitrogen partial pressure and bias voltage of the tool body as applied for reactive cathodic arc eruption in accordance with the present invention;
FIG. 2 is a diagram showing the relationship between typical intensity and diffraction angle <θ where the titanium aluminum nitride layer is deposited in the Q I ≧1 Region;
FIG. 3 is a diagram similar to FIG. 2 but with the layer deposited on a Q I ≦1 region; and
FIG. 4 is a diagram similar to FIGS. 2 and 3 for the working point P 1 in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLES 1
An arc ion plating apparatus using magnetically controlled arc sources as described in Appendix A was used operated as shown in table 1 to deposit the MeX layer as also stated in table 1 on cemented carbide inserts. The thickness of the MeX layer deposited was always 5 μm. Thereby, in the samples Nr. 1 to 7, the inventively stated Q I values where realised, whereas, for comparison, in the samples number 8 to 12 this condition was not fulfilled. The I(200) value was always significantly larger than 20 times the noise average value, measured according to MS. The coated inserts were used for milling under the following conditions to find the milling distance attainable up to delamination. The resulting milling distance according to the lifetime of such tools is also shown in table
______________________________________Test cutting conditions:______________________________________Material being cut: SKD 61 (HRC45)Cutting speed: 100 m/minFeed speed: 0.1 m/edgeDepth of cut: 2 mm______________________________________
The shape of the inserts coated and tested was in accordance with SEE 42 TN (G9).
It is clearly recognisable from table 1 that the inserts, coated according to the present inventino, are significantly more protected against delamination than the inserts coated according to the comparison conditions.
Further, the result of sample 7 clearly shows that here the stress and thus hardness of the layer was reduced, leading to lower cutting distance than would be expected for a high Q I of 22.5, still fulfilling the stress-requirements as defined above.
TABLE 1__________________________________________________________________________ Attainable Cutting Dis- Coating Conditions tance (m) Bias Arc Q.sub.1 = (distance Voltage N.sub.2 pressure Current I(200)/ Residual till delami-Sample No. (-V) (mbar) (A) Layer x y I(111) Stress GPA nation) Remarks__________________________________________________________________________Present 1 60 2.0 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 1.5 5.2 2.2 m (2.1 m)Invention 2 60 8.0 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 6.7 4.8 2.8 m (2.5 m) 3 40 2.0 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 8.1 4.2 8.8 m (8.5 m) face lapping 4 40 3.0 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.4 0.6 10.2 3.9 3.9 m (3.5 m) 5 40 0.5 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 6.0 5.8 2.0 m (1.7 m) 6 30 2.0 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 15.4 2.5 4.2 m (4.0 m) 7 20 2.0 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 22.5 1.2 3.3 m (3.3 m)Comparison 8 60 0.5 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 0.8 6.1 1.0 m (0.8 m) 9 100 2.0 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 0.7 5.5 0.9 m (0.9 m) 10 100 3.0 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 0.9 4.8 0.8 m (0.7 m) 11 150 2.0 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.5 0.5 0.2 7.2 0.1 m (0.1 m) 12 100 0.5 × 10.sup.-2 150 (Ti.sub.x Al.sub.y)N 0.4 0.6 0.1 6.8 0.2 m (0.1 m)__________________________________________________________________________
EXAMPLES 2
The apparatus as used for coating according to Example 1 was also used for coating the samples Nr. 13 to 22 of table 2. The thickness of the overall coating was again 5 μm. It may be seen that in addition to the coating according to Example 1 there was applied an interlayer of titanium nitride between the MeX layer and the tool body and an outermost layer of the respective material as stated in table 2. The condition with respect to I(200) and average noise level, measured according to MS was largely fulfilled.
It may be noted that provision of the interlayer between the MeX layer and the tool body already resulted in a further improvement. An additional improvement was realised by providing an outermost layer of one of the materials titanium carbonitride, titanium aluminum oxinitride and especially with an outermost layer of aluminum oxide. Again, it may be seen that by realising the inventively stated Q I values with respect to the comparison samples number 19 to 22, a significant improvement is realised.
The outermost layer of aluminum oxide of 0.5 μm thickness, was formed by plasma CVD.
The coated inserts of cemented carbide were tested under the same cutting conditions as those of Example 1, Q I was measured according to MS.
TABLE 2__________________________________________________________________________ Inter- Q.sub.1 = Attainable Cutting layer Outermost I(200)/ Distance (m) (distanceSample No. (μm TiAl Layer x y Layer I(111) till delamination)__________________________________________________________________________Present 13 TiN (Ti.sub.x Al.sub.y)N 0.5 0.5 -- 1.5 4.5 m (4.2)Invention (0.4 μm) (4.6 μm) 14 TiN (Ti.sub.x Al.sub.y)N 0.5 0.5 TiCN 7.2 7.8 (7.6 m) (0.4 μm) (4.1 μm) (0.5 μm) 15 TiN (Ti.sub.x Al.sub.y)N 0.5 0.5 TiCN 6.8 6.0 m (5.5 m) (0.4 μm) (4.4 μm) (0.5 μm) 16 TiCN (Ti.sub.x Al.sub.y)N 0.5 0.5 (TiAl)NO 5.2 6.2 m (6.0 m) (0.4 μm) (4.1 μm) (0.5 μm) 17 TiN (Ti.sub.x Al.sub.y)N 0.5 0.5 Al.sub.2 O.sub.3 12.5 10.1 m (9.8 m) (0.4 μm) (4.1 μm) (0.5 μm) 18 TiN (Ti.sub.x Al.sub.y)N 0.5 0.5 Al.sub.2 O.sub.3 7.0 9.8 m (9.5 m) (0.4 μm) (4.1 μm) (0.5 μm)Comparison 19 TiN (Ti.sub.x Al.sub.y)N 0.5 0.5 -- 0.8 1.5 m (1.2 m) 20 TiN (Ti.sub.x Al.sub.y)N 0.5 0.5 TiCN 0.8 1.9 m (1.5 m) 21 TiN (Ti.sub.x Al.sub.y)N 0.5 0.5 TiCN 0.7 1.8 m (1.5 m) 22 TiN (Ti.sub.x Al.sub.y)N 0.5 0.5 (TiAl)NO 0.1 0.6 m (0.4 m)__________________________________________________________________________
EXAMPLE 3
Again, cemented carbide inserts were coated with the apparatus of Example 1 with the MeX layer as stated in table 3, still fulfilling the Q I conditions as inventively stated and, by far, the condition of I(200) with respect to average noise level, measured according to MS. Thereby, there was introduced one of zirconium, hafnium, yttrium, silicon and chromium, with the amount as stated above, into Me.
The coated inserts were kept in an air oven at 750° C. for 30 min. for oxidation. Thereafter, the resulting thickness of the oxide layer was measured. These results are also shown in table 3. For comparison, inserts coated inventively with different Me compounds of the MeX material were equally tested. It becomes evident that by adding any of the elements according to samples 23 to 32 to Me, the thickness of the resulting oxide film is significantly reduced. With respect to oxidation the best results were realised by adding silicon or yttrium.
It must be pointed out, that it is known to the skilled artisan, that for the MeX material wear resistant layers there is valid: The better the oxidation resistance and thus the thinner the resulting oxide film, the better the cutting performance.
TABLE 3__________________________________________________________________________ Thickness ofSample No. Layer Composition w x y z Oxide Film (μm)__________________________________________________________________________Present 23 (Ti.sub.x Al.sub.y Y.sub.z)N 0.48 0.5 0.02 0.7Invention 24 (Ti.sub.x Al.sub.y Cr.sub.z)N 0.48 0.5 0.02 0.9 25 (Ti.sub.x Al.sub.y Zr.sub.z)N 0.48 0.5 0.02 0.7 26 (Ti.sub.x Al.sub.y Y.sub.z)N 0.25 0.5 0.25 0.1 27 (Ti.sub.x Al.sub.y Zr.sub.z)N 0.25 0.5 0.25 0.5 28 (Ti.sub.z Al.sub.y W.sub.z)N 0.4 0.5 0.1 0.8 29 (Ti.sub.x Al.sub.y Si.sub.z)N 0.4 0.5 0.1 0.1 30 (Ti.sub.x Al.sub.y Si.sub.z)N 0.48 0.5 0.02 0.2 31 (Ti.sub.x Al.sub.y Hf.sub.z)N 0.4 0.5 0.1 0.9 32 (Ti.sub.x Al.sub.y Y.sub.z Si.sub.w)N 0.1 0.3 0.5 0.1 0.05Comparison 33 (Ti.sub.x Al.sub.y)N 0.4 0.6 1.8 34 (Ti.sub.x Al.sub.y Nb.sub.z)N 0.4 0.5 0.1 2.5 35 (Ti.sub.x Al.sub.y Ta.sub.z)N 0.4 0.5 0.1 3.3__________________________________________________________________________
EXAMPLE 4
An apparatus and a coating method as used for the samples of Example 1 was again used.
HSS drills with a diameter of 6 mm were coated with a 4.5 μm MeX and a TiN interlayer was provided between the MeX layer and the tool body, with a thickness of 0.1 μm. The test condition were.
Tool: HSS twist drill, dia. 6 mm
Material: DIN 1.2080 (AISI D3)
Cutting parameters:
v c =35 m/min
f=0.12 mm/rev.
15 mm deep blind holes with coolant.
TABLE 4__________________________________________________________________________ Bias N.sub.2 - Arc Number of Voltage Pressure current inter- Residual drilled (-V) (mbar) (A) layer layer x y z Q.sub.1 Stress (GPa) holes__________________________________________________________________________Present 36 40 3.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 5.4 2.1 230Invention 0.1 μm 37 40 3.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y B.sub.z)N 0.58 0.4 0.02 3.8 2.3 190 0.1 μmComparsion 38 150 1.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 0.03 4.5 10 0.1 μm 39 150 1.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y B.sub.z)N 0.58 0.4 0.02 0.1 4.8 38 0.1 μm__________________________________________________________________________
The lifetime of the tool was determined by the number of holes which could be drilled before failure of the drill.
The results of the inventively coated drills are shown as samples No. 36 and 37 in Table 4, the samples No. 38 and 39 again show comparison samples. Again, I(200) exceeded 20 times intensity average noise level by far, for samples 36, 37, as measured by MS.
EXAMPLE 5
Again, the apparatus and method as mentioned for Example 1 was used for coating HSS roughing mills with a diameter of 12 mm with a 4.5 μm MeX layer. There was provided a titanium nitride interlayer with a thickness of 0.1 μm between the MeX layer and the tool body. The test conditions were:
______________________________________Tool: HSS roughing mill, dia. 12 mm z = 4Material: AISI H13 (DIN 1.2344) 640 N/mm.sup.2Cutting parameters: v.sub.c = 47.8 m/min f.sub.t = 0.07 mm a.sub.p = 18 mm a.sub.a = 6 mm climb milling, dry.______________________________________
The HSS roughing mill was used until an average width of flank wear of 0.2 mm was obtained.
Sample No. 40 in Table No. 5 shows the results of the inventively coated tool, sample 41 is again for comparison. Again, I(200) of sample Nr. 40 fulfilled the condition with respect to noise, as measured by MS.
TABLE 5__________________________________________________________________________ Bias N.sub.2 - Arc Cutting Volatge Pressure current inter- Residual distance (-V) (mbar) (A) layer layer x y Q.sub.1 Stress (GPa) (m)__________________________________________________________________________Present 40 40 3.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 5.4 2.1 35 mInvention 0.1 μmComparison 41 150 1.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 0.03 4.5 11 m 0.1 μm (chipping and pee- ling off)__________________________________________________________________________
EXAMPLE 6
Again, the apparatus and coating method according to Example 1 was used. Solid carbide end mills with a diameter of 10 mm with 6 teeth were coated with a 3.0 μm MeX layer. There was provided a titanium nitride interlayer with a thickness of 0.08 μm between the MeX and the tool body. Test conditions for the end mills were:
______________________________________Tool: Solid carbide end mill, dia. 10 mm z = 6Material: AISI D2 (DIN 1.2379) 60 HRCCutting parameters: v.sub.c = 20 m/min f.sub.t = 0.031 mm a.sub.p = 15 mm a.sub.c = 1 mm Climb milling, dry______________________________________
The solid carbide end mills were used until an average width of flank wear of 0.20 mm was obtained. It is to be noted that solid carbide end mills do no belong to that group of tool which is inventively coated with a hard material layer having Q I ≧1. From the result in Table 6 it may clearly be seen that for this kind of tools Q I >1 does not lead to an improvement. Again, the I(200) to noise condition, measured with MS, was fulfilled for sample No. 42, for sample No. 43 the I(111) to noise condition was fulfilled.
TABLE 6__________________________________________________________________________ Bias N.sub.2 - Arc Cutting Volatge Pressure current inter- Residual distance (-V) (mbar) (A) layer layer x y Q.sub.1 Stress (GPa) (m)__________________________________________________________________________Present 42 40 3.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 5.0 2.2 17 mInvention 0.08 μmComparison 43 150 1.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 0.05 4.7 32 m 0.08 μm__________________________________________________________________________
EXAMPLE 7
Again, an apparatus and method as used for the samples of Example 1 were used.
Solid carbide drills with a diameter of 11.8 mm were coated with a 4.5 μm MeX layer. There was provided a TiN interlayer between the MeX layer and the tool body.
______________________________________Test conditions:______________________________________Tool: Solid carbide drill, diam. 11.8 mmWorkpiece: Cast iron GG25Machining conditions: v.sub.c = 110 m/min f = 0.4 mm/rev. Blind hole 3 × diam. No coolant______________________________________
The solid carbide drills were used until a maximum width of flank wear of 0.8 mm was obtained. The I(200) to noise condition was again fulfilled, measured with MS.
TABLE 7__________________________________________________________________________ Bias N.sub.2 - Arc Drilling Volatge Pressure current inter- Residual distance (-V) (mbar) (A) layer layer x y Q.sub.1 Stress (GPa) (m)__________________________________________________________________________Present 44 40 3.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 5.4 2.1 95 mInvention 0.1 μmComparison 45 150 1.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 0.03 4.5 48.5 m 0.1 μm__________________________________________________________________________
EXAMPLE 8
Again, the apparatus and method as stated in Example 1 were used. Cemented carbide inserts for turning with a shape in accordance with CNGP432 were coated with a 4.8 μm MeX layer. There was provided a TiN interlayer with a thickness of 0.12 μm between the MeX layer and the tool body. The test conditions were:
______________________________________Tool: Carbide insert (CNGP432)Material: DIN 1.4306 (X2CrNi 1911)Cutting parameters: v.sub.c = 244 m/min f = 0.22 mm/rev. a.sub.p = 1.5 mm with emulsion______________________________________
The tool life was evaluated in minutes. The indicated value is an average of three measurements. Again, I(200)/noise condition, measured with MS, was fulfilled.
TABLE 8__________________________________________________________________________ Bias N.sub.2 - Arc Volatge Pressure current inter- Residual Tool life (-V) (mbar) (A) layer layer x y Q.sub.1 Stress (GPa) (min)__________________________________________________________________________Present 46 40 3.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 5.8 1.9 18.1 mInvention 0.12 μmComparison 47 150 1.0 × 10.sup.-2 200 TiN (Ti.sub.x Al.sub.y)N 0.6 0.4 0.04 4.9 5.5 min 0.12 μm__________________________________________________________________________
In FIG. 1 there is shown, with linear scaling a diagram of nitrogen partial pressure versus bias voltage of the tool body as applied for reactive cathodic arc evaporation as the reactive PVD deposition method used to realise the Examples which were discussed above.
All the process parameters of the cathodic arc evaporation process, namely
arc current;
process temperature;
deposition rate;
evaporated material;
strength and configuration of magnetic field adjacent the arc source;
geometry and dimensions of the process chamber and of the workpiece tool to be treated
were kept constant. The remaining process parameters, namely partial pressure of the reactive gas--or total pressure--and bias voltage of the tool body to be coated as a workpiece and with respect to a predetermined electrical reference potential, as to the ground potential of the chamber wall, were varied.
Thereby, titanium aluminum nitride was deposited. With respect to reactive gas partial pressure and bias voltage of the tool body, different working points were established and the resulting Q I values at the deposited hard material layers were measured according to MS.
It turned out that there exists in the diagram according to FIG. 1 and area P, which extends in a first approximation linearly from at least adjacent the origin of the diagram coordinates, wherein the resulting layer lead to very low XRD intensity values of I(200) and I(111). It is clear that for exactly determining the limits of P, a high number of measurements will have to be done. Therein, none of the I(200) and I(111) intensity values is as large as 20 times the average noise level, measured according to MS.
On one side of this area P and as shown in FIG. 1 Q I is larger than 1, in the other area with respect to P, Q I is lower than 1. In both these areas at least one of the values I(200), I(111) is larger than 20 times the average noise level, measured according to MS.
As shown with the arrows in FIG. 1, diminishing of the partial pressure of the reactive gas--or of the total pressure if it is practically equal to the said partial pressure--and/or increasing of the bias voltage of the tool body being coated, leads to reduction of Q I . Thus, the inventive method for producing a tool which comprises a tool body and a wear resistant layer system, which latter comprises at least one hard material layer, comprises the steps of reactive PVD depositing the at least one hard material layer in a vacuum chamber, thereby preselecting process parameter values for the PVD deposition process step beside of either or both of the two process parameters, namely of partial pressure of the reactive gas and of bias voltage of the tool body. It is one of these two parameters or both which are then adjusted for realising the desired Q I values, thus, and according to the present invention, bias voltage is reduced and/or partial reactive gas pressure is increased to get Q I values, which are, as explained above, at least larger than 1, preferably at least larger than 2 or even 5 and even better of 10. Beside the inventively exploited Q I value, in this "left hand" area, with respect to P, I(200) is larger, mostly much larger than 20 times the average noise level of intensity, measured according to MS.
In FIG. 2 a typical intensity versus angle 2θ diagram is shown for the titanium aluminum nitride hard material layer deposited in the Q I ≧1 region according to the present invention of FIG. 1, resulting in a Q I value of 5.4 The average noise level N * is much less than I(200)/20. Measurement is done according to MS.
In FIG. 3 a diagram in analogy of that in FIG. 2 is shown, but the titanium aluminum nitride deposition being controlled by bias voltage and nitrogen partial pressure to result in a Q I ≧1. The resulting Q I value is 0.03. Here the I(111) value is larger than the average noise level of intensity, measured according to MS.
Please note that in FIG. 1 the respective Q I values in the respective regions are noted at each working point measured (according to MS).
In FIG. 4 a diagram in analogy to that of the FIGS. 2 and 3 is shown for working point P 1 of FIG. 1. It may be seen that the intensities I(200) and I(111) are significantly reduced compared with those in the area outside P. None of the values I(200) and I(111) reaches the value of 20 times the noise average level N * .
Thus, by simply adjusting at least one of the two Q I -controlling reactive PVD process parameters, namely of reactive gas partial pressure and of workpiece bias voltage, the inventively exploited Q I value is controlled.
In FIG. 1 there is generically shown with δQ I <0 the adjusting direction for lowering Q I , and it is obvious that in opposite direction of adjusting the two controlling process parameters, and increase of Q I is reached.
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A tool has a tool body and a wear resistant layer system, which layer system has at least one layer of MeX. Me comprises titanium and aluminum and X is nitrogen or carbon. The tool has a tool body of high speed steel (HSS) or of cemented carbide, but it is not a solid carbide end mill and not a solid carbide ball nose mill. In the MeX layer, the quotient Q I as defined by the ratio of the diffraction intensity I(200) to I(111) assigned respectively to the (200) and (111) plains in the X ray diffraction of the material using θ-2θ method is selected to be ≧1. Further, the I(200) is at least twenty times larger than the intensity average noise value, both measured with a well-defined equipment and setting thereof.
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TECHNICAL FIELD
The present invention relates to a method for producing water-absorbing resin particles, water-absorbing resin particles obtained by the method, a water blocking material, and an absorbent article. The present invention specifically relates to a method for producing, under specific production conditions, water-absorbing resin particles having high equilibrium swelling capacity, high initial swelling capacity or a high water-absorption rate, and an appropriate particle size that achieves excellent handling performance; water-absorbing resin particles with an excellent water blocking ability obtained by the method; and a water blocking material and an absorbent article which include the water-absorbing resin particles.
BACKGROUND ART
In recent years, water-absorbing resin particles have been widely used in various fields of, for example, hygienic articles such as disposable diaper and sanitary articles; agricultural and horticultural materials such as water-retaining materials and soil conditioners; and industrial and construction materials such as water blocking materials for cables and dewfall preventing materials. As the water-absorbing resin particles used in such fields, there have been known, for example, a hydrolyzed starch-acrylonitrile graft copolymer, a neutralized starch-acrylic acid graft copolymer, a saponified vinyl acetate-acrylic ester copolymer, and a partially neutralized polyacrylate. Generally, it has been desirable for water-absorbing resin particles to have high water absorption, an excellent water-absorption rate, high swelling capacity, and an appropriate median particle size in accordance with the uses.
Among these, water blocking materials for cables are formed of two or more liquid-permeable sheets and water-absorbing resin particles that are fixed between the sheets, if necessary using an adhesive and the like. The demand for such water blocking materials has increased with development of electrical industry and communication industry. Water blocking materials for cables are used to wrap the cores of cables such as power cables and optical communication cables, and thereby the cores are protected. Then, the outside of the water blocking materials is covered with materials such as rubber. Thus, cables are formed. If the outer materials of cables such as power cables and optical communication cables are deteriorated to produce cracks and moisture enters through the cracks and reaches the cores of the cables, reduction in electric power and communication noise may be caused. The water blocking materials prevent such problems. The water blocking materials absorb such moisture and swell to increase the pressure in the cables, and thereby moisture is prevented from reaching the cores of the cables.
It has been also desirable for a water-absorbing resin used as a water blocking material that is used for cables (e.g., power cables and optical communication cables) to have high absorption capacity of liquid with a high salt concentration such as seawater. In order to achieve such absorption capacity, the following methods are suggested: a method of polymerizing an amino group-containing water-soluble ethylenically unsaturated monomer with acrylic acid in the presence of a crosslinking agent (see Patent Literature 1); a method of mixing a water-absorbing resin with an anionic surfactant (see Patent Literature 2); and a method of coating the surfaces of water-absorbing polymer particles with a water soluble resin solution (see Patent Literature 3).
However, specific materials need to be used in these methods, which leads to an increase in production costs. Rather, use of a large amount of a conventional water-absorbing resin often reduces the costs of a water blocking material and improves the performance of a water blocking material. Therefore, such conventional methods have brought not so great effects to the industries.
Further, a water-absorbing resin used as a water blocking material needs to prevent water penetration from the outside owing to cable damage early and maintain a water blocking effect for a long time. In addition to these, the water-absorbing resin needs to be efficiently formed into a water blocking material and have excellent handling performance as powder in the production of the water blocking material. Therefore, in order to achieve such performances, water-absorbing resin particles used for a water blocking material need to have high swelling capacity, a high water-absorption rate, and an appropriate particle size that achieves good handling performance.
One way of improving swelling capacity of water-absorbing resin particles is to control crosslink density thereof. For example, the following methods are suggested. A method in which reversed-phase suspension polymerization of an acrylic acid/acrylate aqueous solution is carried out in the coexistence of a surfactant with an HLB of 8 to 12, a crosslinking agent is added thereto (immediately after the polymerization), and a crosslinking reaction is carried out (see Patent Literature 4); and a method in which a percentage of water content of a carboxyl group-containing polymer is set at 10 to 30 wt %, and a crosslinking reaction of the surface is started (see Patent Literature 5). However, even these methods do not achieve high swelling capacity that is needed for water-absorbing resin particles used for a water blocking material.
Therefore, a technology for producing water-absorbing resin particles having high equilibrium swelling capacity, a high water-absorption rate or high initial swelling capacity, and an appropriate particle size that achieves good handling performance is desirable.
CITATION LIST
Patent Literature
Patent Literature 1: Japanese Kokai Publication H04-45850 (JP-A H04-45850)
Patent Literature 2: Japanese Kokai Publication H06-322179 (JP-A H06-322179)
Patent Literature 3: Japanese Kokai Publication H03-285918 (JP-A H03-285918)
Patent Literature 4: Japanese Kokai Publication S56-131608 (JP-A S56-131608)
Patent Literature 5: Japanese Kokai Publication H03-195705 (JP-A H03-195705)
SUMMARY OF INVENTION
Technical Problem
An object of the present invention is to provide a method for producing water-absorbing resin particles having high equilibrium swelling capacity, a high water-absorption rate or high initial swelling capacity, and an appropriate particle size that achieves good handling performance; water-absorbing resin particles obtained by the method; and a water blocking material and an absorbent article which include the water-absorbing resin particles.
Solution to Problem
The present invention relates to the following method for producing water-absorbing resin particles, water-absorbing resin particles obtained by the method, a water blocking material and an absorbent article which include the water-absorbing resin particles.
That is, the present invention relates to:
1. a method for producing water-absorbing resin particles, which comprises: preparing a hydrogel polymer by reversed-phase suspension polymerization of a water-soluble ethylenically unsaturated monomer in a hydrocarbon solvent in the absence of an internal crosslinking agent but in the presence of a surfactant with an HLB of 8 to 12; carrying out a post-crosslinking reaction of the hydrogel polymer whose moisture content is adjusted to 30 to 110 mass % based on a water-soluble ethylenically unsaturated monomer component that composes the hydrogel polymer; 2. the method described in 1, wherein the surfactant with an HLB of 8 to 12 is at least one compound selected from the group consisting of sorbitan fatty acid esters, polyglycerin fatty acid esters, and sucrose fatty acid esters; 3. the method described in 1 or 2, wherein a post-crosslinking agent is a glycidyl ether compound; 4. the method described in 1, 2, or 3, wherein the amount of a post-crosslinking agent is 0.0001 to 1 mol % based on the total molar amount of the water-soluble ethylenically unsaturated monomer; 5. the method described in 1, 2, 3, or 4, wherein the amount of a post-crosslinking agent based on the total molar amount of the water-soluble ethylenically unsaturated monomer is in the range of the formula:
(−0.0002 Z+ 0.023)≦ Y ≦(−0.0002 Z+ 0.050) (1)
wherein Y represents the amount (mol %) of the post-crosslinking agent, and Z represents the moisture content (mass %) of the hydrogel polymer that is mixed with the post-crosslinking agent; 6. water-absorbing resin particles obtained by the method described in 1, 2, 3, 4, or 5; 7. the water-absorbing resin particles described in 6, wherein equilibrium swelling capacity is 10 to 28 mm, a water-absorption rate is 1 to 20 seconds, and a median particle size is 80 to 400 μm; 8. an absorbent article, which comprises: a liquid-permeable sheet; a liquid-impermeable sheet; and an absorber sandwiched between the liquid-permeable sheet and the liquid-impermeable sheet, the absorber including the water-absorbing resin particles described in 6 or 7; and 9. a water blocking material, which comprises: two or more liquid-permeable sheets; and an absorber sandwiched with two or more sheets of the liquid-permeable sheets, the absorber including the water-absorbing resin particles described in 6 or 7 in an amount of 30 to 300 g/m 2 .
The present invention is described in detail below.
The method for producing water-absorbing resin particles of the present invention includes preparing a hydrogel polymer by reversed-phase suspension polymerization of a water-soluble ethylenically unsaturated monomer in a hydrocarbon solvent in the absence of an internal crosslinking agent but in the presence of a surfactant with an HLB of 8 to 12.
Examples of the water-soluble ethylenically unsaturated monomer include (meth)acrylic acid (“acryl-” and “methacryl-” as used herein are collectively referred to as “(meth)acryl-”, hereinafter the same applies), nonionic monomers such as 2-(meth)acrylamide-2-methylpropanesulfonic acid and/or an alkali salt thereof, (meth)acrylamide, N,N-dimethyl(meth)acrylamide, 2-hydroxyethyl(meth)acrylate, N-methylol(meth)acrylamide, and polyethylene glycol mono(meth)acrylate; amino group-containing unsaturated monomers such as N,N-diethylaminoethyl(meth)acrylate, N,N-diethylaminopropyl(meth)acrylate, and diethylaminopropyl(meth)acrylamide and quaternary salts thereof. At least one monomer selected from the group may be used. Among these, acrylic acid, methacrylic acid, or alkali salts thereof, acrylamide, methacrylamide, or N,N-dimethylacrylamide is preferably used because they are industrially available.
The water-soluble ethylenically unsaturated monomer may be usually used in the form of an aqueous solution. The concentration of the water-soluble ethylenically unsaturated monomer in the aqueous solution is preferably in the range of from 20 mass % to a concentration of the saturated aqueous solution. The concentration of the water-soluble ethylenically unsaturated monomer is more preferably 25 to 45 mass %, still more preferably 30 to 42 mass %, and particularly preferably 35 to 40 mass % because the state of W/O reversed-phase suspension is improved, particles with an appropriate particle size can be obtained, and swelling capacity of the resulting water-absorbing resin particles is improved.
When the water-soluble ethylenically unsaturated monomer is an acid group-containing monomer such as methacrylic acid and 2-(meth)acrylamide-2-methylpropanesulfonic acid, the acid radical of the monomer may be neutralized by an alkaline neutralizer such as an alkali metal salt. Examples of such an alkaline neutralizer include aqueous solutions of sodium hydroxide, potassium hydroxide, and ammonium hydroxide. Each example of the alkaline neutralizer may be used alone, or two or more of these may be used in combination.
The degree of neutralization of all the acid groups by the alkaline neutralizer is preferably in the range of from 10 to 100 mol %, more preferably in the range of from 30 to 90 mol %, still more preferably in the range of from 50 to 80 mol %, and particularly preferably in the range of from 65 to 78 mol % in order to increase osmotic pressure of the resulting water-absorbing resin particles, whereby their high swelling capacity is achieved, and to prevent disadvantages in safety or the like caused by the remaining excess alkaline neutralizer.
Examples of a radical polymerization initiator added to the aqueous solution of the water-soluble ethylenically unsaturated monomer include: persulfates such as potassium persulfate, ammonium persulfate, and sodium persulfate; peroxides such as methyl ethyl ketone peroxide, methyl isobutyl ketone peroxide, di-t-butyl peroxide, t-butylcumyl peroxide, t-butyl peroxyacetate, t-butyl peroxyisobutyrate, t-butyl peroxypivalate, and hydrogen peroxide; and azo compounds such as 2,2′-azobis[2-(N-phenylamidino)propane]dihydrochloride, 2,2′-azobis[2-(N-allylamidino)propane]dihydrochloride, 2,2′-azobis{2-[1-(2-hydroxyethyl)-2-imidazoline-2-yl]propane}dihydrochloride, 2,2′-azobis{2-methyl-N-[1,1-bis(hydroxymethyl)-2-hydroxyethyl]propioneamide}, 2,2′-azobis[2-methyl-N-(2-hydroxyethyl)-propioneamide], and 4,4′-azobis(4-cyano valeric acid). Each of these radical polymerization initiators may be used alone, or two or more of these may be used in combination.
The radical polymerization initiator is usually added in an amount of from 0.005 to 1 mol % based on the total molar amount of the water-soluble ethylenically unsaturated monomer. An amount less than 0.005 mol % of the radical polymerization initiator is not preferred because the polymerization reaction takes a large amount of time. An amount of the initiator exceeding 1 mol % is not preferred because the polymerization reaction rapidly occurs.
The radical polymerization initiator may be also used as a redox polymerization initiator together with a reducing agent such as sodium sulfite, sodium hydrogen sulfite, ferrous sulfate, and L-ascorbic acid.
In addition, in order to control swelling capacity of the water-absorbing resin particles, a chain transfer agent may be added. Examples of the chain transfer agent include hypophosphites, thiols, thiolic acids, secondary alcohols, and amines.
The method for producing water-absorbing resin particles of the present invention includes reversed-phase suspension polymerization in the absence of an internal crosslinking agent but in the presence of a surfactant with an HLB of 8 to 12.
In aqueous polymerization, swelling capacity, especially equilibrium swelling capacity, of the water-absorbing resin particles may be improved through a polymerization reaction in the absence of an internal crosslinking agent. However, the hydrogel polymer resulting from the polymerization is too viscous to be cut, which considerably increases a load on the subsequent drying process and crushing process. Therefore, water-absorbing resin particles having good swelling capacity and an appropriate particle size are difficult to be obtained.
In the conventional reversed-phase suspension polymerization, a hydrogel polymer can be obtained without using an internal crosslinking agent at the time of the polymerization reaction, but some aggregated substances tend to be generated or particles tend to be adhered to one another to be flocculated.
As a result of intensive investigations by the present inventors, it has been found that particles suitable for a water blocking material can be simply obtained by reversed-phase suspension polymerization of a water-soluble ethylenically unsaturated monomer in an aqueous solution using a specific surfactant and a hydrocarbon solvent. In addition, a post-crosslinking reaction of the particles is carried out, and thereby high-performance water-absorbing resin particles suitable for a water blocking material can be obtained. Thus, the present invention has been completed.
The “internal crosslinking agent” in the present invention refers to a compound contributing to form a cross-linked structure between high polymer chains during polymerization of a monomer. The “internal crosslinking agent” specifically refers to, for example, a compound having, in the molecule, two or more polymerizable unsaturated groups that are polymerizable with the water-soluble ethylenically unsaturated monomer, or a compound having, in the molecule, two or more functional groups that can react with a functional group (for example, a carboxyl group when the water-soluble ethylenically unsaturated monomer is acrylic acid) included in the water-soluble ethylenically unsaturated monomer.
In the present invention, a surfactant with an HLB of 8 to 12 is used. Use of the surfactant with an HLB of 8 to 12 improves the state of the W/O reversed-phase suspension and provides particles with an appropriate particle size. The HLB of the surfactant is preferably 8.5 to 10.5.
Examples of the surfactant includes nonionic surfactants such as sorbitan fatty acid esters, (poly)glycerin fatty acid esters, (the expression “(poly)” indicates both a case in which the prefix “poly” is placed before the term and a case in which “poly” is not placed before the term, hereinafter the same applies), sucrose fatty acid esters, polyoxyethylene sorbitan fatty acid esters, polyoxyethylene glycerin fatty acid esters, sorbitol fatty acid esters, polyoxyethylene sorbitol fatty acid esters, polyoxyethylene alkyl ethers, polyoxyethylene alkylphenyl ethers, polyoxyethylene castor oil, polyoxyethylene hydrogenated castor oil, alkylallylformaldehyde condensed polyoxyethylene ethers, polyoxyethylene polyoxypropylene block copolymers, polyoxyethylene polyoxypropyl alkyl ethers, and polyethylene glycol fatty acid esters; and anionic surfactants such as fatty acid salts, alkylbenzene sulfonates, alkyl methyl taurates, polyoxyethylene alkyl phenyl ether sulfates, polyoxyethylene alkyl ether sulfonates, polyoxyethylene alkyl ether phosphates, and polyoxyethylene alkyl allyl ether phosphates. Among these, sorbitan fatty acid esters, polyglycerine fatty acid esters, and sucrose fatty acid esters are preferred because they improve the state of the W/O reversed-phase suspension and provide particles with a particle size suitable for a water blocking material, and they are industrially available. Among these, sorbitan fatty acid esters are more preferred because the resulting water-absorbing resin particles have high swelling capacity. Each of these surfactants may be used alone, or two or more of these may be used in combination.
In the present invention, polymer protective colloid may be used together with the surfactant in order to stabilize the state of the W/O reversed-phase suspension. Examples of the polymer protective colloid include maleic anhydride-modified polyethylene, maleic anhydride-modified polypropylene, maleic anhydride-modified ethylene-propylene copolymer, maleic anhydride-modified EPDN (ethylene-propylene-diene-terpolymer), maleic anhydride-modified polybutadiene, ethylene-maleic anhydride copolymer, ethylene-propylene-maleic anhydride copolymer, butadiene-maleic anhydride copolymer, oxidized polyethylene, ethylene-acrylic acid copolymer, ethyl cellulose, and ethyl hydroxyethyl cellulose. Among these, maleic anhydride-modified polyethylene, maleic anhydride-modified polypropylene, maleic anhydride-modified ethylene-propylene copolymer, oxidized polyethylene, and ethylene-acrylic acid copolymer are preferred in view of stability of the W/O reversed-phase suspension. Each of these polymer protective colloids may be used alone, or two or more of these may be used in combination.
In order to stabilize the state of the W/O reversed-phase suspension and select the efficient amount for a suspension stabilization effect, the amount of the surfactant is preferably 0.1 to 5 parts by mass, more preferably 0.2 to 3 parts by mass, and still more preferably 0.4 to 2 parts by mass, based on 100 parts by mass of the aqueous solution of the water-soluble ethylenically unsaturated monomer which is to be subjected to reversed-phase suspension polymerization.
Examples of the hydrocarbon solvent include aliphatic hydrocarbons such as n-hexane, n-heptane, and ligroin; alicyclic hydrocarbons such as cyclopentane, methylcyclopentane, cyclohexane, and methylcyclohexane; and aromatic hydrocarbons such as benzene, toluene, and xylene. Each of these may be used alone, or two or more of these may be used in combination. Among these, n-hexane, n-heptane, and cyclohexane are preferred because they are industrially available. Particularly, n-heptane is more preferred because the state of the W/O reversed-phase suspension of the present invention is improved, particles with a particle size suitable for a water blocking material are easily provided, and the resulting water-absorbing resin particles have good swelling capacity.
In order to appropriately remove heat of the polymerization to make the polymerization temperature easy to control, the amount of the hydrocarbon solvent is preferably 50 to 600 parts by mass and more preferably 100 to 550 parts by mass, based on 100 parts by mass of the water-soluble ethylenically unsaturated monomer which is to be subjected to reversed-phase suspension polymerization.
In the present invention, the reaction temperature of the reversed-phase suspension polymerization differs depending on the kind of the water-soluble radical polymerization initiator to be used, and therefore cannot be unconditionally determined. Generally, the reaction temperature is preferably 20° C. to 110° C. and more preferably 40° C. to 90° C. in order to shorten the polymerization time by allowing the polymerization to rapidly proceed, easily remove the heat of the polymerization, and allow the reaction to proceed smoothly. The reaction time is generally 0.5 to 4 hours.
Generally, the water-absorbing resin particles obtained by the reversed-phase suspension polymerization and their precursor (hydrogel polymer) are formed into various forms. For example, they are formed into a spherical shape, granules, debris, or a konpeito shape, or formed as coagulations thereof. In the present invention, the hydrogel polymer is preferably formed into granules because the particles are less likely to be flocculated by adhering, and the particles can be simply obtained in a form suitable for the water blocking material. The granules preferably have uniform irregularities on their surface.
In the method for producing water-absorbing resin particles of the present invention, a post-crosslinking reaction of the hydrogel polymer is subsequently carried out after the moisture content of the hydrogel polymer is adjusted to 30 to 110 mass % based on the water-soluble ethylenically unsaturated monomer component that composes the hydrogel polymer.
Examples of the method (hereinafter, also referred to as the first drying) for adjusting the moisture content of the hydrogel polymer to 30 to 110 mass % based on the water-soluble ethylenically unsaturated monomer component that composes the hydrogel polymer include, but are not particularly limited to: a method of removing water by azeotropic distillation of a solution of the hydrogel polymer dispersed in a hydrocarbon solvent by heating from the outside; a method of low pressure drying a hydrogel polymer that is obtained by decantation; and a method of low pressure drying a hydrogel polymer that is separated using a filter. Among these, removing water by azeotropic distillation of a solution of the hydrogel polymer dispersed in a hydrocarbon solvent is preferred in view of its simple production process.
The post-crosslinking reaction is carried out after the first drying. The post-crosslinking reaction of the hydrogel polymer that is obtained as described above is carried out under the specific conditions. Thereby, water-absorbing resin particles with excellent swelling capacity are prepared.
The post-crosslinking agent is a compound having, in the molecule, two or more functional groups that can react with a functional group (for example, a carboxyl group when the water-soluble ethylenically unsaturated monomer is acrylic acid) included in the water-soluble ethylenically unsaturated monomer. The post-crosslinking agent is preferably a water-soluble compound such as polyols, e.g., ethylene glycol, propylene glycol, 1,4-butanediol, trimethylol propane, glycerin, polyoxyethylene glycol, polyoxypropylene glycol, and polyglycerine; glycidyl ether compounds such as (poly)ethylene glycol diglycidyl ether, (poly)propylene glycol diglycidyl ether, and (poly)glycerin diglycidyl ether; haloepoxy compounds such as epichlorohydrin, epibromhydrin, and α-methyl epichlorohydrin; compounds having two or more reactive functional groups such as isocyanate compounds such as 2,4-tolylenediisocyanate and hexamethylene diisocyanate; oxetane compounds such as 3-methyl-3-oxetane methanol, 3-ethyl-3-oxetane methanol, 3-butyl-3-oxetane methanol, 3-methyl-3-oxetane ethanol, 3-ethyl-3-oxetane ethanol, and 3-butyl-3-oxetane ethanol; oxazoline compounds such as 1,2-ethylenebisoxazoline; carbonate compounds such as ethylene carbonate; and hydroxyalkylamide compounds such as bis[N,N-di(β-hydroxyethyl)]adipamide. Each of these may be used alone, or two or more of these may be used in combination.
Among these, glycidyl ether compounds are preferred in view of their excellent reactivity. Among the glycidyl ether compounds, ethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, glycerin diglycidyl ether, polyethylene glycol diglycidyl ether, and polyglycerol glycidyl ether are more preferred in view of their high water solubility and good handling performance as the post-crosslinking agent. Ethylene glycol diglycidyl ether and propylene glycol diglycidyl ether are still more preferred in view of high swelling capacity of the resulting water-absorbing resin particles.
The amount of the post-crosslinking agent based on the total molar amount of the water-soluble ethylenically unsaturated monomer that composes the hydrogel polymer is preferably 0.0001 to 1 mol %, more preferably 0.0005 to 0.5 mol %, still more preferably 0.001 to 0.1 mol %, and particularly preferably 0.005 to 0.05 mol %. If the amount of the post-crosslinking agent based on the total molar amount of the water-soluble ethylenically unsaturated monomer is less than 0.0001 mol %, the water-absorbing resin particles are weakly cross-linked and the surfaces of the particles tend to be viscous when the particles absorb water and the initial swelling capacity tends to be low. If the amount exceeds 1 mol %, the particles are excessively cross-linked to one another, which results in low equilibrium swelling capacity.
The total molar amount of the water-soluble ethylenically unsaturated monomer component that composes the hydrogel polymer equals to the sum of the molar amounts of the water-soluble ethylenically unsaturated monomers used in the polymerization reaction.
In the present invention, mixing of the hydrogel polymer with the post-crosslinking agent is performed after adjusting the moisture content of the hydrogel polymer to a specific range. Thus, the moisture content of the hydrogel polymer at the time of mixing the hydrogel polymer with the post-crosslinking agent is controlled, which allows the post-crosslinking reaction to more suitably proceed.
The moisture content of the hydrogel polymer in the post-crosslinking process is 30 to 110 mass %, preferably 35 to 105 mass %, more preferably 40 to 100 mass %, still more preferably 45 to 95 mass %, particularly preferably 50 to 90 mass %, and most preferably 55 to 85 mass %, based on the water-soluble ethylenically unsaturated monomer component that composes the hydrogel polymer. Such a moisture content in the above range shortens the time of the first drying process, improves the efficiency of the first drying process, and maximally improves swelling capacity obtained by the post-crosslinking reaction.
The moisture content may be determined as follows: the amount of moisture in the hydrogel polymer is determined as the sum of the amount of moisture, which is used if needed when the post-crosslinking agent is added, and the amount of moisture (amount of moisture of the first-dried gel) obtained by subtracting the amount of moisture removed out in the first drying process from the amount of moisture in an aqueous monomer solution before polymerization; and the ratio of the resulting amount of moisture in the hydrogel polymer to the mass of the water-soluble ethylenically unsaturated monomer component that composes the hydrogel polymer is determined.
The mass of the water-soluble ethylenically unsaturated monomer component that composes the hydrogel polymer may be determined as a theoretical polymer solid content from the total mass of the water-soluble ethylenically unsaturated monomer that is used for the polymerization reaction.
The ratio of the moisture content of the first-dried gel relative to the moisture amount added if needed, when the post-crosslinking agent is added, is preferably from 100:0 to 60:40, more preferably from 99:1 to 70:30, still more preferably from 98:2 to 80:20, and further more preferably from 98:2 to 90:10, from a stand point of rationally improving economic efficiency of the process by shortening the drying process and simultaneously, dispersing the post-crosslinking agent uniformly.
According to the present invention, in order to give water-absorbing resin particles with high swelling capacity, the amount of the post-crosslinking agent based on the total molar amount of the water-soluble ethylenically unsaturated monomer is preferably in the range of the following formula (1), more preferably in the range of the following formula (2), and still more preferably in the range of the following formula (3).
(−0.0002 Z+ 0.023)≦ Y ≦(−0.0002 Z+ 0.050) (1)
(−0.0002 Z+ 0.025)≦ Y ≦(−0.0002 Z+ 0.046) (2)
(−0.0002 Z+ 0.027)≦ Y ≦(−0.0002 Z+ 0.042) (3)
In the formulae (1) to (3), Y represents the amount (mol %) of the post-crosslinking agent and Z represents the moisture content (mass %) of the hydrogel polymer at the post-crosslinking process.
When the hydrogel polymer is mixed with the post-crosslinking agent, water or a hydrophilic organic solvent may be used as a solvent in order to allow the post-crosslinking agent to uniformly disperse. Examples of the hydrophilic organic solvent include lower alcohols such as methyl alcohol, ethyl alcohol, and isopropyl alcohol; ketones such as acetone and methyl ethyl ketone; ethers such as dioxane and tetrahydrofuran; amides such as N,N-dimethylformamide; and sulfoxides such as dimethyl sulfoxide. Each of these may be used alone or if necessary with water, or two or more of these may be used in combination.
The reaction temperature during the crosslinking reaction of the water-absorbing resin with the post-crosslinking agent is 60° C. or higher, preferably 70° C. to 200° C., and more preferably 80° C. to 150° C. If the reaction temperature is lower than 60° C., the crosslinking reaction is less likely to proceed and takes a long time. If the reaction temperature exceeds 200° C., the resulting water-absorbing resin particles tend to be deteriorated and water absorption capacity thereof tends to be reduced.
The reaction time of the post crosslinking differs depending on the reaction temperature, the kind and amount of the post-crosslinking agent, and therefore can not be unconditionally determined. Generally, the reaction time is 1 to 300 minutes and preferably 5 to 200 minutes.
Although the reason why the water-absorbing resin particles having high swelling capacity are obtained according to the method of the present invention is not understood, the following reason is considered: the best balance between the crosslink density near the surfaces of the water-absorbing resin particles and the crosslink density of the inner portions of the water-absorbing resin particles is provided by preparing the hydrogel polymer with an appropriate particle size in the absence of an internal crosslinking agent, adjusting the moisture content of the hydrogel polymer to a specific range, and carrying out a post-crosslinking reaction of the resulting hydrogel polymer under the specific conditions.
In the present invention, a drying process (hereinafter, referred to as the second drying) may be performed after the post-crosslinking reaction as follows: the solvent such as water and an organic solvent is distilled off by the application of energy such as heat from the outside. Powdered water-absorbing resin particles are prepared through such second drying.
Examples of the method for the second drying include, but are not limited to, a method of removing water and a hydrocarbon solvent at the same time by distillation from the mixture of the hydrocarbon solvent and the post-crosslinked resin particles dispersed in the solvent; a method of low pressure drying resin particles that are obtained by decantation; and a method of low pressure drying resin particles that are separated using a filter. Among these, the method of removing water and a hydrocarbon solvent at the same time by distillation from the mixture of the hydrocarbon solvent and the post-crosslinked resin particles that are dispersed in the solvent is preferred in view of the simple production process.
The method for producing the water-absorbing resin particles of the present invention can provide the water-absorbing resin particles having high equilibrium swelling capacity, a high water-absorption rate and high initial swelling capacity, and an appropriate particle size that achieves good handling performance. Such water-absorbing resin particles are also one aspect of the present invention.
The water-absorbing resin particles of the present invention preferably have equilibrium swelling capacity (value after 10 minutes) of 10 to 28 mm. Such high swelling capacity of the water-absorbing resin particles prevents initial water penetration through a crack of an external material of a cable, achieves a long time water blocking effect, and provides appropriate pressure due to the swollen resin particles, but enough to prevent deterioration of the material of a cable. The equilibrium swelling capacity is more preferably 11 to 24 mm, still more preferably 12 to 20 mm, and particularly preferably 13 to 18 mm.
The water-absorbing resin particles of the present invention preferably have an absorption rate of physiological saline of 1 to 20 seconds. Such an excellent absorption rate can prevent water penetration through a crack of a cable more early. The water-absorption rate is more preferably 1 to 15 seconds and still more preferably 2 to 10 seconds.
The water-absorbing resin particles of the present invention preferably have a median particle size of 80 to 400 μm. The water-absorbing resin particles having such a median particle size can be formed into a thin water blocking material with good handling performance as powder. The median particle size is preferably 100 to 350 μm, more preferably 120 to 300 μm, and still more preferably 130 to 250 μm.
The ratio of the initial swelling capacity (after 1 minute) of the water-absorbing resin particles of the present invention to the equilibrium swelling capacity (value after 10 minutes) is preferably 70 to 100%, more preferably 80 to 100%, and still more preferably 85 to 100%.
The physiological saline absorption of the water-absorbing resin particles of the present invention is not Particularly limited, but the water-absorbing resin particles preferably absorb more physiological saline. The absorption is preferably 35 to 80 g/g, more preferably 45 to 75 g/g, and still more preferably 55 to 70 gig.
The initial swelling capacity (value after 1 minute), equilibrium swelling capacity (value after 10 minutes), a physiological saline-absorption rate, physiological saline absorption, and a median particle size, of the water-absorbing resin particles of the present invention are determined by the measurement methods described in the following Examples. The measurement method of swelling capacity of the present invention sufficiently accurately reproduces even a difference as small as about 1 mm. Therefore, such a measurement method is preferred to confirm a difference in swelling capacity of the water-absorbing resin particles depending on the production methods, and is widely used for evaluation of the water-absorbing resin particles that are used for a water blocking material.
Additives such as a heat-resistant stabilizer, an antioxidant, and an antibacteria agent may be added to the water-absorbing resin particles of the present invention in accordance with the intended use.
The amount of each additive differs depending on the use of the water-absorbing resin particles and the kind of the additive, but is preferably 0.001 to 10 parts by mass, more preferably 0.01 to 5 parts by mass, and still more preferably 0.1 to 2 parts by mass, based on the total mass of 100 parts by mass of the water-soluble ethylenically unsaturated monomer that composes the water-absorbing resin particles.
The total mass of the water-soluble ethylenically unsaturated monomer component that composes the water-absorbing resin particles may be determined as a theoretical polymer solid content from the total mass of the water-soluble ethylenically unsaturated monomer used for a polymerization reaction.
An absorbent article may be formed by a liquid-permeable sheet, a liquid-impermeable sheet, and an absorber sandwiched between the liquid-permeable sheet and the liquid-impermeable sheet. The absorber includes the water-absorbing resin particles of the present invention. Such an absorbent article is also another aspect of the present invention. Examples of the absorbent article of the present invention include disposable diapers, incontinence pads, sanitary articles, pet sheets, drip sheets for foods, and water blocking agents for power cables.
If the absorbent article of the present invention is used for a product in contact with skins, the liquid-permeable sheet is disposed on the side in contact with skins, and the liquid-impermeable sheet is disposed on a side opposite to the side in contact with skins.
Examples of the liquid-permeable sheet include a nonwoven fabric comprising a synthetic resin such as polyethylene, polypropylene, polyester, and polyamide; and a porous synthetic resin sheet. Examples of the liquid-impermeable sheet include a film comprising a synthetic resin such as polyethylene, polypropylene, and polyvinyl chloride and a sheet comprising a composite material including the synthetic resin and a nonwoven fabric.
The absorber including the water-absorbing resin particles of the present invention has a structure in which, for example, a laminate including the water-absorbing resin particles and hydrophilic fibers is wrapped with a permeable sheet such as tissue, or a nonwoven fabric, or a laminate including hydrophilic fibers stacked in a sheet-like structure and the water-absorbing resin particles dispersed between the hydrophilic fibers is wrapped with a permeable sheet such as tissue or a nonwoven fabric. Examples of the hydrophilic fiber include: cellulose fibers such as cotton pulp and chemical pulp; and artificial cellulose fibers such as rayon and acetate.
As one example of the absorbent article according to the present invention, a water blocking material is described below.
The water blocking material can be formed by two or more liquid-permeable sheets; and an absorber sandwiched with two or more sheets of the liquid-permeable sheets. The absorber includes the water-absorbing resin particles of the present invention in an amount of 30 to 300 g/m 2 .
The water blocking material of the present invention specifically has, for example, a sheet-like structure in which the water-absorbing resin particles are fixed to a liquid-permeable sheet using an adhesive. The water blocking material of the present invention is used to wrap the core of a cable such as a power cable and an optical communication cable, and absorbs moisture entering through a crack that is created due to the deterioration of the outer material. Further, the swollen water blocking material increases the pressure in the cable, and thereby moisture is prevented from reaching the core of the cable.
The water blocking material of the present invention preferably includes the water-absorbing resin particles of the present invention in an amount of 30 to 300 g/m 2 and more preferably 100 to 250 g/m 2 .
The same sheet as that used in the absorbent article is used as the liquid-permeable sheet. Examples of the adhesive include: adhesives base on rubber such as natural rubber, butyl rubber, and polyisoprene; adhesives including styrene elastomer such as a styrene-isoprene block copolymer (SIS) and a styrene-butadiene block copolymer (SBS); an ethylene-vinylacetate copolymer (EVA) adhesive; an adhesive including an ethylene-acrylic acid derivative copolymer such as an ethylene-ethyl acrylate copolymer (EEA); an ethylene-acrylic acid copolymer (EAA) adhesive; adhesives including a polyamide such as copolymerized nylon; adhesives including a polyolefin such as polyethylene and polypropylene; adhesives including polyester such as polyethylene terephthalate (PET) and copolymerized polyester; and acrylic adhesives.
Advantageous Effects of Invention
The present invention can provide a method for producing water-absorbing resin particles having high equilibrium swelling capacity, a high water-absorption rate or high initial swelling capacity, and an appropriate particle size that achieves good handling performance; water-absorbing resin particles obtained by the method; and a water blocking material and an absorbent article which include the water-absorbing resin particles.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic explanation view of a swelling capacity measuring apparatus.
DESCRIPTION OF EMBODIMENTS
The present invention is described below in more detail with reference to Examples, but is not limited only to these Examples.
Example 1
A cylindrical round bottomed separable flask having an internal diameter of 100 mm, equipped with a reflux condenser, a dropping funnel, a nitrogen gas inlet tube, and a stirring blade (which is coated with a fluororesin) having two-step four pitched paddle blades having a blade diameter of 50 mm as a stirrer was prepared. This flask was charged with 550 mL of n-heptane, and then 0.84 g of sorbitan monolaurate (Nonion LP-20R manufactured by Nippon Oil & Fats Co., Ltd.) having an HLB of 8.6 was added thereto as a surfactant. The contents were heated to 50° C. to dissolve the surfactant, and thereafter the contents were cooled to 40° C.
A 500-mL Erlenmeyer flask was charged with 70 g (0.783 mol) of an 80.5 mass % aqueous solution of acrylic acid, and then 112.3 g of a 20.9 mass % aqueous solution of sodium hydroxide was added dropwise thereto with cooling with ice to neutralize 75 mol % of the acrylic acid. Thereafter, 0.084 g of potassium persulfate was dissolved therein to prepare an aqueous monomer solution. The aqueous monomer solution has 69.3 g of a solids content equivalent to the polymer and 113 g of a moisture content.
Setting the rotational speed of the stirrer at 800 rpm, the resulting aqueous monomer solution was added to the separable flask. The air in the system was purged with nitrogen for 30 minutes. Thereafter, the flask was immersed in a water bath set at 70° C. to increase the temperature. The polymerization reaction was carried out for 2 hours to give a hydrogel polymer.
Subsequently, the temperature was increased using an oil bath to 120° C. and 78.4 g of water was distilled off from the system by azeotropic distillation of water and n-heptan with reflux of n-heptan. Thereafter, 1.40 g (0.00016 mol) of a 2% aqueous solution of ethylene glycol diglycidyl ether was added thereto (first drying process). At this time, the amount of moisture was 1.37 g, and the moisture content (based on polymer solid content) was 52 mass % based on the water-soluble ethylenically unsaturated monomer component constituting the hydrogel polymer. A mixture of the hydrogel polymer with a post-crosslinking agent was prepared, and the mixture was kept at 80° C. for 2 hours.
Then, the mixture was dried by evaporation of the n-heptane (second drying process) to give 72.1 g of granular water-absorbing resin particles.
Examples 2 to 4
The same operations as in Example 1 were performed to give 72.8 g, 72.7 g, and 73.1 g of granular water-absorbing resin particles, except that the amount of water distilled off from the system in the first drying process was changed to 74.9 g, 64.5 g, and 81.8 g; the amount of the 2% aqueous solution of ethylene glycol diglycidyl ether was changed to 1.05 g (0.00012 mol), 0.7 g (0.00008 mol), and 1.75 g (0.0002 mol); and the moisture content (based on polymer solid content) was changed to 57 mass %, 71 mass %, and 48 mass %, respectively.
Example 5
Granular water-absorbing resin particles were obtained in the same manner as in Example 1, except that the amount of water distilled off from the system in the first drying process was changed to 81.8 g; the 2% aqueous solution of ethylene glycol diglycidyl ether was changed to 2.47 g (0.00019 mol) of a 2% aqueous solution of polyglycerol glycidyl ether; and the moisture content (based on polymer solid content) was changed to 49 mass %. The yield of the resin particles was 72.4 g.
Example 6
Granular water-absorbing resin particles were obtained in the same manner as in Example 1, except that 1.40 g of diglycerin monolaurate (POEM DL-100 manufactured by Riken Vitamin Co., Ltd.) having an HLB of 9.4 was added as a surfactant. The yield of the resin particles was 70.8 g.
Example 7
Granular water-absorbing resin particles were obtained in the same manner as in Example 1, except that 1.75 g of sucrose stearate (S-970 manufactured by Mitsubishi-Kagaku Foods Corporation) having an HLB of 9 was added as a surfactant. The yield of the resin particles was 71.1 g.
Example 8
Flocculated granular water-absorbing resin particles were obtained in the same manner as in Example 1, except that 0.02 g of an amorphous silica powder (TOKUSIL P manufactured by Tokuyama Corporation) was added to the polymerization solution after the completion of the polymerization. The yield of the resin particles was 73.2 g.
Comparative Example 1
Granular water-absorbing resin particles were obtained in the same manner as in Example 1, except that the amount of water distilled off from the system in the first drying process was changed to 97.8 g; the amount of the 2% aqueous solution of ethylene glycol diglycidyl ether was changed to 4.2 g (0.00048 mol); and the moisture content (based on polymer solid content) was changed to 28 mass %. The yield of the resin particles was 71.8 g.
Comparative Example 2
A 500-mL four-necked round bottomed flask equipped with a stirrer, a reflux condenser, a dropping funnel, and a nitrogen gas inlet tube was charged with 213 g of cyclohexane, and then 1.9 g of sorbitan monolaurate (Nonion LP-20R manufactured by Nippon Oil & Fats Co., Ltd.) having an HLB of 8.6 was added thereto. The surfactant was dissolved with stirring at room temperature, and dissolved oxygen was purged by bubbling of nitrogen gas.
A 200-mL Erlenmeyer flask was charged with 48.8 g (0.542 mol) of an 80 mass % aqueous solution of acrylic acid, and 67.0 g of a 25.9 mass % aqueous solution of sodium hydroxide was added dropwise thereto with cooling from the outside to neutralize 80 mol % of the acrylic acid. Thereafter, 0.13 g of potassium persulfate was dissolved therein. The aqueous monomer solution has 48.6 g of a solids content equivalent to the polymer and 67.1 g of a moisture amount (moisture content: 138 mass %).
The resulting aqueous solution of partially neutralized acrylate was added to the four-necked flask and dispersed. The air in the system was sufficiently purged with nitrogen again and then heated. The solution was heated and polymerized for 3 hours in a bath kept at 55° C. to 60° C. To the resulting polymerization solution was added 0.05 g (0.00029 mol) of ethylene glycol diglycidyl ether. Then, the solution was dried by distillation of water and cyclohexane to give 48.5 g of a finely granular dried polymer.
Comparative Example 3
Water-absorbing resin particles were obtained in the same manner as in Example 2, except that 7.0 mg (45 μmol) of N,N′-methylenebisacrylamide Was added to the aqueous monomer solution as an internal crosslinking agent before the polymerization. The yield of the resin particles was 72.1 g.
Comparative Example 4
A 500-mL Erlenmeyer flask was charged with 92 g (1.02 mol) of an 80 mass % aqueous solution of acrylic acid, and then 146.0 g of a 21.0 mass % aqueous solution of sodium hydroxide was added dropwise thereto with cooling with ice to neutralize 75 mol % of the acrylic acid. Thus, an aqueous solution of partially neutralized acrylate having a monomer concentration of 38 mass % was prepared. To the resulting aqueous solution of partially neutralized acrylate was added 18.4 mg (106 μmol) of ethylene glycol diglycidyl ether as an internal crosslinking agent and 92 mg of potassium persulfate as a radical polymerization initiator. Thus, an aqueous monomer solution (a) for the first polymerization was prepared. A 2-L five-necked cylindrical round bottomed flask equipped with a stirrer, a two-step paddle blade, a reflux condenser, a dropping funnel, and a nitrogen gas inlet tube was charged with 340 g (500 mL) of n-heptane, and then 0.92 g of a sucrose fatty acid ester (S-370, HLB: 3.0, manufactured by Mitsubishi-Kagaku Foods Corporation) as a surfactant was dissolved in the n-heptane. Then, the temperature inside the flask was set at 35° C. Thereafter, the aqueous monomer solution (a) for the first polymerization was added thereto. The solution was kept at 35° C. and suspended with stirring, and the air in the system was purged with nitrogen. The flask was then immersed in a water bath set at 70° C. to increase the temperature. The polymerization reaction was carried out for 2 hours.
A 500-mL Erlenmeyer flask was charged with 92 g (1.02 mol) of an 80 mass % aqueous solution of acrylic acid, and then 146.0 g of a 21.0 mass % aqueous solution of sodium hydroxide was added dropwise thereto with cooling with ice to neutralize 75 mol % of the acrylic acid. Thus, an aqueous solution of partially neutralized acrylate having a monomer concentration of 38 mass % was prepared. To the resulting aqueous solution of partially neutralized acrylate was added 9.2 mg (53 μmol) of ethylene glycol diglycidyl ether as an internal crosslinking agent and 18.4 mg of potassium persulfate as a radical polymerization initiator. Thus, an aqueous monomer solution (b) for the second reversed-phase suspension polymerization was prepared. After the completion of the first reversed-phase suspension polymerization, the polymerization slurry was cooled to 50° C. Then, the aqueous monomer solution (b) for the second polymerization was added dropwise into the system in which the surfactant was dissolved. The resulting solution was stirred for 30 minutes at 50° C., and simultaneously, the air in the system was sufficiently purged with nitrogen gas. Then, the flask was immersed in a water bath set at 70° C. to increase the temperature. The polymerization reaction was carried out for 1.5 hours to give a hydrogel polymer.
Subsequently, the temperature was increased using an oil bath set at 120° C. and 250 g of water was distilled off from the system by azeotropic distillation of water and n-heptan with reflux of n-heptan. Thereafter, 110 mg (0.00063 mol) of ethylene glycol diglycidyl ether was added thereto (first drying process). At this time, the moisture content (based on polymer solid content) was 25 mass % based on the water-soluble ethylenically unsaturated monomer component constituting the hydrogel polymer. A mixture of the hydrogel polymer with a post-crosslinking agent was prepared, and the mixture was kept at 80° C. for 2 hours.
Then, the mixture was dried by evaporation of the n-heptane (second drying process) to give 188.3 g of spherical water-absorbing resin particles.
Evaluation
The water-absorbing resin particles obtained in Examples and Comparative Examples were evaluated for the following properties. Table 1 shows the results.
(1) Physiological Saline Absorption of Water-Absorbing Resin Particles
A 500-mL beaker was charged with 500 g of 0.9 mass % saline, and thereto was added 2.0 g of the water-absorbing resin particles. The mixture was stirred for 60 minutes. A mass Wa (g) of a JIS standard sieve with a mesh size of 75 μm was previously determined, and the contents of the beaker were filtered using this sieve. Then, the sieve was allowed to stand for 30 minutes in such a state that the sieve was tilted at a tilt angle of about 30 degrees to the horizontal to filter out excess water.
A mass Wb (g) of the sieve containing water-absorbed gel was determined, and the water absorption was determined by the following formula:
Physiological saline absorption=( Wb−Wa )/2.0
(2) Physiological Saline Absorption Rate of Water-Absorbing Resin Particles
This test was performed in a room at 25±1° C. A 100-mL beaker was charged with 50±0.1 g of physiological saline, a stir bar (8 mmφ×30 mm, without ring) for a magnetic stirrer is placed into the beaker, and the beaker was immersed in a thermostatic bath to adjust the temperature of the solution at 25±0.2° C. Then, the beaker was placed on a magnetic stirrer. The rotational speed was set at 600 r/min. After the formation of eddies in the physiological saline, 2.0±0.002 g of water-absorbing resin particles was quickly added to the beaker. The time (second) from the addition of the water-absorbing resin particles until the eddies on the liquid surface vanishes was measured using a stopwatch to determine the water-absorption rate of the water-absorbing resin particles.
(3) Median Particle Size of Water-Absorbing Resin Particles
With 100 g of the water-absorbing resin particles was mixed 0.5 g of amorphous silica (Sipernat 200 manufactured by Evonik Degussa Japan Co., Ltd.) as a lubricant.
The water-absorbing resin particles were allowed to pass through a JIS standard sieve with a mesh size of 250 μm. If 50 mass % or more of the resin particles passes through the sieve, a median particle size was measured using the combination (A) of sieves. On the other hand, if 50 mass or more of the resin particles was left on the sieve, a median particle size was measured using the combination (B) of sieves.
(A) JIS standard sieves were stacked in the following order, from the top, of: a sieve with a mesh size of 425 μm, a sieve with a mesh size of 250 μm, a sieve with a mesh size of 180 μm, a sieve with a mesh size of 150 μm, a sieve with a mesh size of 106 μm, a sieve with a mesh size of 75 μm, a sieve with a mesh size of 45 μm, and a saucer.
(B) JIS standard sieves were stacked in the following order, from the top, of: a sieve with a mesh size of 850 μm, a sieve with a mesh size of 600 μm, a sieve with a mesh size of 500 μm, a sieve with a mesh size of 425 μm, a sieve with a mesh size of 300 μm, a sieve with a mesh size of 250 μm, a sieve with a mesh size of 150 μm, and a saucer.
The water-absorbing resin particles were placed on the sieve at the top of the combination of the sieves and classified by shaking the sieves using a ro-tap sieve shaker for 20 minutes.
A mass of the water-absorbing resin particles left on each sieve relative to the total amount of the water-absorbing resin particles was expressed in mass percent. The resulting values were summed in the order of decreasing particle size, so that the relation between the mesh size of each sieve and the corresponding summed value of the water-absorbing resin particles left on the sieve expressed in mass percent was plotted on a logarithmic probability paper. The plotted points on the logarithmic probability paper were connected by a straight line to determine a particle size corresponding to 50 mass % integrated mass percent, which was defined as a median particle size.
(4) Swelling Capacity of Water-Absorbent Resin Particles
The swelling capacity of one minute after the start of the water absorption and the swelling capacity of 10 minutes after the start of the water absorption were determined using swelling capacity measuring apparatus. FIG. 1 is a schematic explanation view of the swelling capacity measuring apparatus. The swelling capacity measuring apparatus X shown in FIG. 1 includes travel distance measuring apparatus 1 , a concave circular cup 2 (30 mm in height, 80.5 mm in inside diameter), a plastic convex circular cylinder 3 (80 mm in outside diameter, 60 through holes 7 with a diameter of 2 mm are uniformly formed in a contact face that is in contact with the water-absorbing resin particles), and a nonwoven fabric 4 (liquid permeable nonwoven fabric with a basis weight of 12 g/m 2 ). The swelling capacity measuring apparatus X can determine a change in the distance in 0.01 mm increments using a laser beam 6 . The concave circular cup 2 is made so that a predetermined amount of water-absorbing resin particles is uniformly dispersed. The convex circular cylinder 3 is made so as to uniformly apply 90 g of weight to the water-absorbing resin particles 5 .
0.1 g of a sample (water-absorbing resin particles 5 ) was uniformly dispersed in the concave circular cup 2 , and the nonwoven fabric 4 was disposed thereon. The convex circular cylinder 3 is softly disposed on the nonwoven fabric 4 . The travel distance measuring apparatus 1 was set so that the laser beam 6 illuminated the center portion of the cylinder. 130 g of ion exchange water previously adjusted at 20° C. was added in the concave circular cup 2 , whereby the water-absorbing resin particles 5 were swollen to press the convex circular cylinder 3 . The travel distance of the convex circular cylinder 3 was determined. The travel distances of the convex circular cylinder 3 after one minute from the start of the water absorption and after 10 minutes from the start of the water absorption were determined as the initial swelling capacity (value after 1 minute) and equivalent swelling capacity (value after 10 minutes), respectively. The ratio (initial swelling ratio) of the initial swelling capacity (value after 1 minute) to the equilibrium swelling capacity (value after 10 minutes) was determined.
TABLE 1
Post-crosslinking
Swelling capacity
Amount of
agent
Physiological
Ratio of
internal
Amount
Physiological
saline
Median
Equilibrium
initial
crosslinking
Moisture
based on
saline
absorption
particle
swelling
swelling
agent
content
Amount
monomer
absorption
rate
size
capacity
capacity
[μmol]
[mass %]
[mol]
[mol %]
[g/g]
[sec]
[μm]
[mm]
[%]
Example 1
—
52
0.00016
0.020
68
2
160
14.4
91
Example 2
—
57
0.00012
0.015
67
3
150
13.8
91
Example 3
—
71
0.00008
0.010
69
3
140
12.6
84
Example 4
—
48
0.0002
0.026
61
2
150
15.1
88
Example 5
—
49
0.00019
0.024
70
2
160
14.1
90
Example 6
—
52
0.00016
0.020
66
3
220
12.1
85
Example 7
—
52
0.00016
0.020
65
3
250
13.2
88
Example 8
—
52
0.00016
0.020
63
2
340
13.2
88
Comparative
—
28
0.00048
0.061
68
2
160
9.8
94
Example 1
Comparative
—
138
0.00029
0.053
90
2
150
8.4
79
Example 2
Comparative
45
57
0.00012
0.015
59
3
120
9.1
88
Example 3
Comparative
159
25
0.00063
0.031
60
6
60
9.8
67
Example 4
Table 1 shows that the water-absorbing resin particles obtained in Examples 1 to 8 have high swelling capacity and an appropriate median particle size, but the water-absorbing resin particles obtained in Comparative Examples have insufficient swelling capacity.
INDUSTRIAL APPLICABILITY
The water-absorbing resin particles of the present invention may be widely used in various fields of, for example, hygienic articles such as disposable diaper, sanitary articles, and pet sheets; agricultural and horticultural materials such as water-retaining materials and soil conditioners; and industrial and construction materials such as water blocking materials for cables such as power cables and optical communication cables and dewfall preventing materials. Particularly, the resin particles are used for industrial and construction materials such as water blocking materials for power cables and optical communication cables.
REFERENCE SIGNS LIST
1 Travel distance measuring apparatus
2 Concave circular cup
3 Convex circular cylinder
4 Nonwoven fabric
6 Water-absorbing resin particle
6 Laser beam
7 Through hole
X Swelling capacity measuring apparatus
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The present invention provides a method for producing water-absorbing resin particles having high equilibrium swelling capacity, a high water-absorption rate or high initial swelling capacity, and an appropriate particle size that achieves good handling performance; water-absorbing resin particles obtained by the method; and a water blocking material and an absorbent article which include the water-absorbing resin particles. The present invention is a method for producing water-absorbing resin particles, which comprises: preparing a hydrogel polymer by reversed-phase suspension polymerization of a water-soluble ethylenically unsaturated monomer in a hydrocarbon solvent in the absence of an internal crosslinking agent but in the presence of a surfactant with an HLB of 8 to 12; carrying out a post-crosslinking reaction of the hydrogel polymer whose moisture content is adjusted to 30 to 110 mass % based on a water-soluble ethylenically unsaturated monomer component that composes the hydrogel polymer.
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The present invention relates to a method for controlling the sodium and sulphur balance of a pulp mill while separating lignin from black liquor, and also a lignin product or an intermediate lignin product obtainable by said method. The present invention also provides use of a lignin product or an intermediate lignin product for the production of fuel (solid, gaseous or liquid) or materials.
BACKGROUND OF THE INVENTION
WO2006/031175 discloses a method for separation of lignin from black liquor comprising the following steps: a) Precipitation of lignin by acidifying black liquor and thereupon dewatering, b) suspending the lignin filter cake obtained in step a) whereupon a second lignin suspension is obtained and adjusting the pH level to approximately the pH level of the washing water of step d) below, c) dewatering of the second lignin suspension, d) addition of washing water and performing a displacement washing at more or less constant conditions without any dramatic gradients in the pH, and e) dewatering of the lignin cake produced in step d) into a high dryness and displacement of the remaining washing liquid in said filter cake, whereby a lignin product is obtained which has an even higher dryness after the displacement washing of step e).
WO2006/038863 discloses a method for precipitating (separation) of lignin, using small amounts of acidifying agents, whereby a lignin product or an intermediate lignin product is obtained which can be used as fuel or chemical feed stock (or as a chemical or a raw material for further refining), from a lignin containing liquid/slurry, such as black liquor.
The present invention also provides a method for separation of lignin from a lignin containing liquid/slurry, such as black liquor, whereby a more pure lignin is obtained. Said document also discloses a lignin product or an intermediate lignin product obtainable by the above methods. Said document also discloses use, preferably for the production of heat or for use as chemical, of said lignin product or intermediate lignin product.
When separating lignin from black liquor, which may be achieved through a precipitation in a process, the resulting lignin slurry may be filtered, e.g. in a filter press. The filtrate remaining in the filter cake may cause an increased acid consumption in subsequent process steps. If a large amount of sulphuric acid is added in the process, it can lead to problems with the Na/S balance in the pulp mill as well as increased chemical costs. Therefore, it would be of interest to wash the filter cake and displace the filtrate with another solution. The solubility of lignin is dependent on temperature, ionic strength and pH in the solution (Magnus Norgren, “On the Physical Chemistry of Kraft Lignin, Fundamentals and Applications”, Doctoral Thesis, Physical Chemistry 1, Lund University, 2001). It is not possible to successfully wash lignin by directly applying an acidic wash liquor because of problems with plugging of the filter cake and high yield losses (Fredrik Öhman “Precipitation and separation of lignin from kraft black liquor”, Forest products and Chemical Engineering, Department of Chemical and Biological Engineering, Chalmers University of Technology, Göteborg, Sweden, 2006 and Öhman, F. & Theliander, H., “Washing lignin precipitated from kraft black liquor”, Paperi Ja Puu, Vol. 88, no 5, 287-292 (2006) and Öhman, F., Wallmo, H. & Theliander, H., “A Novel method for washing lignin precipitated from kraft black liquor—Laboratory trails”, Nordic Pulp and Paper Research J., 22 (2007): 1, 9-16
Mixing acidic wash liquor and alkaline filtrate also leads to uncontrolled release of hydrogen sulphide, which can increase the costs of the process.
Accordingly it would be desirable to be able to provide a method for controlling the Na/S balance in a pulp mill when at the same time lignin is separated from black liquor.
SUMMARY OF THE INVENTION
The present invention provides a solution for controlling the Na/S balance in a pulp mill at the same time lignin in separated from black liquor, which there is a need for as set out above, and said invention provides, according to a first aspect, a method for separation of lignin from black liquor comprising the following steps:
a) precipitation of lignin by acidifying black liquor, preferably by using CO 2 , resulting in a lignin suspension and if necessary followed by maturing of the lignin suspension and thereupon separation, thereby forming a cake of solid material, thus a lignin filter cake, and optionally washing the lignin filter cake with a filtrate as set out under step d), and when needed enhancement of the lignin filter cake dryness, which optionally involves conveying the filtrate back to a pulp mill, b) suspending the lignin filter cake obtained in step a) and during the suspension operation adjusting the pH level to approximately the pH level of the washing water of step d) below, preferably at least a pH below 8, whereupon a second lignin suspension is obtained and leaving said suspension to mature (age), whereby also optionally additionally acidic liquid is added, c) separation of the second lignin suspension thereby forming a second cake of solid material, thus a second filter cake, and when needed enhancement of the lignin cake dryness, and thereafter adding acidified wash water and/or virgin acid for displacement washing and virgin washing liquid, such as clean water, also for said displacement washing followed by enhancement of the lignin filter cake dryness to the level specified for different use of lignin, and d) conveying the filtrate from step c) or selected part/-s of the filtrate from c) for using in the suspending of the lignin filter cake of step b) and/or for dilution before separation in step a) and/or addition as wash water to the filter cake produced in step a) whereby if needed the ionic strength and pH is adjusted before addition, preferably by adding ESP-dust (ElectroStatic Precipitator dust), such as pulp mill recovery boiler precipitator dust, in order to control the Na/S balance in a pulp mill.
The present invention also provides, according to a second aspect, a lignin product or an intermediate lignin product obtainable by said method. The present invention also provides, according to a third aspect, use of a lignin product or an intermediate lignin product according to the second aspect for the production of fuel (solid, gaseous or liquid) or materials.
DETAILED DESCRIPTION OF THE INVENTION
It is intended throughout the present description that the expression “acidifying” embraces any means for acidify the black liquor. Preferably the acidifying is performed by adding SO 2 (g), organic acids, HCl, HNO 3 , carbon dioxide or sulphuric acid (in the form of fresh sulfuric acid or a so called “spent acid” e.g. from a chlorine dioxide generator) or mixtures thereof to said black liquor, most preferred by adding carbon dioxide or sulphuric acid.
It is intended throughout the present description that the expression “separation” embraces any means for separation. Preferably the separation is performed by using dewatering. Dewatering may be performed by using a mechanical method, such as by using centrifugation, a filter press apparatus, a band filter, a rotary filter, such as a drum filter, or a sedimentation tank, or similar equipment, or by using evaporation. Most preferred a filter press apparatus is used.
It is intended throughout the present description that the expression “filtrate” embraces any liquid obtained through any of the separation methods as set out above.
According to a preferred embodiment of the first aspect of the invention step d) also involves conveying filtrate back to a pulp mill optionally also involving that filtrate is conveyed to the black liquor before the precipitation of step a).
According to a preferred embodiment of the first aspect of the invention step d) also involves conveying filtrate from step c) either for using in a displacement washing in step a) during the separation, such as filtration, according to a) or for diluting the suspension before separation, such as filtration, and optionally displacement washing of the lignin cake, of the lignin suspension in a), wherein optionally the filtrate from step c) is adjusted regarding ionic strength and in pH, preferably to keep the pH equal to or below the pH to which precipitation in a) has been adjusted by CO 2 , to avoid dissolution of lignin. The ionic strength is optionally adjusted preferably to keep the ionic strength equal or higher than the ionic strength in the lignin slurry which is filtered in a). However a lower pH of the filtrate from c) to be used as wash water and/or dilution liquid in a) results in less demand for ionic strength adjustments.
According to a preferred embodiment of the first aspect of the invention the fresh acidic liquid added in step b) is sulphuric acid and/or residual acid from chlorine dioxide manufacture, i.e. sesquisulfate, and/or acidic scrubber liquid, preferably sulphuric acid and sequisulfate.
According to a preferred embodiment of the first aspect of the invention the fresh acidic liquid added in step b) is virgin sulphuric acid and/or sulphuric acid and/or sulphurous acid both obtained from gaseous SO 2 in turn obtained from rich gases and/or by collecting recycled H 2 S gas from the suspending step b) and converting it into said SO 2 , or sulphuric acid obtained by electrolysis of sodium sulphate. Said sodium sulphate is preferably emanating from ESP-dust (ElectroStatic Precipitator dust) (also known as ESP-catch or ESP-ash). The recovery boiler in a pulp mill produces significant amount of ESP-dust which contains mainly sodium sulphate. This ESP-dust may to a large extent be recycled to the recovery boiler. Some amounts may further be removed to adjust imbalances in S or Na in the recovery cycle. Said sodium sulphate may as set out above be converted into sodium hydroxide and sulphuric acid by electrolysis (see e.g. U.S. Pat. No. 4,561,945). The sodium hydroxide can further be used in different positions in the pulp mill such as the bleach plant or in the recovery area. This approach eliminates the need for purchased sulphuric acid, the need to purge excess S by purging ESP-dust and thus the intake of sodium make up can be eliminated.
According to a preferred embodiment of the first aspect of the invention the virgin sulphuric acid and/or sulphuric acid and/or sulphurous acid obtained from SO 2 is added to the filtrate conveyed in step d).
According to a preferred embodiment of the first aspect of the invention step b) and/or c) involve addition of acidic liquid and/or virgin acid and/or CO 2 , whereby the addition of acidic liquid and/or acid and/or CO 2 is increased if necessary and in step d) filtrate is conveyed for performing a soap acidulation thereby providing tall oil.
According to a preferred embodiment of the first aspect of the invention step d) also involves conveying filtrate or specific parts of the filtrate to an external treatment step such as different types of effluent treatments.
According to a preferred embodiment of the first aspect of the invention a salt is added before the separation (preferably filtration) of step c) and/or during the suspending in step b) thereby avoiding a low pH level, preferably said salt is ESP dust, such as recovery boiler ashes or boiler dust.
According to a preferred embodiment of the first aspect of the invention the filtrate from step c) is adjusted, when to be before the separation, preferably filtration, in step a) or as wash water in step a) separation, when regarding ionic strength and in pH, preferably to keep the pH equal to or below the pH to which precipitation in a) has been adjusted by CO 2 , to avoid dissolution of lignin involving adding a salt, preferably said salt is ESP dust, such as recovery boiler ashes or boiler dust, or sodium sulphate.
According to a preferred embodiment of the first aspect of the invention step b) involves adjusting the pH level to approximately the pH level of the washing water of step c) below, preferably a pH below 8.
According to a preferred embodiment of the first aspect of the invention the separation of step a) and/or step c) is performed using dewatering in a filter press apparatus wherein the filter cake is blown through by gas or a mixture of gases, preferably flue gases, air or steam (vapour), most preferred air or overheated steam, in order to dispose of the remaining liquid.
According to a preferred embodiment of the first aspect of the invention the pH level is adjusted to below approximately pH 6 in step b), preferably below approximately pH 4, most preferred the pH level is a pH from 1 to 3.5.
According to a preferred embodiment of the first aspect of the invention the washing water used in step c) has a pH level of below approximately pH 6, preferably below approximately pH 4, most preferred the pH level is a pH from 1 to 3.5.
According to a preferred embodiment of the first aspect of the invention the lignin filter cake dryness of the filter cake obtained in step a) and/or c) is enhanced by displacement of the remaining liquid with gas or a mixture of gases, preferably flue gases, air, steam or superheated steam, most preferred air or superheated steam.
According to a preferred embodiment of the first aspect of the invention the filtrate from the first separation (preferably involving filtration) stage step a) is re-circulated directly to the pulp mill recovery system, if necessary, after re-alkalization.
According to a preferred embodiment of the first aspect of the invention the remaining washing liquor in the filter cake in step c) is removed as far as possible with air or flue gases, preferably flue gases from a recovery boiler, a lime kiln or a bark boiler, or steam or superheated steam.
The problems mentioned above can accordingly be solved by washing the lignin filter cake with a solution with sufficient ionic strength to keep the lignin in solid form. The solutions should preferably be prepared using substances that will not cause problems in the pulp mill recovery cycle or other parts of the pulp mill, and most preferred substances that already exist in the pulp mill to avoid disruptions of the chemical balances (example: recovery boiler ash). If the filtrates from the above described process are not recycled back to the pulp mill, other substances can also be used. The pH of the wash solution should preferably be equal to, or lower, than the precipitation pH but preferably not low enough to cause substantial uncontrolled release of hydrogen sulphide when it is mixed with alkaline filtrate. The temperature of the solution should preferably be the same as for the separation, preferably filtration, to avoid excessive energy consumption for heating and cooling.
Preferred features of each aspect of the invention are as for each of the other aspects mutatis mutandis. The prior art documents mentioned herein are incorporated to the fullest extent permitted by law. The invention is further described in the following example in conjunction with the appended figures, which do not limit the scope of the invention in any way. Embodiments of the present invention are described in more detail with the aid of an example of embodiments, the only purpose of which is to illustrate the invention and are in no way intended to limit its extent.
SHORT DESCRIPTION OF THE DRAWING
FIG. 1 shows the results obtained in a pilot plant study where acid addition in b) is reduced according to the above described new method.
FIG. 2 shows one preferred embodiment of the invention; dilution before filtration step 1.
FIG. 3 shows one preferred embodiment of the invention; washing in filtration step 1.
FIG. 4 shows one preferred embodiment of the invention; use of an acid rich filtrate flow from c) to the pulp mill soap separation process (soap acidulation).
FIG. 5 shows one preferred embodiment of the invention; discharge of an acid rich filtrate from c) into the external treatment.
FIG. 6 shows one preferred embodiment of the invention; use of an internal source for acidification, such as remaining acid from ClO 2 -production in the pulp mill.
FIG. 7 shows one preferred embodiment of the invention; use of H 2 S to SO 2 or sulphuric acid produced from strong gases in the pulp mill.
EXAMPLES
Examples
Washing Lignin in the First Filtration Stage of the Process According to the First Aspect of the Invention
Two examples are given below where the method of the first aspect of the invention as set above is successfully applied in order to reduce the sulphuric acid consumption in the subsequent lignin washing steps, which thus enables the controlling of the Na/S balance in a pulp mill.
Example 1
Lignin was precipitated according to the method of the first aspect of the invention (see in particular appended FIG. 3 ). A filter cake of lignin was formed in a filter press. The filter cake was successfully washed by applying in this specific example a 7.5%-w solution of sodium sulphate in water. Sodium sulphate was chosen since it can be brought back to the recovery system without problems, is used by many kraft pulp mills as a make-up chemical, and is often also produced internally in the mill in many cases in form of sodium sesquisulphate for chlorine dioxide production in pulp bleaching. The sulphuric acid consumption in the subsequent re-slurrying stage could be reduced from the reference case (a filter cake pressed and air-dried to approximately 65% DS) by 50%.
Example 2
Lignin was precipitated according to the method of the first aspect of the invention (see in particular appended FIG. 3 ). A filter cake of lignin was formed in a filter press. The filter cake was successfully washed by applying in this specific example a 10%-w solution of recovery boiler precipitator dust (which is an ESP-dust) in water. The recovery boiler dust consists mainly of sodium sulphate, and is normally mixed together with strong black liquor before firing in the recovery boiler. The sulphuric acid consumption in the subsequent re-slurrying stage could be reduced in the same way as in Example 1.
The sulphuric acid consumption was lowered 170-180 kg/ton lignin to 90-105 kg/ton lignin. Experiments with the half amount of washing water gave also logically results between the well washed filter cake and the unwashed filter cake.
In the pilot plant study as set out above titrations were done on lignin slurry to study acid consumption for acidification. Lignin filter cakes from the first filtration step (10% suspension conc.) were titrated with H 2 SO 4 . The below appearing parameters were used in the pilot plant study:
Wash procedure according to the method of the first aspect of the invention during 2.5 minutes; test 1
Wash procedure according to the method of the first aspect of the invention during 2.5 minutes; test 2
Wash procedure according to the method of the first aspect of the invention during 5 minutes; test 1
Wash procedure according to the method of the first aspect of the invention during 5 minutes; test 2
Reference 1, 2 and 3 was without washing.
As can be seen from FIG. 1 the wash procedure according to the first aspect of the invention during 5 minutes (test 2) gave the best results. There the washing was driven as far as possible.
Example 3
In a case with a pulp mill producing 350.000 tonnes of pulp with 50.000 tonnes/year lignin production with the process as set out above according to the first aspect the need of 160 kg of H 2 SO 4 is used per tonne of lignin, the need for external sodium hydroxide to handle the purge of ESP-dust is 92 kg per tonne of lignin. Per tonne of pulp this corresponds to 30 kg H 2 SO 4 and 17 kg NaOH. By using electrolysis of ESP-dust the input of H 2 SO 4 and thus the need to purge ESP-dust is reduced.
Various embodiments of the present invention have been described above but a person skilled in the art realizes further minor alterations, which would fall into the scope of the present invention. The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. For example, any of the above-noted methods can be combined with other known methods. Other aspects, advantages and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.
CITED DOCUMENTS
WO2006/031175
WO2006/038863
Magnus Norgren, “On the Physical Chemistry of Kraft Lignin, Fundamentals and Applications”, Doctoral Thesis, Physical Chemistry 1, Lund University, 2001
Fredrik Öhman “Precipitation and separation of lignin from kraft black liquor”, Forest products and Chemical Engineering, Department of Chemical and Biological Engineering, Chalmers University of Technology, Göteborg, Sweden, 2006
Öhman, F. & Theliander, H., “Washing lignin precipitated from kraft black liquor”, Paperi Ja Puu, Vol. 88, no 5, 287-292 (2006)
Öhman, F., Wallmo, H. & Theliander, H., “A Novel method for washing lignin precipitated from kraft black liquor—Laboratory trails”, Nordic Pulp and Paper Research J., 22 (2007): 1, 9-16
and
U.S. Pat. No. 4,561,945
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A method for controlling the sodium and sulphur balance of a pulp mill while separating lignin from black liquor, and also a lignin product or an intermediate lignin product obtainable by the method. The present invention also provides use of a lignin product or an intermediate lignin product for the production of fuel (solid, gaseous or liquid) or materials.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for manufacturing planar fiber webs from short, oriented reinforcing fibers or fiber blends, wherein the reinforcing fibers or fiber blends are elutriated in a slurry liquid and subsequent to passing through a hydrodynamic orientation section, the fibers are deposited in an oriented condition on a filter surface while the slurry liquid is filtered off.
2. Discussion of the Prior Art
Methods are currently known for manufacturing planar performs or semifinishes, also referred to as fleece of fiber mats, of discontinuous (short), non-oriented reinforcing fibers. Their particular advantage, besides being inexpensive and ease of processing, lies in their uniform strength at all cutting angles. This strength, however, is in general rather low.
For the manufacture of high-strength components, the reinforcing fibers must be oriented in the form of continuous, endless individual filament strands (rovings), or layers (woven fabrics, roving bands, unidirectional roving prepregs, woven fabric prepregs), or in the form of unidirectionally oriented short fibers (UD short fibers) in the form of mats or mat prepregs. A prepreg is a semifinished article which is preimpregnated with a reactive resin blend and then predried.
The use of such UD short-fiber mats represents a compromise between high strength and good processability (ability to hug the contours of complex-surface molds, and so forth), between maximum utilization of the material and cost economy, and it facilitates the homogeneous, selective admixture of various types of fibers (socalled hybrid fiber materials).
Until the present, principally two methods for manufacturing UD short fiber mats have become known: the ERDE process (Explosives Research and Development Establishment, Waltham Abbey, UK; Lit.: Dingle, L.E., Conf. Carbon Fibres, London, February 1974, the Plastics INstitute ISBN 090310704X Paper No. 11); and the socalled MBB vacuum barrel filter process (German Patent Specification 2 163 799; Richter, H., Kunststoffe 67 (1977) 12, p. 739). Both methods have the common feature in that the short reinforcement fibers or fiber blends are converted into a slurry by employing a suitable liquid, preferably glycerine, and after passing through a hydrodynamically operating orientation section, they are deposited in an oriented condition. In the ERDE process this is achieved through orienting within a single moving nozzle and deposition on plane filter panels, whereas in the MBB vacuum barrel filter process this is achieved by means of a wide pouring trough which is formed by a separate component and has guide ducts running in parallel with the direction of the slope and with the deposition of the fibers on the exterior of a horizontally rotating filter barrel, with the slurry liquid being aspirated into the interior of the barrel under the effect of a vacuum.
In both of the prior art methods the filter cake, after deposition, must be carefully washed several times in order to remove the glycerine, which is incompatible with the subsequent resin impregnating process. Hereby the orientation of the fibers may again be disturbed. The two methods also have in common that they operate very slowly because, initially, the slurry liquid must flow laminarly in the nozzles or ducts so as to effect the orientation of the fibers and, secondly, both methods operate only a single deposition nozzle or trough. Moreover, both methods operate principally discontinuously.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a method and apparatus for manufacturing planar fiber webs from short, oriented reinforcing fibers of fiber blends of said type, in which the deposition process is accelerated with the degree of orientation remaining unchanged while eliminating the need for subsequent washing so as to improve the overall degree of efficiency.
It is a more specific object of the present invention to provide a method in which the slurry of reinforcing fibers or fiber blends is introduced at a central location to the inlet of a hydrodynamic orientation section rotating about a vertical axis at an essentially laminar flow. In particular, the rotational speed of the outlet of the orientation section is selected to be different, preferably somewhat higher than the rotational speed of the rotating filter surface which at least partially encompass in concentricity the orientation section. Firstly, the present invention utilizes the centrifugal force acting on the orientation section in order to produce an accelerated laminar flow of the slurry liquid together with the fibers so that the originally uniformly distributed reinforcing fibers or fiber blends will orient themselves. Secondly, in accordance with the rotational speed, the oriented fibers which exit from the orientation section are slung with a comparably high speed relating onto the adjacent rotating filter surface without impairing the degree of orientation. Inasmuch as the filter surface rotates at a speed differing from that of the orientation section, conversely, the orientation extent is further improved. The rotating filter surface additionally serves as an internal filter centrifuge in which the slurry liquid is centrifuged off under the effects of centrifugal force. Due to the centrifugal force acting on the filter surface the fibers remain fixed in their oriented position during the entire filtration process. Accordingly, the present invention not only accelerates the deposition of the fibers, but also, particularly as a result of the centrifugal action of the filter surface, obviates the need for rinsing or rewashing as is required in the known methods. The methods of the present invention can be applied either continuously or discontinuously.
Another advantageous feature of the inventive method provides for the reinforcing fibers or fiber blends in the slurry being conducted centrally to serveral orientation sections arranged in a star-shaped format relative to each other.
In a further advantageous embodiment of the present invention the viscosity of the slurry liquid is selected to be low, enabling the inner wall of the orientation section to be formed with a relatively rough surface without causing the laminar parabolic distribution of the flow velocity needed for orientation to be subjected to turbulent flow. This facilitates the employment of solvents as slurry liquid which can either be easily evaporated through subsequent drying, or correlated so as to be adapted with the impregnating resin, which normally also contains a solvent, in the subsequent impregnating process. This eliminates the need for the repeated, time-consuming rewashing operations which are performed on the known UD mats. Instead, the slurry solvent can have added thereto a small amount of the resin or resin-hardener mixture as a temporary binder.
The separation speed is considerably increased by the plurality of star format-arranged orientation sections and by the relatively high throughput for each orientation section, due the pumping pressure and the low viscosity of the slurry liquid.
A further feature of the inventive process resides in that the filtration process is supported through the application of a partial vacuum on the radially outer region of the filter surface.
Pursuant to another aspect of the present invention, a separating substrate foil is deposited on the oriented, deposited fibers subsequent to an impregnating and drying operation, and the filter surface drawn off. The substrate foil is suitably applied through rolling. This method is especially suitable when continuously employed; in essence, with an essentially endless filter surface which is then only partially conducted about the rotating orientation section (FIG. 3).
For other requirements, at a suitable selection of the material for the filter surface, the filter material itself can also advantageously constitute the substrate and consist of an integral component of the UD short-fiber mat. The finished product will then be a hybrid laminate onto which the separating foil is rolled after the impregnating and drying.
The inventive method can be also particularly employed in the manufacture of glass, ceramic or metal foils with short-fiber reinforcement, for example, when the filter surface is replaced by an externally cooled steel web.
An arrangement which is operated in accordance with the method of the present invention distinguishes itself through a centrifugal pump impeller rotating about an essentially vertical axis, and having substantially radially extending laminar-flow nozzles, the pump inlet for the slurried reinforcing fibers of which is arranged at a radially inward or intermediate location.
In particular, the centrifugal pump impeller includes flow ducts, the inlet at the axial side thereof is essentially tangential relative to the outer periphery of the centrifugal pump impeller.
Each nozzle passageway in the star-shaped arrangement is divided vertically by thin partitions, which in adjacent nozzles are so vertically staggered relative to each other (FIG. 6) as to mutually overlap. They are intended to raise the degree of orientation of the short fibers. When a lower viscosity slurry liquid is selected, the nozzle wall can be relatively rough without causing the laminar flow to become turbulent, which would impair the degree of orientation.
A particularly preferable structural embodiment of the present invention is obtained when a centrifugal pump impeller rotating at a somewhat higher speed is arranged within a drum rotating somewhat more slowly about an essentially vertical axis, where a filter is supported on the perforated inner wall of the drum, which is located in the immediate proximity to the radially outer end of the centrifugal pump impeller. The rotating perforated inner wall of the drum acts herein as an inside centrifuge at a high degree of efficiency and compact overall arrangement.
Another arrangement which can advantageously be continuously operated provides in particular that a portion of a roller-conducted, driven perforated endless carrier belt lies opposite to the rotating centrifugal pump impeller along a major portion of its outer circumference, wherein a portion of an endless filter belt is arranged between said carrier belt portion and the oppositely located outer circumference of the centrifugal pump impeller, with this filter belt being driven at the speed of the endless carrier belt, which is lower than the speed of the centrifugal pump impeller (FIGS. 3 and 4).
Suitably, the guide and tension rollers of the endless carrier belt and/or of the filter web are arranged to allow for three-dimensional adjustment.
The filter web leads away from the centrifugal pump impeller in a direction tangential relative to the latter inorder to prevent any premature separation of the fiber mat from the filter.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference may now be had to the following detailed description of the preferred embodiments of the invention, taken in conjunction with the accompanying drawings; in which:
FIG. 1 schematically illustrates a sectional view through an essentially vertically arranged apparatus for discontinuous operation pursuant to the invention;
FIG. 2 is a vertical section through the apparatus of FIG. 1 showing the inner centrifugal pump impeller in a partial sectional view;
FIG. 3 is a sectional view similar to that of FIG. 1 of a modified apparatus for preferably continuous operation; and
FIG. 4 is a vertical section similar to that of FIG. 2 through the drum of FIG. 3 in the region of the centrifugal pump impeller.
DETAILED DESCRIPTION
The discontinuously operated apparatus, schematically shown in FIGS. 1 and 2 of the drawings, for manufacturing planar fiber webs from short, reinforcing fibers oriented in a preferred direction comprises essentially a vertically arranged drum with a stationary drum shroud 1 which is provided at its upper side with a central opening for the inlet of a reinforcing fiber slurry, as well as a vertical outlet 8 for the vacuum connection, and which includes at its bottom side a further eccentrically located, vertical outlet 9 for the filtered out slurry liquid. Additional horizontal outlets 9 for the filtered out slurry liquid are provided along the circumference of the essentially cylindrical shroud.
Arranged within the drum shroud 1 is a perforated inner wall 2 rotating during operation about a vertical axis, with a removable filter cloth 7 and the deposited fiber fleece 13 as shown in the drawing. The arrangement is such that the inner wall serves the function of a conventional, internally supplied centrifugal filter drum.
A centrifugal pump impeller 3 rotates at a speed which differs from and, preferably, is somewhat higher than that of the perforated inner wall 2, and which can also be designated as a pumping wheel or orientation wheel. The axis of rotation a of the centrifugal pump impeller 3 is identical with the axis of rotation of the encompassing centrifugal filter drum.
As can be particularly ascertained from FIG. 1 of the drawings, the centrifugal pump impeller 3 has a plurality of essentially radially extending interior flow passageways 3a which are traversed by the laminar flow of the fiber slurry, and the length of their flow forms the orientation section 11. The flow passageways terminate at their radially outer ends in the nozzles 12.
The flow passageways have a hydrodynamic form (sickle shape pursuant to FIG. 1) and are essentially characterized in that the flow inlet is effected approximately radially (radially inwardly), in that the flow outlet from the nozzles 12 is as tangential as possible to the circumference of the centrifugal pump impeller, and the velocity distribution is obtained parabolically due to the laminer flow.
Each flow passageway 3a is subdivided into a plurality of orientation sections or nozzles through the use of thin sheet metal partitions 3c in planes extending perpendicular to the axis. These nozzles can be disposed vertically and parallel relative to each other, as indicated in FIG. 2, but are preferably mutually disposed vertically offset as shown in FIG. 4. The nozzles can also be disposed in axially parallel arrangement or on a helix generated on the cylindrical surface of the impeller.
A central inlet opening 3b for the slurry liquid and the therein distributed non-oriented reinforcing fibers is arranged in the middle of the centrifugal pump impeller 3, at its upper side.
During operation of the arrangement, the inner centrifugal pump impeller 3 is driven by a drive arrangement (not shown) at the speed n1 or v1, and the perforated inner wall 2 of the centrifugal filter drum is driven at the speed n2 or v2, wherein the rotational speed n1 of the centrifugal impeller 3 is preferably slightly higher than the speed n2 of the outer centrifugal filter drum, the perforated inner wall 2 of which rotates about the same axis a as that of the centrifugal pump impeller 3. The filter cloth or fleece which is removably applied on the perforated inner wall 2, which defines the filter surface 7, is positioned intermediate the radially outer outlets of the centrifugal pump impeller 3 and the encompassing perforated inner wall 2, such that the reinforcing fibers 10 in the slurry, which during operation are centrally conveyed into the apparatus, enter the essentially radially extending flow passageways 3c of the nozzles 12, are therein oriented along the formed laminer flow, and then accelerated radially outwardly through the nozzles 12 onto the filter surface 7. The filter surface 7 rotates hereby at the speed of the perforated inner wall 2, which is slightly lower than that of the inner centrifugal pump impeller 3, so that during the egress of the essentially oriented fibers from the nozzle, there is encountered a short delay which will still further improve the orientation. The oriented fibers 13 which are stabilized through the socalled "transfer-delay", are deposited on the filter surface 7, which concurrently filters off slurry liquid under the centrifugal force and fixes the filter cake from the oriented deposited fibers 13 on the filter surface. The slurry liquid which is centrifuged out exits from the apparatus through the outlets 9 and can be reused after a filtering out of fiber particles. Due to the high pumping action of the centrifugal pump impeller 3 which acts as an impeller and orientation wheel, the flow passages can be narrowed with a suitable configuration and have relatively rough surfaces, while the viscosity of the slurry liquid is concurrently extensively lowered without causing the laminar parabolic distribution of the flow velocity, which is needed for orientation, to deviate into a turbulent flow. This enables the utilization of solvents as slurry liquids, which can be readily evaporated by subsequent drying, or which can be correlated with the subsequent impregnating process of the impregnating resin, which normally also contains solvents. This resin, which normally also contains solvents. This eliminates the need for repeated, time-consuming washing and rewashing of conventional UD mats. Instead, if needed, a small portion of the resin or resin hardener mixture can be added to the slurry solvent as a temporary binder.
The modified embodiment of the apparatus of the present invention as schematically illustrated in FIGS. 3 and 4 allows for continuous operation. A centrifugal pump impeller 3, as previously illustrated in the embodiment of FIGS. 1 and 2, is arranged within an encompassing box-like drum shroud 1, which has vacuum extraction outlets 8 and outlets 9 for the slurry liquid centrifuged off as illustrated in FIGS. 1 and 2.
In lieu of the centrifugal filter drum of the preceding embodiment, a preferably endless fiber belt 6 is conveyed about almost the entire periphery of the centrifugal pump impeller 3 in a manner wherein the belt exits in a direction preferably tangential to the centrifugal pump impeller in order to prevent any premature detaching of the fiber mat from the filter.
The filter belt 6 which defines the filter surface 7, is supported and concurrently transported by means of one or more, likewise perforated, endless support webs or transport belts 22 which are driven by two guide rollers 5 at a speed n2 which slightly differs from the speed n1 of the centrifugal pump impeller 3, wherein the speed of the centrifugal pump impeller 3 is preferably selected so as to be high than the speed of the endless support belt 22.
The endless support belt or belts 2 are suitably guided within the drum shroud 1 over guide rollers 14 and a tension roller 4.
If desired, the circumferential portion of the centrifugal pump impeller 3 which is not encompassed by the filter belt 6 can contain a directly adjoining, vertically extending screen which will prevent fibers egressing in that region from the centrifugal pump impeller 3 from uncontrolledly impinging against the filter belt 6.
As in the first embodiment, also in this instance, the filtration process, besides the centrifugal action, can also be supported by the application of a partial vacuum over a portion of the circumference of the centrifugal pump impeller.
If it is intended to employ the resulting UD short fiber mat itself as a semifinished product, a separating and carrier foil is preferably rolled on subsequent to the impregnating and drying process, while concurrently there is peeled off the filter belt.
A premature detaching of the filter cake (the UD fiber mat) can be prevented through the application of a (partial) vacuum behind the filter belt until the (air-impermeable) separating and carrier foil has been rolled on.
However, for other requirements, at a suitable selection of the filter belt material, this belt material itself can be the carrier and an integral component of the semi-finish UD short fiber mat (for instance, a glass fiber reinforced fleece mat having a poorly soluble binder as a substrate and for increasing the impact strength of the glass fiber-reinforced UD short fiber mat). The finished product will then be a hybrid laminate onto which the separating foil is rolled after impregnating and drying.
The continuous orientation and deposition process can be used at a suitable construction (for example, replacing the filter belt 6 with an externally-cooled steel belt), also in the manufacture of short fiber-reinforced glass, ceramic or metal foils.
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Method and apparatus for manufacturing planar fiber webs from reinforcing fibers which are oriented in their passage through a hydrodynamic orientation section and deposited on a filter surface. In the process, the rotating orientation section produces a laminar flow pattern causing the reinforcing fibers in the slurry to be oriented. The filter surface is rotated, as is the orientation section, to hasten the extraction of the slurry liquid by filtration, to improve the degree of orientation of the fibers, and to fix the oriented fiber cake on the filter area. Extraction of the slurry liquid by filtration eliminates the need for washing or rewashing.
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TECHNICAL FIELD
[0001] This invention relates to devices used in aid of surgery and, more particularly, to a device for holding suture clamps and/or sutures and for organizing sutures during surgery.
BACKGROUND OF THE INVENTION
[0002] Many kinds of surgery require the use of multiple sutures that are used to pull severed muscles, nerves and tendons away from the surgery site. One of these surgeries is heart surgery, where multiple sutures are used to repair the mitral vessels. If the sutures are not properly organized, they become tangled and complicate the surgeon's job. To aid the heart surgeon, many suture organizers have been developed, the most common of which is known as the Gabbay-Frater organizer. Examples of this type of device are shown in U.S. Pat. No. 4,185,636 —Gabbay, and U.S. Pat. No. 4,492,229 —Grunwald. These heart surgery suture organizers are specific to heart surgery, where the patient is supine and motionless.
[0003] Another suture organizer, designed for hysterectomies is disclosed in U.S. Pat. No. 2,692,599, which is also useful when the patient is supine and motionless. In these surgeries, gravity is often used to tension the sutures, thus necessitating a motionless surgery site. However, in orthopaedic surgeries where ligation of soft tissue, such as muscles, tendons and nerves is necessary, the patient is not supine and the surgery site is not motionless.
[0004] These surgeries include joint surgeries, such as common rotator cuff repair surgery. Other similar procedures, involving non-supine and non-motionless surgical site are total shoulder arthroplasty, ORIF shoulder procedure, patellar and quadriceps tendon ruptures, shoulder fractures with hemi replacement, Bankart repairs, and crush injuries affecting multiple tendons and digits of the hand and foot.
[0005] During these surgical procedures, the patient is often not in a supine position, and the joint is moved or exercised for soft tissue balancing during the surgery, before the muscles, tendons and nerves are reattached. During these surgical procedures, sutures are attached to the damaged or cut ends of muscles, tendons and nerves, hemostats are attached to the sutures and the surgeon grasps a handful of the hemostats to remove this material and open up the surgical site. During the procedure, the joint is manipulated, which can cause these sutures to become tangled and must be untangled to accurately balance the soft tissue. After the surgery is complete, the hemostats are again manually grasped to pull the ends together to balance the soft tissue; then these cut ends are reattached. Tangled sutures require extra, unneeded surgical staff time during the surgical procedure to untangle these sutures.
[0006] The prior art devices, the use of which is predicated on the patient being supine and motionless, are not adaptable to these joint and other surgeries, where motion of the surgical site is common, and where the patient is not usually supine.
[0007] There is a need for a clamp and/or suture retainer and organizer that is useful during joint surgery and other surgeries where the surgery site is not necessarily supine and where the surgery site may experience motion during the surgical procedure.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of this invention to provide a suture and/or clamp retainer and organizer device which is useful during joint surgery and other surgeries where the patient is not necessarily supine and where the surgery site may experience motion during the surgical procedure. It is also an object of this invention to provide a holder for a plurality of suture hemostats, or clamps, to enhance the ability of the surgeon to balance and/or retract the soft tissue.
[0009] In one aspect, this invention features a suture clamp and/or suture device for use in surgery that involves movement of the surgery site during the surgical procedure, comprising an elongated body formed of resilient material and having a plurality of lateral slits through one surface thereof. The slits are sized to receive a surgical suture. The body includes a means adjacent each slit for receiving and retaining a hemostat attached to a suture.
[0010] In one embodiment each slit opens into a lateral passage through said body that is sized to receive and grip a hemostat. A tab, notch, surface or adhesive strips are provided to facilitate attachment of the body to a surgical drape or other supportive surface. In another embodiment the passage is a tapered pocket extending only partially through the body, and the slits and adjacent pockets are mounted in spaced pod mounted on a flexible strip.
[0011] These and other objects and features of this invention will become more readily apparent upon reference to the following detailed description of a preferred embodiment, as illustrated in the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a front view of a suture and/or clamp retainer and organizer device according to this invention;
[0013] [0013]FIG. 2 is a perspective view of the device of FIG. 1;
[0014] [0014]FIG. 3 is a perspective view of the device of FIGS. 1 and 2, shown holding a suture-clamping hemostat.
[0015] [0015]FIG. 4 is a perspective view of a shoulder surgery illustrating use of the device of this invention;
[0016] [0016]FIG. 5 is an enlarged partial view a portion of FIG. 4;
[0017] [0017]FIG. 6 is a plan view of another embodiment of this invention;
[0018] [0018]FIG. 7 is a front view of the embodiment of FIG. 6;
[0019] [0019]FIG. 8 is a sectional view, taken along line C-C of FIG. 7;
[0020] [0020]FIG. 9 is a sectional view, taken along line B-B of FIG. 7; and
[0021] [0021]FIG. 10 is a perspective view of the FIGS. 6 - 9 embodiment, shown retaining two hemostats and attached sutures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] As shown in FIGS. 1 and 2, a suture holder and organizer 10 comprises an elongated cruciform body 12 that is made of a resilient material, such as rubber, silicone or other plastic material. Body 12 has a semi-cylindrical cross-section and includes a flat base 14 and a curved upper surface 16 . A plurality of lateral slits 18 , 20 , 22 , 24 , 26 , 28 , 30 , 32 extend downwardly from the top 34 of upper surface 16 down through body 12 . Each of the slits terminates in a through bore 38 , 40 , 42 , 44 , 46 , 48 , 50 , 52 , each of which tapers from a larger entry hole 38 a , 40 a , 42 a , 44 a , 46 a , 48 a , 50 a , 52 a , to a smaller exit hole 38 b , 40 b , 42 b , 44 b , 46 b , 48 b , 50 b , 52 b.
[0023] At the body top 34 , each slot is beveled at 18 ′, 20 ′, 22 ′, 24 ′, 26 ′, 28 ′, 30 ′, 32 ′. Pairs of slots 54 , 56 and 58 , 60 are formed adjacent each end of body 12 . In addition, an adhesive strip can be mounted on bottom of base 14 at 66 , 67 adjacent each end. Preparatory to surgery, several of the suture holders are attached to a surgical drape surrounding the surgical site by clamps which act through slot pairs 54 , 56 and 58 , 60 and/or by the adhesive strips.
[0024] Referring now to FIG. 3, during surgery, a plurality of hemostats, exemplified here by hemostat 63 are attached to the ends of sutures, exemplified here by suture 64 , that are attached to the ends of severed tendons, muscles and nerves (not illustrated) in a well-known manner. These hemostats are then used to insert the sutures into slots 18 , 20 , 22 , 24 , 26 , 28 , 30 , 32 , assisted by the beveled edges which guide the sutures into the slots. The hemostats are then inserted into through bores 38 , 40 , 42 , 44 , 46 , 48 , 50 , 52 , where they are securely gripped by the resilient material and held. The sutures are pulled tight to fully expose the surgery site by grasping holder 10 and pulling on it. In this manner, the surgeon is relieved of the necessity of untangling the sutures and grabbing a handful of hemostats to open the site or balance the tissue. Thus holder 10 both holds the hemostats and organizes the sutures to speed the surgical procedure and simplifying this aspect of the procedure for the surgeon.
[0025] As can be seen, hemostat 63 cannot be pulled fully through bore 50 because of its taper. When it is desired to reattach the soft tissue ends, hemostat 63 (and the others, not illustrated) is easily withdrawn back out the bore 50 to pull suture 64 back up and out of slot 30 . Alternatively, the tip of hemostat 63 may wedge through slot 30 to remove suture 64 . These actions are facilitated by the resilience of the silicone or other material of body 12 .
[0026] To aid the surgeon in identifying sutures, identifying indicia, shown here as dots 68 , 70 , 72 , 74 , 76 , 78 , 80 , 82 , are placed on the surface 16 adjacent each bore near base 14 . These indicia can be color coded, such as the colored dots shown here, or alpha-numeric, comprising numbers or letters, which can be color-coded, or combinations of each.
[0027] As illustrated in FIGS. 4 and 5, normally, multiple clamp and suture retainers and organizers 10 will be employed in an operation, preferably in identical pairs, as shown. In this manner, for example, sutures attached to the mating ends of a tendon can be placed in the same slots (e.g. “red” or “ 2 -A”) of each of the pair of suture holders. At the end of the surgery, identifying these mating sutures is quick and positive.
[0028] [0028]FIGS. 4 and 5 show a surgery patient 90 , substantially covered by a surgical drape 92 , with shoulder 94 of right arm 96 in the process of surgery at site 98 . An incision 100 has exposed fat layer 102 , and layers of various muscle groups, including the rotator cuff 104 , which has been incised. Sutures 106 a, b, c, d and 108 a, b, c, d are attached to both of the severed ends of rotator cuff 104 , and are gripped by respective hemostats 110 , a, b, c, d and 112 a, b, c, d.
[0029] A pair of clamp and/or suture retainer and organizer devices 114 and 116 . The upper device 116 is held to drape 92 by a pair of hemostats 118 to maintain tension on the sutures and to prevent dislodgement by patient movement or surgical action. In contrast, lower device 114 is left to hang, with gravity supplying the necessary tension. Note that the sutures cannot tangle and are held in any desired position as dictated by the surgeon (not shown). At surgery's end, the hemostats are removed from the devices, freeing the sutures for selective use by the surgeon.
[0030] Another embodiment of this invention is shown in FIGS. 6 - 10 . Here, a clamp and/or suture retainer and organizer device 120 . A thin, elongated, flexible base 122 mounts a plurality (here, 7 are shown) of egg-shaped pods 124 , denominated on base 122 by embossed letters, a-h. Each pod 124 has a vertical through slit 126 , which opens into a tapered pocket 128 for receiving the nose of a hemostat 130 , as shown in FIG. 10. Each pod 124 includes a recess 132 , which is adjacent to and opens into the slit 126 . Recess 132 guides the nose of hemostat 130 as it slides suture 134 into slit 126 . Pockets 128 closely grip and retain the nose of hemostat 130 , but prevent it from being pulled through. Ends 136 of base 122 provide a surface for enabling a hemostat to clamp device 120 onto a surgical drape, in the manner shown in FIGS. 4 and 5. Slits 126 are sufficiently narrower than the thickness of a suture to cause the walls to grip the sutures themselves, regardless of whether a hemostat is inserted into the adjacent recess 132 . In this manner, the sutures themselves can be organized and retained.
[0031] Thus, use of this invention will simplify and facilitate uniform movement of sutures attached to soft tissue for retraction and/or balancing of the soft tissue during orthopaedic surgeries, and may find use in other surgical procedures where suture clamping and organization are used.
[0032] While only a preferred embodiment has been described and shown, obvious modifications are contemplated within the scope of this invention, as defined by the appended claims. For example, the device could have different means for holding the hemostats, such as adhesive strips on the bottoms of the devices. Any sterilizable flexible material, such as “C-Flex’ can be utilized.
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A suture clamp and/or suture retainer and organizer device for use during a surgical procedure, comprises an elongated body formed of resilient material and has a plurality of spaced lateral slits through one surface. The slits are individually identified and are sized to receive and grip a surgical suture. A tapered pocket is located adjacent to and opens into each slit for receiving and retaining the nose of a hemostat attached to a suture. The device may be attached by adhesive backing or by clamps to a surgical drape or other support surface.
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RELATED APPLICATIONS
The present application is a divisional of U.S. application Ser. No. 09/423,939, now U.S. Pat. No. 6,244,076, which was filed in the U.S. Patent and Trademark Office on Mar. 27, 2000 as a national application of PCT/IL98/00111, filed Mar. 8, 1998, which is a continuation-in-part of PCT/IL/97/00160 filed on May 15, 1997.
FIELD OF THE INVENTION
The present invention relates to knitting machines and in particular to means and methods for activating latch needles in knitting machines and monitoring latch needle positions.
BACKGROUND OF THE INVENTION
Automatic knitting machines use banks of large numbers of closely spaced latch needles to interlock threads in a series of connected loops to produce a knitted fabric. The latch needle is a long flat needle having, at one end, a small hook and a latch that swivels to open and close the hook. The hook ends of the latch needles are moved forwards and backwards towards and away from the threads being knitted into the fabric. As a latch needle is moved, its latch alternately opens and closes so that the hook catches a thread close to it, pulls it to create a loop of fabric, and then releases the thread to start the cycle over again and produce another loop of fabric.
Latch needles are arranged parallel to each other, in arrays of many hundreds to thousands of latch needles in modem knitting machines. The latch needles are placed into narrow latch needle slots that are machined into a planar surface, hereafter referred to as a “needle bed surface”, of a large rectangular metal plate, hereafter referred to as a “needle bed”. The latch needle slots hold the latch needles in position and confine their motion to linear displacements along the lengths of the latch needle slots. The latch needle slots are parallel to each other and equally spaced one from the other with spacing that varies depending upon the quality and type of fabric being produced. Spacing of two to three millimeters is typical, but spacing significantly less than and greater than two millimeters are also common.
The latch needle slots in a needle bed are sufficiently deep so that all or most of the body of a latch needle lies completely in the latch needle slot in which it is placed and below the needle bed surface into which the latch needle slots are machined. A small square fin that sticks out from one side of the shaft of the latch needle protrudes above the needle bed surface. The fins of all latch needles in a needle bed are accurately aligned in a single straight row perpendicular to the latch needle slots.
The latch needles are moved, hereafter referred to as “activated”, back and forth in their respective latch needle slots in order to form loops in a fabric being knitted, by a shuttle that travels back and forth along the length of the needle bed surface parallel to the row of aligned latch needle fins. The shuttle has a flat planar surface facing and parallel to the needle bed surface that extends the full length of the shuttle along the direction of travel of the shuttle. The surface has a channel extending the full length of the shuttle along the direction of travel of the shuttle. The channel is open at both of its two ends, and both ends are aligned with the row of aligned fins. As the shuttle moves along the row of latch needle fins, the fins of the latch needles sequentially enter the channel at one end of the channel, travel along the channel length and exit the channel at the other end of the channel. For most of its length the channel is parallel to the row of aligned fins, i.e. the direction of travel of the shuttle, however towards its middle it has a bend. A latch needle is activated when its fin encounters the bend and moves along the direction of the bend. In moving along the direction of the bend, the fin and its latch needle are moved back and forth along the direction of the latch needle slot in which the latch needle is placed, i.e. perpendicular to the row of aligned fins.
The conventional method for moving latch needles in a knitting machine as described above has a number of drawbacks.
For one, the sequential activation of latch needles by a shuttle as the shuttle moves along a needle bed limits the production rates of fabrics. Production rates of fabric produced by knitting machines could be increased if latch needles were individually activated and different combinations of latch needles could be moved simultaneously. Some shuttles in fact have more than one channel in order to simultaneously activate more than one latch needle and increase production rate.
In addition, in the process of knitting a fabric, dust and dirt accumulate in the slots in which latch needles of a knitting machine move. As the dust and dirt accumulate, more force is required to move the latch needles. At some point, dust and dirt accumulate to such an extent that a latch needle jams in its slot. The shuttle is too massive and moves too quickly for it to be practical for the shuttle to be sensitive to, or respond to, changes in the force needed to move a particular latch needle. As the shuttle rushes along the needle bed and encounters a jammed latch needle it breaks the fin or some other part of the jammed latch needle. When this happens physical damage to the knitting machine is often considerably more extensive than the damage to the single latch needle that jammed and knitting machine down time as a result of the damage is prolonged.
In order to prevent damage to knitting machines from jammed latch needles it would be advantageous to have a system for moving latch needles in a knitting machine that activates latch needles individually and is responsive to changes in the forces required to move individual latch needles.
Prior art direct needle drive systems exist that provide for individual activation of latch needles in a knitting machine. These systems, hereafter referred to as “DND” systems, generally provide an actuator for each latch needle and a system for monitoring the position of each latch needle. However, the prior art systems have not been completely satisfactory. The dimensions of actuators used in the prior art systems are large compared to the spacing between latch needles. Complicated spatial configurations are therefore required to pack large numbers of the actuators in a convenient volume of space near to the latch needles in order to couple the actuators to the latch needles.
Additionally, the response times of prior art DND systems are slow. This is the result of slow response times of actuators and of latch needle position monitoring systems used in these systems. The advantages in production rate and decreased knitting machine down time that should be provided by prior art DND systems are at least partly neutralized by the slow response times of these systems.
SUMMARY OF THE INVENTION
It is an object of one aspect of the present invention to provide a knitting machine comprising a fast response time DND system for activating latch needles in the knitting machine.
It is an object of another aspect of the present invention to provide a DND system in which each latch needle of a knitting machine is activated exclusively by at least one piezoelectric micromotor which activates only that latch needle.
An object of another aspect of the present invention is to provide a piezoelectric micromotor suitable for use in a fast response time DND system.
An additional aspect of the present invention is to provide a transmission for coupling each latch needle in a DND system, in accordance with a preferred embodiment of the present invention, to an at least one piezoelectric micromotor, which at least one piezoelectric micromotor, hereafter referred to as “at least one exclusive piezoelectric micromotor”, is not coupled to any other latch needle.
Piezoelectric micromotors can be made small and powerful and response times of piezoelectric micromotors can satisfy the fast response time requirements of modem knitting machines. The dynamic range of motion available from piezoelectric micromotors and the energy that can be transmitted in short periods of time from piezoelectric micromotors to moveable elements are also consistent with the requirements of modem knitting machines. A piezoelectric micromotor and transmission, in accordance with preferred embodiments of the present invention, can therefore be used to provide fast response time activation of individual latch needles in a kitting machine.
It is an object of yet another aspect of the present invention to provide a DND system comprising a fast response time system for monitoring the position of latch needles activated by the DND system.
It is a further object of another aspect of the present invention to provide an electro-optical latch needle position monitoring system, hereafter referred to as an “OPM”, that operates with a fast response time.
DND systems by their nature require fast response time position monitoring systems for monitoring the positions of latch needles that they activate. The positions of the latch needles are controlled in knitting machines to accuracy on the order of 25-50 micrometers (μm). A DND system that moves latch needles with a velocity “V” must therefore sample the position of each latch needle it activates with a frequency of between ˜2x(Vm/sec÷25 μm) to 2x(Vm/sec÷50 μm), in order to control the position the latch needle to an accuracy of 25 μm-50 μm. It therefore requires a position monitoring system with a response time on the order of (25 μm-50 μm)/2V. In many conventional knitting machines V is on the order of 1.5 m/sec. A DND system that moves latch needles with this velocity therefore requires a system that samples the position of latch needles with a frequency, or sampling rate, of between 50-100 kHz and a response time between 10 μsec and 20 μsec.
Electro-optical systems inherently operate at frequencies that are much faster than typical mechanical cycle frequencies of motion of knitting machine components. In particular an electro-optical OPM, in accordance with a preferred embodiment of the present invention, can provide the fast response time and accuracy of measurement required for monitoring latch needle positions in DND systems.
A piezoelectric micromotor for operating individual latch needles in a DND, in accordance with a preferred embodiment of the present invention, comprises a ceramic vibrator formed in the shape of a thin flat plate having two large planar surfaces and narrow edge surfaces. Piezoelectric vibrators of this type are described in U.S. Pat. No. 5,453,653, which is incorporated herein by reference. The thickness of the vibrator preferably ranges from one to a few millimeters. The thickness of the vibrator thus has dimensions on the order of the size of the spacing between latch needles in a needle bed. It is therefore possible to pack large numbers of these vibrators close to each other with their large planar surfaces parallel and with a thin edge of each vibrator aligned with a single latch needle in the needle bed. Each latch needle is activated (i.e. moved back and forth in its latch needle slot in order to form a loop in a fabric being knitted) by coupling to the latch needle vibratory motion of at least one exclusive piezoelectric micromotor having a thin edge aligned with the latch needle. Coupling of the latch needle and the vibratory motion of the at least one exclusive piezoelectric motor may be accomplished by means of a transmission, in accordance with a preferred embodiment of the present invention.
In a DND, in accordance with a preferred embodiment of the present invention, latch needles in a knitting machine needle bed and piezoelectric micromotors are coupled by a rotary transmission comprising a bearing shaft on which a plurality of annuli is stacked. The annuli rotate freely on the bearing shaft. Each latch needle in the knitting machine needle bed is coupled to vibratory motion of a different at least one exclusive piezoelectric motor via one of the plurality of annuli.
The bearing shaft is mounted over the needle bed, preferably close to the needle bed and with its axis parallel to the needle bed and perpendicular to the latch needle slots in the needle bed. The spacing between the annuli on the shaft is such that the fin of each latch needle in the needle bed is aligned with a different annulus on the bearing shaft. A preferably rigid connecting arm connects the fin of each latch needle in the needle bed to the annulus with which the latch needle fin is aligned. The connecting arm is attached to the fin, preferably by a slideable or flexible joint, formed using methods known in the art.
Each annulus on the bearing shaft is coupled to its own at least one exclusive piezoelectric micromotor, in accordance with a preferred embodiment of the present invention by resiliently pressing the at least one exclusive piezoelectric micromotor against the annulus. Activation of the piezoelectric micromotors coupled to an annulus causes the annulus to rotate. The rotation of the annulus is transmitted to the fin of the latch needle to which the annulus is connected, by the connecting arm. The joint connecting the fin and the connecting arm translates the rotational motion of the connecting arm to a linear motion of the latch needle forwards and backwards in its latch needle slot parallel to the length of the latch needle slot, thereby activating the needle.
In a DND system, in accordance with an alternative preferred embodiment of the present invention latch needles in a knitting machine needle bed and piezoelectric micromotors are coupled by a linear transmission. With the linear transmission each latch needle in a knitting machine needle bed has at least one exclusive piezoelectric micromotor pressed, preferably by resilient force, directly onto the shaft of the latch needle or onto a suitable extension of the shaft of the latch needle. The latch needle slots in which the latch needles are placed, and/or, the surfaces of the needles in contact with the latch needle slots are preferably provided with bearings or nonstick surfaces. This reduces the possibility of a latch needle jamming or sticking in its latch needle slot under the application of the resilient force pressing the at least one exclusive piezoelectric micromotor to the latch needle shaft or suitable extension thereof. Coupled in this way, vibratory motion of the at least one exclusive micromotor pressed to a latch needle shaft or extension thereof activates the latch needle by causing the latch needle to move back and forth in its latch needle slot.
In another form of linear transmission, in accordance with a preferred embodiment of the present invention, piezoelectric micromotors are coupled directly to a “coupling” fin of a latch needle in order to transmit motion to the latch needle. The coupling fin, except for its dimensions, is preferably similar in shape and construction to conventional latch needle fins. The coupling fin is a planar extension of the body of the latch needle having first and second parallel planar sides and thin edges. Preferably, the coupling fin is formed as an integral part of the latch needle and lies in the plane of the body of the latch needle (the latch needle is flat). A rectangular region of the first side and a rectangular region of the second side, hereafter referred to as first and second “coupling regions” respectively, are preferably clad in wear resistant material suitable for friction coupling with piezoelectric micromotors, such as for example, alumina. Preferably, the first and second coupling regions are congruent and directly opposite each other.
In one configuration for coupling piezoelectric micromotors to the coupling fin, in accordance with a preferred embodiment of the present invention, at least one micromotor is resiliently pressed to each of the first and second coupling regions so that a surface region of the micromotor used for transmitting motion from the micromotor to a moveable element, or a hard wear resistant friction nub on the surface region, contacts the coupling region. Preferably, the same number of piezoelectric micromotors is resiliently pressed to each of the first and second coupling regions. Preferably the at least one micromotor pressed to the first coupling region is identical to the at least one micromotor pressed to the second coupling region. Preferably, points at which the at least one micromotor pressed to the first coupling region contacts the first coupling region and points at which the at least one micromotor pressed to the second coupling region contacts the second coupling region are directly opposite each other. Preferably, the magnitude of the forces exerted on the coupling fin perpendicular to the plane of the coupling fin by the at least one micromotor pressed to the first and second coupling regions are equal. Preferably, the at least one piezoelectric micromotor pressed to each coupling region comprises one micromotor.
The latch needle is driven back and forth in its latch needle slot when the at least one piezoelectric micromotor pressed to the first and second coupling regions are activated so as to transmit linear motion in the same direction to the coupling fin. Preferably, the at least one piezoelectric micromotor pressed to the first and second coupling regions are activated in phase. This substantially prevents a torque that tends to twist the latch needle in its latch needle slot from developing.
In another configuration for coupling piezoelectric micromotors to the coupling fin, accordance with a preferred embodiment of the present invention, a piezoelectric micromotor coupled to a coupling fin is mounted in a transmission bracket. The transmission bracket comprises a bearing or a non-stick surface area against which a surface region of the micromotor used for transmitting motion to a moveable element, or preferably, a wear resistant friction nub on the surface region of the micromotor, is resiliently pressed. In order to couple the piezoelectric micromotor to the coupling fin, the coupling fin is inserted between the friction nub and the bearing or the non-stick surface. With this coupling configuration a single piezoelectric micromotor can be used to activate a latch needle without causing unwanted torque that twists the latch needle in its latch needle slot. Force exerted by the piezoelectric micromotor perpendicular to the plane of the coupling fin is opposed by an equal and opposite force exerted on the coupling fin by the bearing or the non-stick surface.
In order to couple adjacent latch needles in a needle bed to piezoelectric micromotors using coupling fins, in accordance with a preferred embodiment of the present invention, coupling fins of adjacent latch needles are preferably displaced with respect to each other in the direction of motion of the latch needles and/or protrude different distances above the latch needle bed. This provides sufficient space between piezoelectric micromotors coupled to coupling fins of adjacent latch needles so that the piezoelectric micromotors do not interfere with the motion of the latch needles.
A DND system controls latch needle actuators responsive to the position of the particular latch needle to which the actuators are coupled. In a DND system, in accordance with a preferred embodiment of the present invention, latch needle positions are monitored by an OPM.
An OPM, in accordance with a preferred embodiment of the present invention, monitors the position of a latch needle by optically tracking the position of a small light reflecting region, or a region comprising areas of substantially different reflectivity, such as a light reflecting region with a black line, hereafter referred to as a “fiducial”, located at a known fixed position on the latch needle. The fiducial is illuminated by light from an appropriately located light source, hereafter referred to as a “fiducial illuminator”. The fiducial reflects a portion of the light from the fiducial illuminator with which it is illuminated into an optical device, hereafter referred to as a “fiducial imager”, comprising a detector having a light sensitive surface. The fiducial imager uses the reflected light to form an image of the fiducial on the light sensitive surface of its detector. A change in the position of the fiducial causes a change in the image of the fiducial on the light sensitive surface, which change is used to determine the change in position of the fiducial.
There are a number of other ways in which the latch needle can be provided with a fiducial, in accordance with preferred embodiments of the present invention. For example, a small retro-reflector can be fixed to a point on the body of the latch needle or an appropriate reflecting discontinuity, such as a scratch or dimple, can be formed on a region of the surface of the latch needle. Preferably, the fiducial reflects incident light diffusely within a cone of half energy angle on the order of 10°-20°. The detector and fiducial illuminator comprised in a fiducial imager, in accordance with a preferred embodiment of the present invention, are located so that at any position occupied by the latch needle in its operating range of motion, substantially all the light reflected by the latch needle fiducial into the half energy cone is incident on the detector.
In order to provide position measurements for a plurality of latch needles in a needle bed of a knitting machine, an OPM, in accordance with a preferred embodiment of the present invention, comprises a plurality of fiducial imagers arranged in an array. Preferably, the fiducial imagers are aligned collinearly in a line array defined by an axis that is a straight line. Preferably, the axis is parallel to the needle bed surface of the needle bed and perpendicular to the directions of the needle bed slots.
The number of the plurality of fiducial imagers in the array in a preferred embodiment of the present invention is preferably equal to the number of the plurality of latch needles. Each fiducial imager is aligned with a different one of the plurality of latch needles and provides position data for the latch needle with which it is aligned. The positions of all latch needles in the plurality of latch needles are thus, preferably, simultaneously measurable by the OPM. Preferably, the number of the plurality of latch needles is equal to the number of latch needles in the knitting machine.
In some preferred embodiments of the present invention, the number of the plurality of fiducial imagers in the array of fiducial imagers of an OPM is less than the number of the plurality of latch needles whose positions are to be determined using the OPM. In order to provide position measurements for all the latch needles of the plurality of latch needles, the array of fiducial imagers in the OPM is moved along the needle bed in which the latch needles are held. Preferably, the array of fiducial imagers is moved over the needle bed in a direction collinear with the axis of the array.
In one preferred embodiment of the present invention the fiducial imager comprises a lens and a detector having a light sensitive surface that is divided into first and second regions. The areas of the two regions are preferably equal and preferably abut each other along a straight line. The straight line is preferably oriented substantially perpendicular to the direction of motion of the latch needle. The detector sends first and second signals that are functions of the amounts of reflected light from the fiducial incident on the first and second regions respectively to a controller. The lens focuses reflected light from the fiducial to form an image of the fiducial on the light sensitive surface of the detector. The portions of the image, and thereby the amounts of reflected light, that fall on the first and second regions are different for different positions of the fiducial. The first and second signals, are therefore functions of the position of the fiducial and thereby of the position of the latch needle on which the fiducial is located. The controller uses the first and second signals to determine the position of the latch needle.
In another preferred embodiment of the present invention the fiducial imager comprises a lens, a detector and a light filter. The detector comprises a light sensitive surface sensitive to light in first and second non-overlapping wavelength bands of light. The light filter has first and second filter regions. Each of the filter regions transmits light in a different one of the wavelength bands and does not transmit light in the other wavelength band. The areas of the two filter regions are preferably equal and preferably abut each other along a straight dividing line.
The lens focuses light from the fiducial illuminator that is reflected from the fiducial to form an image of the fiducial on the light sensitive surface of the detector. The filter is positioned with respect to the detector and lens so that the dividing line of the filter and the optic axis of the lens intersect and so that all light from the fiducial focused on the light sensitive surface of the detector passes through the filter. (The filter can also be comprised in an appropriate coating on the lens.) As a result reflected light from the fiducial incident on a first one half of the lens is filtered by the first filter region and reflected light from the fiducial incident on the other half of the lens, a “second half”, is filtered by the second filter region. Therefore the amounts of light in the image of the fiducial in the first and second wavelength bands are proportional to the amounts of light incident on the first and second halves of the lens respectively.
Preferably, the fiducial illuminator illuminates the fiducial with substantially equal intensities of light in the first and second wavelength bands and the fiducial has substantially the same reflectivity for light in both wavelength bands. Preferably, the transmittance of the first filter region for light in the first wavelength band is substantially equal to the transmittance of the second filter region for light in the second wavelength band. Preferably, intensities registered by the light sensitive surface in the first and second wavelength bands are normalized to the intensities of light radiated by the fiducial illuminator in the first and second wavelength bands. The intensities are preferably corrected for differences in reflectivity of the fiducial in the two wavelength bands. Preferably, the intensities are corrected for differences between the transmittance of the first filter region for light in the first wavelength band and the transmittance of the second filter region for light in the second wavelength band. The intensities are preferably corrected for differences in sensitivity of the light sensitive surface to light in the two wavelength bands.
Hereinafter, when intensities, integrated intensities or amounts of light on light sensitive surfaces are compared, it is understood that they are appropriately normalized to the intensity of light radiated by the fiducial illuminator and corrected for biases introduced by various optical components.
The amounts of light incident on the first and second halves of the lens are functions of the position of the fiducial. When the fiducial is located on the optic axis of the lens the first and second halves of the lens receive the same amounts of reflected light. When the fiducial is displaced from the optic axis in the direction of one or the other halves of the lens, the half towards which the fiducial is displaced gets more light and the other half gets less light. Preferably, the dividing line of the filter is substantially perpendicular to the motion of the latch needle and thereby to the fiducial in order to maximize change in the amounts of light incident on the first and second halves of the lens with change of position of the fiducial. The first and second signals sent by the detector to the controller are therefore functions of the position of the fiducial. These signals are used by the controller to determine the position of the fiducial and the latch needle on which the fiducial is located.
In an alternate preferred embodiment of the present invention, the fiducial imager comprises two preferably identical light detectors, each having its own lens that focuses an image of the fiducial onto the detector's light sensitive surface. The two light detectors are displaced from each other by a short distance. The line between the two detectors is aligned parallel with and in the plane of the latch needle slot of the latch needle whose position the detectors are used to determine. The difference between the amounts of light from the fiducial illuminator that is reflected into each of the two detectors is different for different positions of the latch needle along the latch needles range of motion. For example, assume the fiducial illuminator is equidistant from both detectors. When the fiducial is equidistant from both detectors each detector receives the same amount of reflected light from the fiducial and the difference between the amounts of light received by the detectors is substantially zero. If the fiducial is displaced along the direction of motion of the latch needle towards one of the detectors, the detector towards which it is displaced receives an increased amount of reflected light and the other detector receives a decreased amount of light. The difference between the amounts of reflected light received by the detectors from the fiducial is a function of the displacement of the fiducial from the position of the fiducial at which both detectors receive the same amount of reflected light. This difference, and thereby the location of the fiducial and the latch needle, is determined by a circuit that receives an input signal from each detector that is a function of the intensity of light incident on the detector.
In another preferred embodiment of the present invention the fiducial imager comprises one light detector and two lenses. The light sensitive surface of the light detector is sensitive to light in two non-overlapping wavelength bands of light. The fiducial illuminator illuminates the fiducial with preferably equal intensities of light from both wavelength bands. Each of the lenses transmits light in only one of the two different wavelength bands. Both lenses focus light reflected from the fiducial onto the light sensitive surface of the detector. The lenses are displaced a short distance from each other and the line connecting the centers of the lenses is aligned parallel with and in the plane of the latch needle slot of the latch needle whose position the fiducial imager is used to determine. As in the previous fiducial imager, when the fiducial is equidistant from both lenses the detector registers equal intensity (appropriately normalized as discussed above) of light in both of the wavelength bands for which it is sensitive. As the fiducial is displaced towards one or the other of the lenses, the difference between the intensities of light registered by the detector in the two wavelength bands changes as a function of the amount of the displacement.
In a yet another preferred embodiment of the present invention, the fiducial imager comprises one light detector and a lens. The light sensitive surface of the light detector is sensitive to light in two non-overlapping wavelength bands of light. The lens transmits light in both of the two wavelength bands. The latch needle whose position is measured using the fiducial imager is provided with two fiducials displaced from each other by a short distance along the length of the latch needle. Each of the fiducials reflects light in a different one of the wavelength bands to which the detector is sensitive and absorbs light in the other wavelength band. The lens focuses both fiducials on the light sensitive surface of the light detector. The difference between the light intensity registered by the detector in the two different wavelength bands is used to determine the position of the two fiducials and thereby of the latch needle.
In still yet another preferred embodiment of the present invention, the fiducial imager comprises a monochromatic light detector having a pixelated light sensitive surface, such as a CCD, and a lens that focuses an image of the fiducial on the pixelated surface. The location of the fiducial image on the pixelated surface is determined to be the center of gravity of the illumination pattern on the surface that is caused by the fiducial image. The location of the center of gravity is determined to sub-pixel resolution from the locations of pixels illuminated by the fiducial image and the intensities with which these pixels are illuminated using techniques known in the art. The position of the fiducial and its latch needle is determined from the location of the fiducial image on the pixelated surface by techniques that are well-known in the art.
It should be realized that an OPM, in accordance with a preferred embodiment of the present invention, is useable for any application requiring position monitoring of latch needles and its use is not restricted for use only in cooperation with a DND system. It should also be realized that an OPM, in accordance with a preferred embodiment of the present invention, is useable for providing latch needle position measurements for a DND system irrespective of the type of actuators used to activate latch needles in the DND system, and is not limited to use with DND systems that use piezoelectric micromotors or actuators.
There is therefore provided in accordance with a preferred embodiment of the present invention an optical position monitor for determining the position of a latch needle in a knitting machine comprising: at least one fiducial at a known fixed location on the body of the latch needle; a fiducial imager that produces at least one optical image of the at least one fiducial on at least one light sensitive surface, wherein the at least one optical image changes with changes in position of the at least one fiducial; and a controller that receives at least one signal responsive to the changes in the at least one image and uses the at least one signal to determine the position of the at least one fiducial and thereby of the latch needle.
Preferably, the optical position monitor comprises at least one fiducial illuminator that illuminates the at least one fiducial. Additionally or alternatively, the changes in the at least one image comprise changes in integrated intensity of the at least one image. Alternatively or additionally, the at least one fiducial comprises a single fiducial.
In some preferred embodiments of the present invention the at least one light sensitive surface comprises first and second light sensitive surfaces and the at least one signal comprises first and second signals responsive to the intensity of light reflected by the at least one fiducial imaged on the first and second light sensitive surfaces respectively.
Preferably, the first and second light sensitive surfaces comprise first and second contiguous light sensitive surfaces. The at least one image preferably comprises a single image having first and second portions on the first and second light sensitive surfaces respectively and the ratio between the first and second portions depends upon the position of the at least one fiducial.
Alternatively, the first and second light sensitive surfaces comprise first and second light sensitive surfaces that are preferably displaced from each other by a distance. Preferably, the optical position monitor comprises first and second lenses and the at least one image comprises first and second images, wherein the first and second light sensitive surfaces are optically aligned with the first and second lenses respectively, and the first lens produces the first image on the first light sensitive surface and the second lens produces the second image on the second light sensitive surface and wherein the ratio between the integrated intensities of the first and second images depends upon the position of the at least one fiducial.
In still other preferred embodiments of the present invention the at least one light sensitive surface comprises a single light sensitive surface sensitive to light in first and second non-overlapping wavelength bands of light and the at least one signal comprises first and second signals responsive to the integrated intensity of light incident on the single light sensitive surface in the first and second wavelength bands respectively.
Preferably, the optical position monitor comprises a light filter having first and second filter regions wherein the first region transmits light only in the first wavelength band and the second filter region transmits light only in the second wavelength band and light reflected from the single fiducial that is imaged on the light sensitive surface, passes through either the first filter region or the second filter region.
Preferably, the at least one image comprises a single image, wherein a first portion of light in the single image reflected from the fiducial passes through the first filter region and a second portion of light in the single image reflected from the fiducial passes through the second filter region, and wherein the ratio between first and second portions depends upon the position of the fiducial.
Alternatively, the optical position monitor comprises a first lens and a second lens displaced from each other by a distance, wherein the first lens transmits light only in the first wavelength band and the second lens transmits light only in the second wavelength band, wherein the first and second lenses produce first and second images of the fiducial on the light sensitive surface respectively, and the relative integrated intensity of light in the first and second images is a function of the position of the fiducial.
In some preferred embodiments of the present invention the at least one fiducial comprises at least a first and a second fiducial. Preferably, the at least one light sensitive surface comprises a single light sensitive surface sensitive to light in first and second non-overlapping wavelength bands of light and wherein the at least one signal comprises first and second signals responsive to the integrated intensity of light incident on the single light sensitive surface in the first and second wavelength bands respectively. Preferably, the first fiducial reflects light only in the first wavelength band and the second fiducial reflects light only in the second wavelength band, and the optical position monitor comprises: a lens that produces a first image of the first fiducial and a second image of the second fiducial on the light sensitive surface using light reflected from the first and second fiducials respectively; wherein the integrated intensity of light in the first and second images depends upon the position of the first and second fiducials.
In an optical position monitor in accordance with some preferred embodiments of the present invention, changes in the at least one image comprise changes in the location of the at least one image on the at least one light sensitive surface. Preferably, the at least one light sensitive surface comprises at least one pixelated surface. Preferably, the at least one signal comprises signals responsive to the intensity of light incident on each pixel of the at least one pixelated surface. The at least one image preferably comprises a single image on each of the at least one pixelated surface. In some preferred embodiments of the present invention the at least one pixelated surface comprises a single pixelated surface.
In some preferred embodiments of the present invention a location for each of the at least one image is defined as the location of an optical center of gravity of the at least one image, which location is determined from the signals responsive to the intensity of light incident on each pixel of the at least one pixelated surface, and wherein the location of the optical center of gravity is responsive to the position of the at least one fiducial.
In some preferred embodiments of the present invention wherein changes in the at least one image comprise changes in the location of the at least one image on the at least one light sensitive surface, the at least one fiducial comprises a single fiducial.
In some preferred embodiments of the present invention the single fiducial of a plurality of latch needles is imaged on different regions of the at least one pixelated surface, and the optical position monitor is used to determine the positions of a plurality of latch needles. Preferably, the number of the plurality of latch needles is greater than 5. Alternatively, the number of the plurality of latch needles is preferably greater than 10. Alternatively, the number of the plurality of latch needles is preferably greater than 20.
In some preferred embodiments of the present invention an optical position monitor comprises a means for selectively aligning the optical position monitor with different latch needles in the needle bed.
There is further provided an optical position monitor for simultaneously monitoring the position of a plurality of latch needles in a knitting machine needle bed, which needle bed has a plane surface having latch needle slots that are parallel to each other, comprising a plurality of optical position monitors in accordance with a preferred embodiment of the present invention.
Preferably, each of the plurality of the optical position monitors is aligned with a different latch needle and is used to determine the position of at least the latch needle with which it is aligned.
The optical position monitors in the plurality of optical position monitors are preferably aligned in a line array along a straight line. Preferably, the line array is parallel to the needle bed surface and perpendicular to the latch needle slots. Alternatively or additionally, the spacing between an optical position monitor in the line array and an adjacent optical position monitor is the same for any optical position monitor in the line array. Preferably, the spacing is equal to the spacing between adjacent latch needles of the plurality of latch needles.
In some preferred embodiments of the present invention, the number of the plurality of needles is equal to the number of needles in the needle bed.
In other preferred embodiments of the present invention the number of the plurality of latch needles is less than the number of needles in the needle bed and the optical position monitor includes a means for selectively aligning the optical position monitor with different groups of latch needles in the needle bed. Preferably the means for aligning the optical position monitor with different groups of latch needles comprises means for translating the optical position monitor in a direction parallel to the needle bed and perpendicular to the latch needle slots.
In some preferred embodiments of the present invention the optically reflective fiducial comprises at least two regions on the surface of the latch needle having different reflectivities. Preferably, at least one of the at least two regions comprises a retroreflector. Alternatively or additionally, at least one of the at least two regions comprises at least one discontinuity in the surface of the latch needle. Preferably, the at least one discontinuity comprises at least one straight line groove on the surface of the latch needle. Alternatively or additionally, the discontinuity preferably comprises at least one dimple depressed into the surface of the latch needle. Alternatively or additionally, at least one of the at least two regions is preferably substantially non-reflecting.
Additionally or alternatively, light reflected from the fiducial is substantially confined within a cone of half energy angle less than 20°. Additionally or alternatively light reflected from the fiducial is substantially confined within a cone of half energy angle less than 15°. Additionally or alternatively, light reflected from the fiducial is substantially confined within a cone of half energy angle less than 10°.
There is further provided an actuator system for activating a latch needle, which latch needle has a shaft, comprising: a flat planar extension of the shaft having first and second parallel planar surfaces; at least one piezoelectric micromotor having a first surface region for transmitting motion to a moveable element, which first surface region is resiliently pressed to the first surface and at least one additional piezoelectric motor having a second surface region for transmitting motion to a moveable element which second surface region is resiliently pressed to the second surface; and wherein vibratory motions of the first and second surface regions apply forces to the flat extension that cause motion in the latch needle.
There is also provided an actuator system for activating a latch needle, which latch needle has a thin flat shaft comprising: a flat planar extension of the shaft having first and second planar surfaces; a piezoelectric micromotor having a surface region for transmitting motion to a moveable element; a transmission bracket for holding the piezoelectric micromotor, the transmission bracket comprising a bearing surface and a means for resiliently urging the surface region of the piezoelectric micromotor towards the bearing surface; and wherein the flat extension is inserted between the surface region of the piezoelectric micromotor and the bearing or the non-stick surface and wherein vibratory motion of the surface region applies force to the flat extension causing motion in the latch needle.
Preferably, the bearing surface is the surface of a rotatable roller or ball. Alternatively or additionally, the bearing surface is a surface having a low friction coating.
In an actuator system for activating a latch needle according to some preferred embodiments of the present invention, the surface region for transmitting motion to a moveable element comprises a wear resistant nub that makes contact with a surface of the moveable element towards which the surface region for transmitting motion is resiliently pressed in order to transmit motion to the moveable element.
In an actuator system for activating a latch needle according to some preferred embodiments of the present invention, points on surfaces of the flat extension at which said surface regions of the piezoelectric micromotors make contact are clad in wear resistant material.
BRIEF DESCRIPTION OF FIGURES
The invention will be more clearly understood by reference to the following description of preferred embodiments thereof read in conjunction with the attached figures listed below, wherein identical structures, elements or parts that appear in more than one of the figures are labeled with the same numeral in all the figures in which they appear, and in which:
FIG. 1 shows the basic structure of a latch needle;
FIG. 2 is a schematic illustration of a conventional system for activating latch needles in a knitting machine;
FIG. 3 is a schematic illustration of a system for coupling piezoelectric micromotors to latch needles in a needle bed by rotary transmission, in accordance with a preferred embodiment of the present invention;
FIG. 4 shows a schematic of a system for coupling piezoelectric micromotors to latch needles in a needle bed by linear transmission in accordance with an alternative preferred embodiment of the present invention;
FIG. 5 illustrates schematically the coupling of a latch needle with a coupling fin to two piezoelectric micromotors in accordance with a preferred embodiment of the present invention;
FIG. 6 illustrates schematically the coupling of a latch needle with a coupling fin to a single piezoelectric micromotor mounted to a transmission bracket in accordance with yet another preferred embodiment of the present invention;
FIGS. 7A-7C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with a preferred embodiment of the present invention;
FIG. 8 schematically illustrates an OPM comprising a linear array of a plurality of imaging fiducials shown in FIGS. 7A-7C, imaging an equal plurality of latch needle fiducials in accordance with a preferred embodiment of the present invention;
FIGS. 9A-9C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with an alternative preferred embodiment of the present invention;
FIGS. 10A-10C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with another preferred embodiment of the present invention;
FIGS. 11A-11C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with yet another preferred embodiment of the present invention;
FIGS. 12A-12C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with still another preferred embodiment of the present invention; and
FIGS. 13A-13C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with another alternative preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a profile of a latch needle 20 . Latch needle 20 is a thin metallic structure with a long shaft 22 having a hook 24 and a tip 30 formed on one of its ends. A latch 26 is rotatable about a pivot 28 and is shown in the figure in the position where it caps tip 30 to close hook 24 and prevents hook 24 from hooking a thread. In an open position latch 26 is rotated clockwise almost to a position where it is parallel to shaft 22 . A fin 32 extends out from shaft 22 , generally on the same side of shaft 22 as hook 24 .
FIG. 2 is a schematic illustration of the arrangement of needle beds in a conventional knitting machine and a shuttle which transmits motion to latch needles in the needle beds.
Two needle beds 36 and 38 are rigidly joined at an angle to each other so that an edge 39 of needle bed 36 is close to and parallel to an edge 40 of needle bed 38 . A long narrow space 44 separates edge 39 and edge 40 . Needle beds 36 and 38 are identical or very similar and detailed discussion will be confined to needle bed 36 with the understanding that details and structures described for needle bed 36 apply equally to needle bed 38 .
Threads to be woven into fabric (not shown) are held under tension close to and parallel to edges 39 and 40 . Fabric (not shown), as it is produced moves downwardly from edges 39 and 40 into space 44 . As the fabric moves down it exits the knitting machine.
Needle bed 36 is provided with an array of equally spaced parallel latch needle slots 42 that are perpendicular to edge 39 . A latch needle 20 is placed in each latch needle slot 42 . The bodies of latch needles 20 are completely inside latch needle slots 42 and are not visible. Only fins 32 of latch needles 20 protrude above the surface of needle bed 36 and are visible. Fins 32 of all latch needles 20 that are at rest in slots 42 are aligned along a straight row which is perpendicular to latch needle slots 42 . Each needle 20 is moveable back and forth in its latch needle slot 42 .
A shuttle 46 , having ends 52 and 54 , moves back and forth parallel to edges 39 and 40 along the length of needle bed 36 . An interior face 48 of shuttle 46 is parallel to needle bed 36 and has a channel 50 formed in the face. Channel 50 is open on both ends 52 and 54 of shuttle 46 . The two open ends of channel 50 are in line with the row of fins 32 . A section 56 of channel 50 is not collinear with the ends of channel 50 . Channel 50 is just wide enough and deep enough so that fins 32 can pass into and move through it.
As shuttle 46 moves back and forth with interior face 48 parallel to latch needle bed 36 , fins 32 of latch needles 20 enter channel 50 at one end and move along the length of channel 50 . When a fin 32 of a latch needle 20 encounters non-collinear section 56 of channel 50 the fin 32 and the latch needle 20 to which fin 32 is attached are displaced parallel to latch needle slot 42 in which the latch needle 20 is found. In FIG. 2, for clarity of presentation, only a few of latch needles 20 that are moving in channel 50 are shown.
FIG. 3 shows a system for exclusively coupling each of the latch needles in a needle bed to at least one exclusive piezoelectric micromotor using a rotary transmission, according to a preferred embodiment of the present invention. A long bearing shaft 58 is mounted over a needle bed 60 that is provided with slots 62 into which have been placed latch needles 63 . Bearing shaft 58 is mounted with a multiplicity of thin annuli 64 , one annulus for each latch needle (for clarity only three are shown). The annuli rotate freely on bearing shaft 58 . Each annulus is positioned opposite a fin 65 of a particular latch needle 63 . A connecting arm 66 connects each annulus 64 to a point 68 on fin 65 , to which annulus 64 is opposite. The connection at point 68 is a flexible or slideable connection produced by methods known in the art. One or more piezoelectric micromotors 70 , 72 , and 74 , are resiliently pressed against each annulus 64 by methods known in the art. When piezoelectric micromotors 70 , 72 , and 74 , are activated they cause annulus 64 and connecting arm 66 to rotate, which in turn moves latch needle 63 linearly in its slot 62 . The flexible connection at point 68 translates rotational motion of arm 66 to linear motion of latch needle 63 . It should be understood that this arrangement allows for a much higher speed of the latch needle than that available from the motor itself.
While three exclusive piezoelectric micromotors are shown coupled to annulus 64 in FIG. 3, a greater or lesser number of micromotors can be used depending on the speed or torque required for motion of the needle. Also, other types of piezoelectric micromotors constructed differently than the ones shown in FIG. 3 and described above may be used to rotate annulus 64 and are advantageous. U.S. Pat. No. 4,562,374 and the publication by Hiroshi et al., IEEE Transactions on Ultrasonics, Ferroelectrics, and Frequency Control, Vol. 42, No. 2, March 1995, incorporated herein by reference, describe rotary piezoelectric micromotors. These rotary piezoelectric micromotors comprise a cylindrical, annular or disc shaped rotor that is caused to rotate by coupling to a stator that is a cylindrical, annular or disc shaped vibrator. The rotor and stator are concentric. A vibrating surface of the stator is coupled to an inside edge surface or an outside edge surface of the rotor to impart a rotary motion to it. Alternatively, a vibrating surface of the stator may be coupled to a face surface of the rotor to impart rotational motion to the rotor. Annulus 64 can be rotated by the use of stators similar to those described in the above references. Annulus 64 is coupled to the stators in similar fashion to the way that the rotors are coupled to the stators in the described rotary piezoelectric micromotors.
FIG. 4 shows another system for coupling each of the latch needles in a needle bed to at least one exclusive piezoelectric micromotor using a linear transmission, according to an alternative preferred embodiment of the present invention.
A latch needle bed 76 is provided with latch needle slots 78 in which are placed latch needles 80 . One or more thin piezoelectric micromotor 82 is resiliently pressed against the shaft 84 of each latch needle 80 (only one is shown for each latch needle for simplicity). Piezoelectric micromotors 82 on adjacent latch needles 80 are in line with each other so that they form a straight row. Alternatively, piezoelectric micromotors 82 may be staggered with respect to each other so that they are arrayed in two or more parallel rows. FIG. 4 shows an embodiment according to the present invention in which piezoelectric micromotors are aligned in two parallel rows. Staggered configurations allow for more space between closely packed vibrators 82 than would be available if vibrators 82 were arrayed in a single row and thus allow for thicker more powerful piezoelectric micromotors to be coupled to latch needles 63 .
Vibrations of piezoelectric micromotors 82 are directly translated into linear motion of latch needles 80 . Slots 78 are fitted with bearings (not shown) or with a non-stick surface so that the resilient force which presses a vibrator 82 to a shaft 84 of a needle 80 does not result in excessive friction between needle 80 and the bottom or sides of latch needle slot 78 in which needle 80 is placed.
Rotary piezoelectric micromotors similar to those described in U.S. Pat. No. 4,562,374 and the publication by Hiroshi et al. cited above may also be used to drive latch needles 80 . The edge surface of a rotor of a rotary piezoelectric micromotor is resiliently pressed against shaft 84 of each latch needle 80 . The axes of the rotors are perpendicular to latch needle slots 78 in which latch needles 80 are placed. Frictional forces at the area of contact between the edge surface of a rotor and the surface of shaft 84 of a needle 80 acts to prevent the edge surface of the rotor from slipping on the surface of shaft 84 when the rotor rotates. As the rotor rotates it therefore causes shaft 84 of latch needle 80 to displace linearly in latch needle slot 78 in which latch needle 80 is placed in the direction of motion of the mass points of the edge surface of the rotor which are in contact with the surface of shaft 84 .
FIG. 5 shows a latch needle 300 coupled to two identical piezoelectric micromotors 302 and 304 , in accordance with yet another preferred embodiment of the present invention. Latch needle 300 comprises a latch needle shaft 301 and a coupling fin 306 . Coupling fin 306 has two parallel planar surfaces 308 and 310 . A coupling region 312 of each surface 308 and 310 (coupling region 312 of surface 308 is not seen in the perspective of FIG. 5) is preferably clad with a wear resistant material suitable for friction coupling with piezoelectric micromotors.
Piezoelectric micromotors 302 and 304 preferably comprise friction nubs 314 and 316 respectively. Piezoelectric micromotors 302 and 304 are resiliently pressed to coupling fin 306 so that friction nubs 314 and 316 contact coupling regions 312 of surfaces 308 and 310 respectively at points that are directly opposite each other. In order to move latch needle 300 back and forth in its latch needle slot (not shown) piezoelectric micromotors 302 and 304 are preferably simultaneously activated in phase to transmit motion to coupling fin 306 .
FIG. 6 shows latch needle 300 coupled to a single piezoelectric micromotor 320 , in accordance with still another preferred embodiment of the present invention. Piezoelectric micromotor 320 is mounted to a transmission bracket 322 preferably comprising a bearing 324 and a biasing means 326 such as a spring or resilient pad. Dashed lines indicate parts of piezoelectric micromotor 320 hidden by transmission bracket 322 . Piezoelectric micromotor 320 preferably comprises a friction nub 328 (shown in dashed lines). Biasing means 326 resiliently presses piezoelectric micromotor 320 in a direction so that friction nub 328 is urged towards bearing 324 . Transmission bracket 322 is held by an appropriate mechanical structure (not shown) so that coupling fin 306 is located between friction nub 328 and bearing 324 .
As a result of the action of biasing means 326 bearing 324 presses resiliently on coupling region 312 of surface 310 and friction nub 328 presses resiliently on coupling region 312 of surface 308 . Transmission bracket 322 is oriented so that the direction in which friction nub 328 is urged by biasing means 326 is substantially perpendicular to the plane of coupling fin 306 . Bearing 324 and friction nub 328 exert equal and opposite forces on coupling fin 306 perpendicular to the plane of coupling fin 306 . As a result piezoelectric micromotor 320 does not produce a torque on latch needle 300 that tends to rotate latch needle 300 in its latch needle slot (not shown).
Coupling fin 306 can be located at different positions along shaft 301 of different latch needles 300 . In addition coupling fin 306 can be formed so that it extends different distances from shaft 301 of different latch needles 300 . Adjacent latch needles in a needle bed can therefore preferably, have coupling fins that protrude different heights above the needle bed and/or are displaced with respect to each other in a direction parallel to their shafts in order to provide space for piezoelectric micromotors that are coupled to the coupling fins.
It is clear from the above discussion that piezoelectric micromotors in accordance with preferred embodiments of the present invention can be conveniently coupled to latch needles in a latch needle bed of a knitting machine so that each latch needle is exclusively coupled to at least one piezoelectric micromotor.
FIGS. 7A-7C schematically illustrate an OPM 98 comprising a fiducial imager 100 and a fiducial illuminator 101 imaging a latch needle fiducial 102 located on a latch needle 104 , in accordance with a preferred embodiment of the present invention. Fiducial imager 100 comprises a lens 106 and a detector 108 . Detector 108 has a light sensitive surface 110 (shown greatly exaggerated in thickness for convenience and clarity of presentation) that is divided into a first detector region 112 and a second detector region 114 . A region of Light sensitive region 110 is schematically shown from “underneath”, in a ventral view, as seen from fiducial 102 , in views 116 , 118 and 120 to the left of detector 108 in each of FIGS. 7A-7C respectively. The areas of detector regions 112 and 114 preferably have the same shape, are equal and abut each other along a straight dividing line 122 . Detector 108 registers the intensity of light incident on first detector region 112 and second detector region 114 separately. Detector 108 sends a first signal to a controller (not shown) that is a function of the intensity of light registered on first detector region 112 and a second signal to the controller that is a function of the intensity of light registered by second detector region 114 .
Detector 108 is oriented with respect to latch needle 104 so that dividing line 122 is substantially perpendicular to the plane (the same as the plane of FIGS. 7A-7C) of the latch needle slot (not shown,) in which latch needle 104 is held, and perpendicular to the direction of the back and forth motion of latch needle 104 indicated by doubled headed arrow 124 .
Fiducial 102 is illuminated by light from fiducial illuminator 101 and reflects some of the light, indicated by dotted line 128 , onto lens 106 . Fiducial 102 preferably reflects light from fiducial illuminator 101 diffusely in a cone (not shown) of half energy angle on the order of 10°-15°. Fiducial illuminator 101 and fiducial imager 100 are located with respect to each other so that for any position of latch needle 104 in the operating range of motion of latch needle 104 , fiducial 102 reflects light from fiducial illuminator 101 into fiducial imager 100 .
Lens 106 forms an image 130 of fiducial 102 on light sensitive surface 110 from the light reflected by fiducial 102 . A first image portion 132 of image 130 falls on first detector region 112 and a second image portion 134 of image 130 falls on second detector region 114 (views 116 , 118 and 120 ). First detector region 112 registers an intensity of light on its surface that is a function of the size of first image portion 130 and second detector region 114 registers an intensity of light that is a function of the size of second image portion 134 . Detector 108 therefore sends a first signal to the controller that is as function of the size of first image portion 130 and a second signal to the controller that is a function of the size of second image portion 134 . The relative sizes of first image portion 132 and second image portion 134 are a function of the position of fiducial 102 and first and second signals are used by the controller to determine the position of fiducial 102 and thereby of latch needle 104 .
The dependence of the sizes of first image portion 132 and second image portion 134 on the position of fiducial 102 is shown schematically in ventral views (seen from “beneath”, from the perspective of fiducial 102 ) 116 , 118 and 120 in FIGS. 7A-7C respectively. In FIG. 7A fiducial 102 is located along the axis of fiducial imager 100 , which is coincident with the direction of line 128 that indicates the direction of reflected light from fiducial 102 . First image portion 132 and second image portion 134 are equal. In FIG. 7B fiducial 102 is shown displaced far to the right of the axis of fiducial imager 100 and first image portion 132 is much larger than second image portion 134 . In FIG. 7C fiducial 102 is shown displaced far to the left of the axis of fiducial imager 102 and second image portion 134 is much larger than first image portion 132 .
FIG. 8 shows an OPM 138 , in accordance with a preferred embodiment of the present invention, that comprises a plurality of fiducial imagers 100 shown in FIGS. 7A-7C. Fiducial imagers 100 are fixed with respect to each other by an appropriate mechanical structure (not shown) in a collinear line array 140 having an axis 142 . Line array 140 is mounted over a needle bed (not shown) of a knitting machine (not shown) in which a plurality of latch needles 104 are placed. Each latch needle 104 has a fiducial 102 . Axis 142 of line array 140 is preferably parallel to the surface of the needle bed and perpendicular to latch needles 104 (and thereby perpendicular to the directions of motion of latch needles 104 ). Dividing lines 122 (not shown) of light sensitive surfaces 110 of fiducial imagers 100 are preferably parallel to axis 142 . Each of fiducial imagers 100 in line array 140 is aligned over a different one of latch needles 104 and is used to measure the position of latch needle 104 over which it is aligned.
In OPM 138 , each fiducial 102 is illuminated with light from a fiducial illuminator 101 and reflects some of this light into the fiducial imager 100 that is aligned over and images the fiducial 102 . A central ray of light from each fiducial 102 reflected into the fiducial imager 100 that images the fiducial 102 is indicated by a dotted line 128 . Each dotted line 128 starts at a fiducial 102 , and ends on the image 130 of the fiducial 102 in the fiducial imager 100 that is used to measure the position of fiducial 102 . The positions of the first and second leftmost latch needles 104 and their fiducials 102 in FIG. 8 correspond to the positions of latch needles 104 and fiducials 102 shown in FIGS. 7C and 7A respectively. The positions of the rest of latch needles 104 shown in FIG. 8 correspond to the position of latch needle 104 shown in FIG. 7 B.
OPM 138 can be used to determine positions only for those latch needles 104 that are aligned with a fiducial imager 100 of line array 140 . At any one time therefore, the number of latch needles 104 in a knitting machine whose positions can be determined by OPM 138 is equal to the number of fiducial imagers in line array 140 . Preferably, the number of fiducial imagers 100 in line array 140 is equal to the number of latch needles in the knitting machine. If the number of the fiducial imagers in line array 140 is less than the number of latch needles in the knitting machine, OPM 138 must be moved in order to provide position measurements for all latch needles 104 in the knitting machine. Preferably, OPM 138 is moved parallel to axis 142 along the knitting machine needle bed in order to provide position measurements for all the latch needles 104 in the knitting machine.
In FIG. 8 each fiducial 102 is shown illuminated by its own fiducial illuminator 101 . This is not a necessity and some OPMs, in accordance with preferred embodiments of the present invention, comprise fiducial illuminators that illuminate groups of more than one fiducial 102 . Additionally, in some preferred embodiments of the present invention, lenses 106 , each of which is used to image one fiducial 102 , are replaced by lenses, such as extended cylindrical lenses, each of which is used to image more than one fiducial 102 .
FIGS. 9A-9C schematically illustrate an OPM 270 imaging fiducial 102 of latch needle 104 , in accordance with an alternate preferred embodiment of the present invention. OPM 270 comprises a fiducial imager 272 and a fiducial illuminator 274 . Fiducial imager 272 comprises a lens 276 having an optic axis indicated by line 278 , a detector 280 and a light filter 282 . Detector 280 comprises a light sensitive surface 282 , sensitive to light in first and second non-overlapping wavelength bands of light. Detector 280 sends a first signal to a controller (not shown) that is a function of the intensity of light registered on light sensitive surface 280 in the first wavelength band and a second signal to the controller that is a function of the intensity registered by light sensitive surface 282 in the second wavelength band.
Light filter 282 has a first filter region 284 and a second filter region 286 . First filter region 284 transmits light only in the first wavelength band and second filter region 286 transmits light only in the second wavelength band. First and second filter regions 284 and 286 are preferably equal and abut each other along a straight dividing line (not shown in fiducial imager 272 ). Filter 282 is oriented with respect to lens 276 so that reflected light from fiducial 102 incident on lens 276 passes through filter 282 . A central ray of reflected light from fiducial 102 is indicated by dotted line 288 in FIGS. 9B and 9C. In FIG. 9A the central ray is coincident with optic axis 278 . The dividing line of filter 282 and optic axis 278 of lens 276 intersect. Preferably, the dividing line is perpendicular to the direction of motion of latch needle 104 and the plane (the plane of the FIG. ) of the latch needle slot (not shown) that holds latch needle 104 . As a result, light incident on a first half 290 of lens 276 is filtered by first filter region 284 and light incident on a second half 292 of lens 276 is filtered by second filter region 286 . Lens 276 focuses reflected light from fiducial 102 to form an image 130 of fiducial 102 on light sensitive surface 282 of detector 280 . A first portion of the intensity of image 130 results from light incident on first half 290 of lens 276 and a second portion of the intensity of image 130 results from light incident on second half 292 of lens 276 . Since first half 290 of lens 276 is filtered by first filter region 284 , the first portion of the intensity of image 130 results from light in the first wavelength band. Similarly, the second portion of the intensity of image 130 results from light in the second wavelength band. The first and second portions of the intensity of image 130 are proportional to the amounts of light from fiducial 102 that are incident on first and second halves 290 and 292 of lens 276 respectively. As a result, the intensities of light registered by light sensitive surface 282 in the first and second wavelength bands are proportional to the amounts of reflected light from fiducial 102 incident on first and second halves 290 and 292 of lens 276 respectively.
However, the amounts of light incident on first half 290 and second half 292 are functions of the location of fiducial 102 with respect to optic axis 278 of lens 276 . When fiducial 102 is on optic axis 278 , halves 290 and 292 of lens 276 receive the same amounts of reflected light. When fiducial 102 is displaced along the direction of motion of latch needle 104 (along the direction of double headed arrow 124 in FIGS. 9A-9C) towards one or the other of halves 290 and 292 , the half towards which fiducial 102 is displaced receives more light and the other half less light. This is because the distance from fiducial 102 to the half of lens 276 towards which fiducial 102 is displaced decreases and the distance towards the other half increases. The first and second signals that detector 280 sends to the controller are therefore functions of the position of fiducial 102 . These signals are used by the controller to determine the position of fiducial 102 and latch needle 104 on which fiducial 102 is located.
FIGS. 9A-9C show schematically the relationship between positions of fiducial 102 and the intensities of image 130 in the first and second wavelength bands A region of light sensitive surface 282 is shown schematically with image 130 , in ventral view, in a view 294 in each of FIGS. 9A-9C. The dividing line of filter 282 is shown as line 296 in view 294 . The relative intensities of image 130 in the first and second wavelength bands are represented schematically in greatly exaggerated scale and only qualitatively in proportion to the actual intensities of light in image 130 in the first and second wavelength bands by the size of arrows 298 and 300 respectively.
In FIG. 9A fiducial 102 is located on optic axis 278 and image 130 has the same (appropriately normalized and corrected) integrated intensity (i.e. integrated over the area of image 130 ) in both wavelength bands. Arrows 298 and 300 are shown the same size. In FIG. 9B fiducial 102 is displaced away from optic axis 278 towards first half 290 of lens 276 . Image 130 is displaced from optic axis 278 in the opposite direction and the integrated intensity of image 130 increases in the first wavelength band and decreases in the second wavelength band. Arrow 300 is shown much larger than arrow 298 . Similarly, in FIG. 9C, fiducial 102 is shown displaced away from optic axis 278 towards second half 292 of lens 276 . The integrated intensity of image 130 increases in the second wavelength band and decreases in the first wavelength band.
FIGS. 10A-10C schematically illustrate an OPM 150 , in accordance with another preferred embodiment of the present invention, imaging fiducial 102 of latch needle 104 . OPM 150 comprises a fiducial illuminator 152 and a fiducial imager 154 comprising two, preferably identical, detectors 156 and 158 . Fiducial illuminator 152 illuminates fiducial 102 of latch needle 104 . Fiducial 102 reflects some of the light incident on fiducial 102 towards each of detectors 156 and 158 .
Detectors 156 and 158 have light sensitive surfaces 160 and 162 (shown greatly exaggerated in thickness for convenience and clarity of presentation) and lenses 164 and 166 respectively. Lens 160 focuses reflected light from fiducial 102 to provide an image 168 of fiducial 102 on light sensitive surface 160 . Similarly, lens 166 provides an image 170 of fiducial 102 on light sensitive surface 162 . Light sensitive surface 160 with image 168 , and light sensitive surface 162 with image 170 , are shown schematically, in ventral view, in views 172 and 174 respectively in each of FIGS. FIGS. 10A-10C. The intensities of images 168 and 170 are schematically represented in each of views 172 and 174 by the length of arrows 169 and 171 respectively. The relative sizes of arrows 169 and 171 are greatly exaggerated for clarity and ease of presentation in comparison to the actual relative intensities of images 168 and 170 . Each of detectors 156 and 158 provides a signal to a controller (not shown) that is a function of the intensity of reflected light imaged on its light sensitive surface.
Detectors 156 and 158 are displaced from each other a small distance, “d”, and both are located at a height, “r”, directly above latch needle 104 . OPM 150 is oriented with respect to latch needle 104 so that a line between the centers of lenses 164 and 166 is parallel to latch needle 104 . Dashed lines 176 and 178 represent central rays of light reflected from fiducial 102 into detectors 156 and 158 respectively.
In FIG. 10A fiducial 102 is located at a point 180 that is equidistant from detectors 156 and 158 . Both detectors receive substantially the same amounts of reflected light from fiducial 102 . Arrows 169 and 171 in views 172 and 174 respectively are therefore shown the same size. The difference between the intensities of light reaching detectors 156 and 158 is zero.
In FIG. 10B fiducial 102 is displaced from point 180 to the right. As a result of the displacement, the distance from fiducial 102 to detector 158 decreases and the distance from fiducial 102 to detector 156 increases. This increases the amount of reflected light reaching detector 158 from fiducial 102 and decreases the amount of reflected light reaching detector 156 from fiducial 102 . The size of arrow 171 in view 174 is therefore shown much larger than the size of arrow 169 in view 172 . The difference between the intensities of light reaching detectors 156 and 158 , defined as the amount of light reaching detector 156 minus the amount of light reaching detector 156 , is negative.
In FIG. 10C fiducial 102 is displaced from point 180 to the left. This increases the amount of reflected light reaching detector 156 from fiducial 102 and decreases the amount of reflected light reaching detector 158 from fiducial 102 . In this case, the size of arrow 171 in view 174 is therefore shown much smaller than the size of image 169 in view 172 . The difference between the intensities of light reaching detectors 156 and 158 , as defined above, is positive.
From considerations of geometry it can readily be shown that when r>>d, if the displacement of fiducial 102 from point 180 is represented by “Δx”, the difference between the intensities of light reaching detectors 156 and 158 is proportional to Δxd/r 4 . The difference between the signals sent by detectors 156 and 158 to the controller, which are functions of the intensities of reflected light registered by detectors 156 and 158 respectively, can therefore be used to determine Δx and the position of fiducial 102 .
FIGS. 1A-11C schematically show an OPM 190 , in accordance with yet another preferred embodiment of the present invention, imaging fiducial 102 of latch needle 104 . OPM 190 comprises a fiducial illuminator 192 and a fiducial imager 194 . Fiducial imager 194 comprises a single detector 196 and two lenses 198 and 200 . Fiducial illuminator 192 illuminates fiducial 102 of latch needle 104 . Fiducial 102 reflects some of the light incident on it from fiducial illuminator 192 towards each of lenses 198 and 200 . A central ray of reflected light from fiducial 102 to lens 198 is represented by dashed line 202 and dashed line 204 represents a central ray from fiducial 102 to lens 200 .
Detector 196 comprises a light sensitive surface 206 (shown greatly exaggerated in thickness for convenience and clarity of presentation) that is sensitive to light in two non-overlapping wavelength bands of light. Fiducial illuminator 192 illuminates fiducial 102 with preferably equal intensities of light from both wavelength bands. Each of lenses 198 and 200 transmits light in only one of the two different wavelength bands. Lens 198 focuses reflected light in one of the two wavelength bands to form an image 214 on light sensitive surface 206 . Lens 200 focuses reflected light in the other of the two wavelength bands to form an image 216 on light sensitive surface 206 . Detector 196 sends a first signal to a controller (not shown) that is a function of the amount of light in image 214 and a second signal to the controller that is a function of the amount of light in image 216 .
Lenses 198 and 200 are displaced a short distance from each other and the line connecting the centers of lenses 198 and 200 is aligned parallel with and directly above latch needle 104 . Assume that fiducial illuminator 192 is either located equidistant from lenses 198 and 200 , or that any biases in the relative amounts of light reflected by fiducial 102 onto lenses 198 and 200 resulting from an asymmetric location of fiducial illuminator 192 with respect to lenses 198 and 200 are corrected for. Then, when fiducial 102 is equidistant from lenses 198 and 200 , detector 196 registers equal intensities of light for both images 214 and 216 (i.e. surface 206 registers the same intensity of light in both of the wavelength bands to which it is sensitive). As fiducial 102 is displaced towards one or the other of lenses 198 and 200 , the relative intensities of light registered for images 214 and 216 changes.
FIG. 11A shows fiducial light 102 located at a point 208 equidistant from lens 198 and 200 . FIGS. 11B and 11C show fiducial 102 displaced right and left respectively of point 208 . View 210 each of FIGS. 11A-11C is a ventral view of light sensitive surface 206 . View 210 shows schematically images 214 and 216 of fiducial 102 that are formed on light sensitive surface 206 by lenses 198 and 200 respectively. The sizes of arrows 215 and 217 in view 210 represent schematically with greatly exaggerated scale the relative amounts of light in images 214 and 216 respectively for the different positions of fiducial 102 shown in FIGS. 11A-11C.
From considerations of geometry it can readily be shown, as in the case of OPM 150 shown in FIGS. 10A-10C, that for a displacement Δx of fiducial 102 from point 208 , the difference between the intensities of light registered by detector 196 for images 214 and 216 is substantially proportional to Δx. The signals sent by detector 206 to the controller, which are functions of the intensities of light registered by detector 206 for images 214 and 216 can therefore be used to determine Δx and thereby the position of fiducial 102 .
FIGS. 12A-12C schematically show an OPM 220 , in accordance with yet another preferred embodiment of the present invention that is used to measure the position of a latch needle provided with two fiducials. In FIGS. 12A-12C, OPM, 220 is shown imaging a latch needle 222 provided with a fiducial 224 and a fiducial 226 .
OPM 220 comprises a fiducial illuminator 228 and a fiducial imager 230 . Fiducial imager 230 comprises a single detector 232 and a single lens 234 having a lens axis 235 . Detector 232 comprises a light sensitive surface 233 (shown greatly exaggerated in thickness for convenience and clarity of presentation) that is sensitive to light in two non-overlapping wavelength bands of light. Fiducial illuminator 228 illuminates fiducials 224 and 226 preferably with light having equal intensities in both wavelength bands. Fiducial 224 reflects light in only one of the two wavelength bands and fiducial 226 reflects light in only the other of the two wavelength bands. Lens 234 images the reflected light from fiducials 224 and 226 to form an image 236 of fiducial 224 on surface 233 in one of the two wavelength bands and an image 238 of fiducial 226 on surface 233 in the other of the two wavelength bands. Detector 232 sends a signal to a controller (not shown) for each of images 236 and 238 that is a function of the intensity of light in the image.
Images 236 and 238 have the same intensities, in their respective wavelength bands, only when fiducials 224 and 226 are substantially equidistant from axis 235 of lens 234 . For different positions of latch needle 222 , one or the other of fiducials 224 and 226 is closer to axis 235 . The image of the fiducial closer to axis 235 is more intense than the image of the fiducial farther from axis 235 . Differences in intensities of images 236 and 238 registered by detector 232 are used to determine the position of fiducials 224 and 226 and thereby of latch needle 222 .
FIG. 12A shows latch needle 222 in a position for which fiducials 224 and 226 are equidistant from axis 235 . FIG. 12B shows latch needle 222 in a position in which fiducials 224 and 226 are displaced to the right of their respective positions shown in FIG. 12A, and FIG. 12C shows latch needle 222 in a position in which fiducials 224 and 226 are displaced to the left of their respective positions shown in FIG. 12 A. In each of FIGS. 12A-12C, view 240 is a ventral view of light sensitive surface 234 schematically showing images 236 and 238 . The sizes of arrows 237 and 239 shown in ventral view 240 represent schematically and in greatly exaggerated scale, the relative intensities of images 236 and 238 for the position of latch needle 222 shown in the FIG.
FIGS. 13A-13C show an OPM 250 imaging fiducial 102 , in accordance with yet another preferred embodiment of the present invention. OPM 250 comprises a fiducial illuminator 252 and a fiducial imager 254 . Fiducial imager 254 comprises a lens 256 having an optic axis 257 and a detector 258 , such as a CCD, having a pixelated light sensitive surface 260 (shown greatly exaggerated in thickness for convenience and clarity of presentation). Lens 256 focuses reflected light from fiducial 102 to form an image 262 of fiducial 102 on pixelated surface 260 .
In OPM 250 the position of fiducial 102 is determined using the rules of basic optics from the location of image 262 on pixelated surface 260 . FIGS. 13A-13C show schematically the spatial relationship between the position of fiducial 102 and image 262 of fiducial 102 on pixelated surface 260 . Image 262 and pixels 264 of pixelated surface 260 are shown schematically in a ventral view 266 of pixelated surface 260 in each of FIGS. 13A-13C. In FIG. 13A fiducial 102 is located on optic axis 257 and image 262 is located at the center of pixelated surface 260 shown in view 264 (assuming lens 256 and detector 258 are aligned). In FIGS. 13B and 13C, fiducial 102 is displaced to the right and to the left of optic axis 257 respectively. Image 262 on pixelated surface 260 moves accordingly to the left and the right of the point at which image 262 is located when fiducial 102 is on optic axis 257 .
Image 262 is preferably focused by lens 256 so that it covers a plurality of pixels on light sensitive surface 260 . Using methods well known in the art, an optical center of gravity of image 262 can be defined and located on pixelated surface 260 to sub-pixel accuracy. Using the location of the optical center of gravity of image 262 , the position of fiducial 102 and latch needle 104 are determined by OPM 250 with an accuracy sufficient for controlling latch needle actuators in a DDM.
FIGS. 13A-13C show OPM 250 being used to determine the position of a single latch needle 104 , by imaging a fiducial 102 located on the latch needle 104 . However, a single OPM of the form of OPM 250 , in accordance with a preferred embodiment of the present invention, can be used to determine the position of a plurality of latch needles 104 . This is accomplished by providing the detector 258 of the OPM with a field of view that includes the fiducial 102 of each of the plurality of latch needles 104 . Each fiducial 102 of a latch needle of the plurality of latch needles is imaged on a different rectangular region of pixelated surface 260 of the OPM. As the latch needle 104 on which the fiducial 102 is located moves back and forth in its operational range of motion, (indicated schematically by double headed arrow 124 ) the image of its fiducial 102 moves back and forth along the length of the rectangular region of pixelated surface 260 on which it is imaged.
For example, in one preferred embodiment of the present invention, detector 258 is provided with a field of view that focuses an area of a needle bed having a dimension perpendicular to latch needles 104 that is on the order of 5 cm. The dimension of the field of view in the direction parallel to latch needles 104 is on the order of the operational range of motion of latch needles 104 . If the spacing between latch needles 104 in the needle bed is 2 mm the fiducials 102 of 25 latch needles 104 will be in the field of view of the OPM. Assuming that pixelated surface 260 of detector 258 comprises a square matrix, 5 mm on a side, comprising 512 rows and 512 columns of pixels fiducials 102 of the 25 latch needles 104 in the field of view of detector 258 are imaged on parallel rectangular regions of pixelated surface 260 that are approximately 20 pixels wide and 512 pixels long. If the operational range of motion of a latch needle 104 is on the order of 5 cm, and the optical center of gravity of the image of a fiducial is located with a resolution of 0.4 pixels, the position of fiducial 102 and its latch needle 104 are located with an accuracy of about 40 micrometers.
Variations of the above-described preferred embodiments will occur to persons of the art. The above detailed descriptions are provided by way of example and are not meant to limit the scope of the invention, which is limited only by the following claims.
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An actuator system for activating a latch needle, which latch needle has a shaft, comprising: a flat planar extension of said shaft having first and second parallel planar surfaces; at least one piezoelectric micromotor having a first surface region for transmitting motion to a moveable element, which first surface region is resiliently pressed to said first surface and at least one additional piezoelectric motor having a second surface region for transmitting motion to a moveable element which second surface region is resiliently pressed to said second surface; and wherein vibratory motions of said first and second surface regions apply forces to said flat extension that cause motion in said latch needle.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to valves in general and, more particularly, to valves which reaches one fluid input and provides two fluid outputs.
SUMMARY OF THE INVENTION
Valve means includes a first pipe which receives a signal fluid stream. The stream is separated into two substreams in accordance with a control signal. A second and third pipe are connected to the separating apparatus provides the substreams external to the valve.
The objects and the advantages of the invention will appear more fully hereinafter from a consideration of the detailed description which follows, taken together with the accompanying drawings, wherein one embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for illustration purposes only and not to be construed as defining the limits of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of valve means constructed in accordance with the invention.
FIG. 2 is an end view of the valve means shown in FIG. 1.
FIG. 3 is a top view of the valve means shown in FIG. 1.
FIG. 4 is an example of a pulse signal utilized in the practice of the present invention.
DESCRIPTION OF THE INVENTION
FIG. 1 shows a side view of a valve means, including a mounting flange 8 affixed to a pipe 12. The cross-sectional area of pipe 12 is rectangular in shape as shown in FIG. 2. Pipe 12 is connected to two separate rectangular pipes, 16 and 18 by a "Y" member 20. In "Y" member 20, there is a moveable member 26 whose position is controlled by a shaft 30. As shaft 30 is rotated, as explained hereinafter, moveable member 26 move accordingly. Pipes 16, 18 also have mounting flanges 8 attached to them.
With reference to FIG. 3, which is a top view of the valve mean, we can see a stepper motor 35 which is connected to shaft 30 and positions shaft 30, in accordance with a signal E1.
In operation, there is a single stream having stratified layers. Generally this/type of stream is disclosed in U.S. application Ser. No. 07/814,534, filed Dec. 30, 1991. However, the present invention may be used in any situation where it is desirable to split a single stream into two separate streams. The objective of the valve means is to use moveable member 26 to separate the stratified layers into two separate streams which are provided to pipes 16 and 18.
In practice, a system such as described in the aforementioned application utilizes a water-cut monitor to monitor the water-cut of two separate streams. That system then develops pulse signals in accordance with the monitoring. Thus, with reference to FIG. 4, which is only shown for an example, signal E1 may at some period of time provide three positive pulses to stepper motor 35. Stepper motor 35 is arranged with shaft 30 so that it will rotate shaft 30 clockwise, in response to a positive pulse, a predetermined angular distance, and rotate shaft 30 counter clockwise the same predetermined angular distance in response to a negative pulse. Thus, the three positive pulses in FIG. 4, represent a command to shaft 30 to rotate moveable member 26 a desired angular distance (3 X times the predetermined angular distance) which would cause more of the single stream to flow through pipe 18, and less of the single stream to flow through pipe 16. At a later point in time, the water-cut monitor of the aforementioned application determines that gate member 26 has to be moved again and provides a negative pulse. The negative pulse causes stepper motor 35 to rotate member 26 counter clockwise the predetermined angular distance.
It should be noted that because of the limitation of pipe 12, it would be desirable to have stops provided with stepper motor 35 so that moveable member 26 does not try to rotate through pipe 12, but stop at a small incremental distance just short of contact with pipe 12.
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Valve means includes a first pipe which receives a signal fluid stream. The stream is separated into two substreams in accordance with a control signal. A second and third pipe are connected to the separating apparatus provides the substreams external to the valve.
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BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The invention relates to a process for the removal of m-dichlorobenzene from dichlorobenezene mixtures with an m-dichlorobenzene content of up to 35% by weight, relative to the total amount of dichlorobenezene in the mixture, by chlorination in the liquid phase at elevated temperature in the presence of Friedel-Crafts catalysts.
BACKGROUND INFORMATION
From U.S. Pat. No. 4,089,909, a process is known for the separation of dichlorobenzene isomers in which, in a dichlorobenzene mixture, m-dichlorobenzene is preferentially chlorinated to 1,2,4-trichlorobenzene and higher poly-chlorobenzenes with elemental chlorine in the liquid phase in the presence of Friedel-Crafts catalysts. The residual o-/p-dichlorobenzene can then be separated from higher chlorinated chlorobenzenes by conventional fractional distillation and crystallization.
In this separation process, it is disadvantageous that not only the m-dichlorobenzene in the mixture is chlorinated, but also, to a significant degree, the valuable o- and p-dichlorobenzene, as the tables in the U.S. Pat. No. 4,089,909 mentioned.
Thus, significant losses of the desired o- and p-dichlorobenzene are unavoidable during the separation and purification of the dichlorobenzene isomers according to the process described in U.S. Pat. No. 4,089,909. The economics of this process are therefore poor.
SUMMARY OF THE INVENTION
A process has now been found for the removal of m-dichlorobenzene from dichlorobenzene mixtures with an m-dichlorobenzene content of up to 35% by weight, relative to the total amount of dichlorobenzene in the mixture, by chlorination in the liquid phase at elevated temperature in the presence of Friedel-Crafts catalysts which is characterized in that the chlorination is carried out with addition of sulphur, sulphur compounds, iodine and/or iodine compounds and the chlorination mixture is then worked-up in the usual way.
DETAILED DESCRIPTION OF THE INVENTION
In the process according to the invention, dichlorozenzene mixtures as obtained in the nuclear chlorination of benzene or chlorobenzene, for example, in the liquid phase in the presence of Friedel-Crafts catalysts, can be used (cf. Ullmanns Encyclopadie der technischen Chemie, volume 5, page 463 and Houben-Weyl, Methoden der organischen praparativen Chemie, volume 5, page 653). Such dichlorobenzene mixtures contain, depending on the preparative method, about 0.5 to 3% by weight of m-dichlorobenzene and about 60 to 70% by weigth of o- and p-dichlorobenzene, the ortho/para ratio fluctuating in the range of about 3.5:1 to 1.5:1 (p-:o-dichlorobenzene). The remainder consists of unreacted benzene and monochlorobenzene as well as more highly chlorinated chlorobenzenes.
Benzene and chlorobenzene are distilled off in the usual way from the chlorination mixture obtained during the nuclear chlorination and, if necessary, the remaining dichlorobenzene mixture is subjected to a further separation by distillation. Depending on the number of separation stages, an m-dichlorobenzene-enriched dichlorobenzene mixture is obtained which contains up to 35% by weight, preferably 0.3 to 5% by weight, particularly preferably 1 to 3% by weight of m-dichlorobenzene, about 0.2 to 40% by weight, preferably 25 to 38% by weight, of o-dichlorobenzene and about 50 to 99% by weight, preferably 90 to 98% by weight, of p-dichlorobenzene. The remainder of the mixture consists of trichlorobenzenes and higher chlorinated chlorobenzenes.
The m-dichlorobenzene-enriched dichlorobenzene mixture is used in the process according to the invention as described above.
The chlorination of the dichlorobenzene mixture is usually carried out at temperatures of about 30° to 120° C., preferably 35° to 70° C.
As Friedel-Crafts catalysts, the following can, for example, be used: iron(III) chloride, aluminium chloride, zinc chloride and/or tin chloride, preferably iron(III) chloride. The amount of Friedel-Crafts catalyst to be used is not critical and usually amounts to less than 5% by weight, relative to the amount of dichlorobenzene, preferably 0.1 to 4% by weight.
In the process according to the invention, sulphur, sulphur compounds, iodine and/or iodine compounds are added to the Friedel-Crafts catalyst. As sulphur compounds, the following may be mentioned: sulphur chlorides, such as S 2 Cl 2 , iron(II) sulphide, mercaptans and thioethers; as iodine compounds, the following may be mentioned: alkyl iodides and aromatic iodine compounds. Preferably, sulphur, S 2 Cl 2 and/or iodine are added.
The amounts of sulphur, iodine, sulphur compounds and/or iodine compounds which are added to the Friedel-Crafts catalyst are usually about 0.01 to 5% by weight, preferably 0.01 to 1% by weight, relative to the total amount of dichlorobenzene in the mixture.
The ratio of the amount of Friedel-Crafts catalyst to the amount of iodine or sulphur is about 1:1 to 5:1, preferably 1.2:1 to 3:1.
The chlorination of the dichlorobenzene mixture is conveniently continued until the m-dichlorobenzene content in the mixture lies below about 0.05% by weight, preferably about 0.02% by weight. It is however also possible to continue the chlorination, if this becomes necessary, until the m-dichlorobenzene content in the mixture lies under 0.005% by weight. m-Dichlorobenzene contents of significantly more than 0.05% by weight in the dichlorobenzene mixture are disadvantageous as the separation of the dichlorobenzene isomers is complicated by this.
In general, a slight excess of chlorine, relative to the aromatics to be chlorinated, is used in the chlorination according to the invention. About 1.0 to 1.5 moles of chlorine, preferably 1.0 to 1.05 moles of chlorine, are used per mole of the aromatics to be chlorinated.
After the chlorination is completed, the dichlorobenzene mixture obtained can be fractionally distilled to separate o- and p-dichlorobenzene.
In the process according to the invention, it is surprising that, as a result of the addition of sulphur, iodine, sulphur compound and/or iodine compounds, practically only the m-dichlorobenzene is chlorinated to higher chlorobenzenes during the chlorination of m-dichlorobenzene-enriched dichlorobenzene mixtures and that the o- and p-dichlorobenzene is hardly chlorinated any further under thse chlorination conditions. Because of this, hardly any losses of the desired o- and p-dichlorobenzene occur. In addition, the amount of chlorine to be used in the chlorination of the mixture is reduced by the addition of sulphur, iodine, sulphur compounds and/or iodine compounds.
The following examples are intended to illustrate the process according to the invention, but without limiting it to these examples.
EXAMPLE 1
Mixture used:
95.0% of para-dichlorobenzene (p-DClB)
4.5% of meta-dichlorobenzene (m-DClB)
0.2% of ortho-dichlorobenzene (o-DClB)
0.3% of trichlorobenzene, benzene and monochlorobenzene
__________________________________________________________________________ TriClB + Cl.sub.2 more highlyTemp. Catalyst consumed p-DClB m-DClB o-DClB chlorinated benzenes°C. % by weight % % % % %__________________________________________________________________________55 0.1 FeCl.sub.3 0 95.0 4.5 0.20 0.30 (comparison) 68 93.3 0.16 0.11 6.43 76 82.3 0.11 0.10 17.49 84 80.2 0.07 0.09 19.64 92 79.1 0.05 0.09 20.76 100 77.5 0.03 0.09 22.3855 0.1 FeCl.sub.3 + 0 95.0 4.5 0.20 0.30 0.1 iodine 100 92.25 0.02 0.09 7.6455 0.1 FeCl.sub.3 + 0 95.0 4.5 0.20 0.30 0.05 iodine 100 91.7 0.03 0.14 8.1355 0.1 FeCl.sub.3 + 0 95.0 4.5 0.20 0.30 0.02 sulphur 100 94.2 0.03 0.13 5.64__________________________________________________________________________
The example shows that p- and o-dichlorobenzene are consumed markedly during the chlorination with FeCl 3 without addition of iodine or sulphur.
EXAMPLE 2
Mixture used:
73.75% of p-DClB
25.40% of o-DClB
0.35% of m-DClB
0.50% of trichlorobenzene (TriClB)
__________________________________________________________________________ TriClB Cl.sub.2 more highlyTemp. Catalyst consumed p-DClB m-DClB o-DClB chlorinated benzenes°C. % by weight % % % % %__________________________________________________________________________50 0.1 FeCl.sub.3 0 73.75 0.35 25.40 0.50 (comparison) 25 71.00 0.29 24.40 4.31 62 69.40 0.14 21.60 8.86 100 66.40 0.04 17.50 16.0675 0.1 FeCl.sub.3 + 0 73.75 0.35 25.40 0.50 (comparison) 20 70.90 0.33 23.60 5.17 40 69.60 0.24 21.70 8.46 100 64.40 0.06 15.30 20.2450 0.1 FeCl.sub.3 + 0 73.75 0.35 25.40 0.5 0.02 sulphur 50 73.40 0.100 24.40 2.1 75 73.30 0.050 23.70 2.95 100 73.00 0.025 23.00 3.950 0.1 FeCl.sub.3 + 0 73.75 0.35 25.40 0.50 0.1 iodine 33 72.65 0.18 23.30 3.9 66 71.50 0.06 20.70 7.7 100 70.90 0.023 19.10 10.0__________________________________________________________________________
EXAMPLE 3
Mixture used:
55.0% of p-DClB
35.5% of o-DClB
2.8% of m-DClB
6.7% of trichlorobenzene
__________________________________________________________________________ TriClB Cl.sub.2 more highlyTemp. Catalyst consumed p-DClB m-DClB o-DClB chlorinated benzenes°C. % by weight % % % % %__________________________________________________________________________50 0.1 FeCl.sub.3 0 55.0 2.8 35.5 6.7 100 43.8 0.03 13.3 42.8735 0.2 FeCl.sub.3 + 0 55.0 2.8 35.5 6.7 0.08 sulphur 50 54.5 0.2 32.5 12.80 100 54.4 0.02 30.5 15.0850 0.02 FeCl.sub.3 + 0 55.0 2.8 35.5 6.7 0.008 sulphur 100 52.4 0.02 26.7 20.8850 0.1 FeCl.sub.3 + 0 55.0 2.8 35.5 6.7 0.1 iodine 50 53.2 0.5 29.0 17.30 100 52.4 0.02 21.2 26.38__________________________________________________________________________
EXAMPLE 4
The chlorination was carried out in a manner corresponding to Table II of U.S. Pat. No. 4,089,909 at 66° C. The mixture used corresponded approximately to the mixture listed in Table II of the U.S. Pat. No. 4,089,909. It comprised: 0.14% by weight of benzene, 2.062% by weight of monochlorobenzene, 35,701% by weight of m-dichlorobenzene, 35.295% by weight of p-dichlorobenzene and 26.787% by weight of o-dichlorobenzene. 1000 g of the mixture were chlorinated.
__________________________________________________________________________Composition of the mixture used (% by weight)__________________________________________________________________________Benzene MClB m-DClB p-DClB o-DClB 1,2,4-TriClB 1,2,3-TriClB More highly0.14 2.062 35.701 35.295 26.787 -- -- chlorinated benzenes__________________________________________________________________________ Higher chlorinated Introduced m-DClB p-DClB o-DClB 1,2,4-TriClB 1,2,3-TriClB benzenes chlorineExample Catalyst (%) (%) (%) (%) (%) (%) (g)__________________________________________________________________________1 FeCl.sub.3 0.024 21.99 3.291 52.427 8.211 13.994 450U.S. Pat. No. (0 1%)4 089 9092 FeCl.sub.3 0.024 34.997 20.09 39.618 3.578 1.655 245 (0.1%) + S (0.04%)3 FeCl.sub.3 0.024 31.569 10.987 46.417 6.181 4.804 350 (0.1%) + I.sub.2 (0.1%)__________________________________________________________________________
The example shows that p- and o-dichlorobenzene react markedly during the chlorination with FeCl 3 without addition of sulphur or iodine. In addition, a significantly greater excess of chlorine is necessary.
It will be appreciated that the instant specification and claims are set forth by way of illustration and not limitation, and that various modifications and changes may be made without departing from the spirit and scope of the present invention.
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The invention relates to a process for the removal of m-dichlorobenzene from dichlorobenzene mixtures by chlorination in the liquid phase at elevated temperature in the presence of Friedel-Crafts catalysts, the chlorination being carried out with addition of sulphur, sulphur compounds, iodine and/or iodine compounds and the chlorination mixture then being worked up in the usual way.
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FIELD
[0001] The present disclosure concerns a fluid purification system, particularly a liquid purification system, and even more particularly a system for preparing fluids for use in dialysis.
BACKGROUND
[0002] There are, at present, hundreds of thousands of patients in the United States with end-stage renal disease. Most of those require dialysis to survive. United States Renal Data System projects the number of patients in the U.S. on dialysis will climb past 600,000 by 2012. Many patients receive dialysis treatment at a dialysis center, which can place a demanding, restrictive and tiring schedule on a patient. Patients who receive in-center dialysis typically must travel to the center at least three times a week and sit in a chair for 3 to 4 hours each time while toxins and excess fluids are filtered from their blood. After the treatment, the patient must wait for the needle site to stop bleeding and blood pressure to return to normal, which requires even more time taken away from other, more fulfilling activities in their daily lives. Moreover, in-center patients must follow an uncompromising schedule as a typical center treats three to five shifts of patients in the course of a day. As a result, many people who dialyze three times a week complain of feeling exhausted for at least a few hours after a session.
[0003] Given the demanding nature of in-center dialysis, many patients have turned to home dialysis as an option. Home dialysis provides the patient with scheduling flexibility as it permits the patient to choose treatment times to fit other activities, such as going to work or caring for a family member. One requirement of a home dialysis system is a reliable water purification system as dialysis requires purified water for mixing with a dialysate concentrate. Even trace amounts of mineral concentrates and biological contamination in the water can have severe adverse effects on a dialysis patient. In addition, water purification systems in typical dialysis systems must be capable of purifying the very large quantities of water required to run a full dialysis session.
[0004] Unfortunately, existing water purifications have drawbacks that limit practical usage of such systems in a home dialysis system. Existing water purification systems are large and bulky, often being as large as a residential washing machine and weighing over three hundred pounds. Such systems also very often consume large amounts of energy in order to purify relatively small amounts of water. In sum, existing water purification systems are bulky and expensive, making them practically unsuitable for use in the average patient's home.
SUMMARY
[0005] In view of the foregoing, there is a need for improved water purification systems that may be used in conjunction with home dialysis. Such a system would ideally be small, lightweight, portable, and have the capability of reliably, reproducibly, highly efficiently and relatively inexpensively providing a source of purified water of sufficient volumes to enable home dialysis. In addition, such a water purification system could ideally be incorporated into a dialysis system that requires much less purified water at any one time than the volumes typically needed for dialysis today, thereby further reducing the expense of running the system at home. In addition, the system would be capable of producing real-time, on-demand ultrapure water for dialysis, the gold standard of present-day dialysis. Disclosed herein is an in-line, non-batch water purification system that utilizes a microfluidics heat exchanger for heating, purifying and cooling water. The system is compact and light-weight relative to existing systems and consumes relatively low amounts of energy. The water purification system is suitable for use in a home dialysis system although it can be used in other environments where water purification is desired. The system can also be used to purify fluids other than water. The system can be connected to a residential source of water (such as a running water tap to provide a continuous or semi-continuous household stream of water) and can produce real-time pasteurized water for use in home dialysis, without the need to heat and cool large, batched quantities of water.
[0006] In one aspect, disclosed is a method of preparing dialysate for use in a dialysis system. The method includes coupling a water source, such as a household water stream, to a dialysis system; filtering the water stream; heating the water stream to at least about 138 degrees Celsius in a non-batch process to produce a heated water stream; maintaining the heated water stream at or above at least about 138 degrees Celsius for at least about two seconds; cooling the heated water stream to produce a cooled water stream; ultrafiltering the cooled water stream; and mixing dialysate components into the cooled water stream in a non-batch process.
[0007] In another aspect, disclosed is a method of preparing dialysate for use in a dialysis system that includes processing a household water stream in a non-batch process to produce an ultra-high-temperature-pasteurized water stream; and mixing dialysate components into said ultra-high-temperature-pasteurized water stream. The mixing of dialysate components is performed in a non-batch process.
[0008] In another aspect, disclosed is a method of ultrapasteurizing a fluid including providing a microfluidic heat exchanger having a fluid flowpath for only a single fluid. The flowpath includes multiple fluid pathways for said single fluid to travel. The fluid flowpath includes an inlet portion, a heating portion and an outlet portion that thermally communicates with the inlet portion when the heat exchanger is in operation. The method also includes introducing the fluid into the inlet portion of the heat exchanger at a selected flow rate; transferring heat to the fluid in the inlet portion from the fluid in the outlet portion, thereby heating the fluid in the inlet portion and cooling the fluid in the outlet portion; further heating the fluid in the heating portion to a temperature greater than about 130 degrees Celsius; maintaining the fluid at a temperature greater than about 130 degrees Celsius for a period of at least about two seconds at the selected flow rate; and cooling the fluid in the outlet portion at least in part by the transfer of heat to the fluid in the inlet portion, and permitting the fluid to exit the microfluidic heat exchanger without interaction with a second fluid within the heat exchanger.
[0009] In another aspect, disclosed is a fluid purification system including a fluid pathway having an inlet where fluid flows into the system and an outlet where fluid flows out of the system. The fluid pathway further includes a first region where fluid flows in a first direction at a first temperature; a heater region downstream of the first region; and a second region downstream of the heater region where fluid flows in a second direction at a temperature greater than the first temperature. The heater region includes at least one heater that transfers heat into fluid flowing through the heater region to increase the temperature of fluid flowing in the heater region to a second temperature greater than the first temperature. Fluid flowing in the second region thermally communicates with fluid flowing in the first region such that heat transfers from fluid flowing in the second region to fluid flowing in the first region resulting in a temperature reduction in the fluid as it flows through the second region. Fluid flows out of the pathway through the outlet at a temperature less than the second temperature.
[0010] Other features and advantages should be apparent from the following description of various embodiments, which illustrate, by way of example, the principles of the disclosed devices and methods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a high level, schematic view of a fluid purification system adapted to purify a fluid such as a liquid.
[0012] FIG. 2 shows a schematic, plan view of an exemplary embodiment of a microfluidic heat exchange system adapted to heat and cool a single fluid without the use of a second fluid stream to add heat to or remove heat from the fluid.
[0013] FIG. 3A shows an exemplary embodiment of an inlet lamina that forms at least one inlet pathway where fluid flows in an inward direction through the heat exchange system.
[0014] FIG. 3B shows an exemplary embodiment of an outlet lamina that forms at least one outlet pathway where fluid flows in an outward direction through the heat exchange system.
[0015] FIG. 3C shows an exemplary embodiment having superimposed inlet and outlet laminae.
[0016] FIG. 4 shows an enlarged view of an inlet region of the inlet lamina.
[0017] FIG. 5 shows an enlarged view of a heater region of the inlet lamina.
[0018] FIG. 6 shows an enlarged view of a residence chamber of both the inlet lamina and outlet lamina.
[0019] FIG. 7A shows a plan view of another embodiment of an inlet lamina.
[0020] FIG. 7B shows a plan view another embodiment of an outlet lamina.
[0021] FIG. 8 shows a perspective view of an exemplary stack 805 of laminae.
[0022] FIG. 9 shows a perspective view of an example of an assembled microfluidic heat exchange system.
[0023] FIG. 10 shows a schematic view of an exemplary heater control system coupled to the microfluidic heat exchange system.
[0024] FIG. 11 shows a schematic, plan view of another exemplary embodiment of flow pathways for the microfluidic heat exchange system.
[0025] FIG. 12 shows a schematic, plan view of another exemplary embodiment of flow pathways for the microfluidic heat exchange system.
[0026] FIG. 13A shows another embodiment of an inlet lamina that forms an inlet pathway where fluid flows in an inward direction through the heat exchange system.
[0027] FIG. 13B shows another embodiment of an outlet lamina that forms an outlet pathway where fluid flows in an outward direction through the heat exchange system.
DETAILED DESCRIPTION
[0028] In order to promote an understanding of the principals of the disclosure, reference is made to the drawings and the embodiments illustrated therein. Nevertheless, it will be understood that the drawings are illustrative and no limitation of the scope of the disclosure is thereby intended. Any such alterations and further modifications in the illustrated embodiments, and any such further applications of the principles of the disclosure as illustrated herein are contemplated as would normally occur to one of ordinary skill in the art.
[0029] FIG. 1 shows a high level, schematic view of a fluid purification system adapted to purify a fluid such as a liquid. In an embodiment, the system is adapted to be used for purifying water, such as water obtained from a household tap, in a dialysis system and is sometimes described herein in that context. However, it should be appreciated that the fluid purification system can be used for purifying water in other types of systems and is not limited for use in a dialysis system. Also, the purification system can be used to purify liquids other than water.
[0030] With reference to FIG. 1 , the fluid purification system includes a plurality of subsystems and/or components each of which is schematically represented in FIG. 1 . A fluid such as water enters the fluid purification system at an entry location 105 and communicates with each of the subsystems and components along a flow pathway toward an exit location 107 . Upon exiting the fluid purification system, the fluid is in a purified state. This may include the fluid being in a pasteurized state although the fluid system does not necessarily pasteurize the fluid in all circumstances. The embodiment shown in FIG. 1 is exemplary and not all of the components shown in FIG. 1 are necessarily included in the system. The individual components included in the system may vary depending on the type and level of purification or pasteurization required. The quantity and sequential order of the subsystems along the flow pathway shown in FIG. 1 is for purposes of example and it should be appreciated that variations are possible.
[0031] The fluid purification system includes at least one microfluidic heat exchange (HEX) system 110 adapted to achieve pasteurization of the liquid passing through the fluid purification system, as described more fully below. The fluid purification system may also include one or more additional purification subsystems, such as a sediment filter system 115 , a carbon filter system 120 , a reverse osmosis system 125 , an ultrafilter system 130 , an auxiliary heater system 135 , a degassifier system 140 , or any combination thereof. The fluid purification system may also include hardware and/or software to achieve and control fluid flow through the fluid purification system. The hardware may include one or more pumps 150 or other devices for driving fluid through the system, as well as sensors for sensing characteristics of the fluid and fluid flow. The operation of the fluid purification system is described in detail below.
Microfluidic Heat Exchange System
[0032] FIG. 2 shows a schematic, plan view of an exemplary embodiment of the microfluidic heat exchange system 110 , which is configured to achieve pasteurization of a liquid (such as water) flowing through the system without the need for a second fluid stream to add heat to or remove heat from the liquid. FIG. 2 is schematic and it should be appreciated that variations in the actual configuration of the flow pathway, such as size and shape of the flow pathway, are possible.
[0033] As described more fully below, the microfluidic heat exchange system defines a fluid flow pathway that includes (1) at least one fluid inlet; (2) a heater region where incoming fluid is heated to a pasteurization temperature via at least one heater; (3) a residence chamber where fluid remains at or above the pasteurization temperature for a predetermined time period; (4) a heat exchange section where incoming fluid receives heat from hotter (relative to the incoming fluid) outgoing fluid, and the outgoing fluid cools as it transfers heat to the incoming fluid; and (5) a fluid outlet where outgoing fluid exits in a cooled, pasteurized state. Depending on the desired temperature of the outgoing fluid, one or more additional heat exchanges may be required downstream to adjust the actual temperature of the outgoing fluid to the desired temperature for use, for example, in dialysis. This is especially true in warmer climates, where incoming water may be tens of degrees higher than water supplied in colder climates, which will result in higher outlet temperatures than may be desired unless further cooling is applied.
[0034] In an embodiment, the flow pathway is at least partially formed of one or more microchannels, although utilizing microfluidic flow fields as disclosed in U.S. Provisional Patent Application No. 61/220,177, filed on Jun. 24, 2009, and its corresponding utility application entitled “Microfluidic Devices,” filed Jun. 7, 2010, and naming Richard B. Peterson, James R. Curtis, Hailei Wang, Robbie Ingram-Gobel, Luke W. Fisher and Anna E. Garrison, incorporated herein by reference, for portions of the fluid flow pathway such as the heat exchange section is also within the scope of the invention. The relatively reduced dimensions of a microchannel enhance heat transfer rates of the heat exchange system by providing a reduced diffusional path length and amount of material between counterflow pathways in the system. In an embodiment, a microchannel has at least one dimension less than about 1000 μm. The dimensions of a microchannel can vary and are generally engineered to achieve desired heat transfer characteristics. A microchannel in the range of about 0.1 to about 1 mm in hydraulic diameter generally achieves laminar fluid flow through the microchannel, particularly in a heat exchange region of the microchannel. The small size of a microchannel also permits the heat exchange system 110 to be compact and lightweight. In an embodiment, the microchannels are formed in one or more lamina that are arranged in a stacked configuration, as formed below.
[0035] The flow pathway of the microfluidic heat exchange system 110 may be arranged in a counterflow pathway configuration. That is, the flow pathway is arranged such that cooler, incoming fluid flows in thermal communication with hotter, outgoing fluid. The hotter, outgoing fluid transfers thermal energy to the colder, incoming fluid to assist the heaters in heating the incoming fluid to the pasteurization temperature. This internal preheating of the incoming fluid to a temperature higher than its temperature at the inlet 205 reduces the amount of energy used by the heaters 220 to reach the desired peak temperature. In addition, the transfer of thermal energy from the outgoing fluid to the incoming fluid causes the previously heated, outgoing fluid to cool prior to exiting through the fluid outlet. Thus, the fluid is “cold” as it enters the microfluidic heat exchange system 110 , is then heated (first via heat exchange and then via the heaters) as it passes through the internal fluid pathway, and is “cold” once again as it exits the microfluidic heat exchange system 110 . In other words, the fluid enters the microfluidic heat exchange system 110 at a first temperature and is heated (via heat exchange and via the heaters) to a second temperature that is greater than the first temperature. As the fluid follows an exit pathway, the fluid (at the second temperature) transfers heat to incoming fluid such that the fluid drops to a third temperature that is lower than the second temperature and that is higher than the first temperature.
[0036] Exemplary embodiments of a fluid pathway and corresponding components of the microfluidic heat exchange system 110 are now described in more detail with reference to FIG. 2 , which depicts a bayonet-style heat exchanger, with the inlet and outlet on one side of the device, a central heat exchange portion, and a heating section toward the opposite end. The fluid enters the microfluidic heat exchange system 110 through an inlet 205 . In the illustrated embodiment, the flow pathway branches into one or more inflow microchannels 210 that are positioned in a counterflow arrangement with an outflow microchannel 215 . As mentioned, microfluidic heat exchange system 110 may be formed by a stack of layered lamina. The inflow microchannels 210 may be positioned in separate layers with respect to the outflow microchannels 215 such that inflow microchannels 210 are positioned above or below the outflow microchannels 215 in an interleaved fashion. In another embodiment, the inflow microchannels 210 and outflow microchannels 215 are positioned on a single layer.
[0037] The outflow microchannel 215 communicates with an outlet 207 . In the illustrated embodiment, the inlet 205 and outlet 207 are positioned on the same end of the microfluidic heat exchange system 110 , although the inlet 205 and outlet 207 may also be positioned at different positions relative to one another.
[0038] The counterflow arrangement places the inflow microchannels 210 in thermal communication with the outflow microchannel 215 . In this regard, fluid in the inflow microchannels 210 may flow along a directional vector that is oriented about 180 degrees to a directional vector of fluid flow in the outflow microchannels 215 . The inflow and outflow microchannels may also be in a cross flow configuration wherein fluid in the inflow microchannels 210 may flow along a directional vector that is oriented between about 180 degrees to about 90 degrees relative to a directional vector of fluid flow in the outflow microchannels 215 . The orientation of the inflow microchannels relative to the outflow microchannels may vary in any matter that is configured to achieve the desired degree of thermal communication between the inflow and outflow microchannels.
[0039] One or more heaters 220 are positioned in thermal communication with at least the inflow microchannels 210 such that the heaters 220 can provide heat to fluid flowing in the system. The heaters 220 may be positioned inside the inflow microchannels 210 such that fluid must flow around multiple sides of the heaters 220 . Or, the heaters 220 may be positioned to the side of the inflow microchannels 210 such that fluid flows along one side of the heaters 220 . In any event, the heaters 220 transfer heat to the fluid sufficient to cause the temperature of the fluid to achieve a desired temperature, which may include a pasteurization temperature in the case of water to be purified. In an embodiment, the fluid is water and the heaters 220 assist in heating the fluid to a temperature of at least 100 degrees Celsius at standard atmospheric pressure. In an embodiment, the fluid is water and the heaters 220 assist in heating the fluid to a temperature of at least 120 degrees Celsius. In an embodiment, the fluid is water and the heaters 220 assist in heating the fluid to a temperature of at least 130 degrees Celsius. In an embodiment, the fluid is water and the heaters 220 assist in heating the fluid to a temperature of at least 138 degrees Celsius. In another embodiment, the fluid is water and is heated to a temperature in the range of about 138 degrees Celsius to about 150 degrees Celsius. In another embodiment, the fluid is heated to the highest temperature possible without achieving vaporization of the fluid.
[0040] Thus, the microfluidic heat exchange system 110 may maintain the fluid as a single phase liquid. Because water typically changes phases from a liquid into a gaseous state around 100 degrees Celsius, heating water to the temperatures set forth above requires pressurization of the heat exchange system so that the single-phase liquid is maintained throughout. Pressures above the saturation pressure corresponding to the highest temperature in the heat exchange system are sufficient to maintain the fluid in a liquid state. As a margin of safety, the pressure is typically kept at 10 psi or higher above the saturation pressure. In an embodiment, the pressure of water in the microfluidic heat exchange system is maintained greater than 485 kPa to prevent boiling of the water, and may be maintained significantly in excess of that level, such as 620 kPa or even as high as 900 kPa, in order to ensure no boiling occurs. These pressures are maintained in the heat exchange system using a pump and a throttling valve. A pump upstream of the heat exchange system and a throttling valve downstream of the heat exchange system are used where the pump and throttling valve operate in a closed loop control setup (such as with sensors) to maintain the desired pressure and flow rate throughout the heat exchange system.
[0041] Once the fluid has been heated to the pasteurization temperature, the fluid passes into a residence chamber 225 where the fluid remains heated at or above the pasteurization temperature for a predetermined amount of time, referred to as the “residence time”, or sometimes referred to as the “dwell time”. In an embodiment, the dwell time can be less than or equal to one second, between one and two seconds, or at least about two seconds depending on the flow path length and flow rate of the fluid. Higher temperatures are more effective at killing bacteria and shorter residence times mean a more compact device. Ultrahigh temperature pasteurization, that is designed to kill all Colony Forming Units (CFUs) of bacteria down to a concentration of less than 10 −6 CFU/ml (such as for purifying the water for use with infusible dialysate is defined to be achieved when water is heated to a temperature of 138 degrees Celsius to 150 degrees Celsius for a dwell time of at least about two seconds. Ultrapure dialysate has a bacterial load no greater than 0.1 CFU.ml. Table 1 (shown in the attached figures) indicates the required temperature and residence time to achieve various levels of pasteurization. The heat exchange system described herein is configured to achieve the various levels of pasteurization shown in Table 1.
[0042] The fluid then flows from the residence chamber 225 to the outflow microchannel 215 , where it flows toward the fluid outlet 207 . As mentioned, the outflow microchannel 215 is positioned in a counterflow relationship with the inflow microchannel 210 and in thermal communication with the inflow microchannel 210 . In this manner, outgoing fluid (flowing through the outflow microchannel 215 ) thermally communicates with the incoming fluid (flowing through the inflow microchannel 210 ). As the heated fluid flows through the outflow microchannel 215 , thermal energy from the heated fluid transfers to the cooler fluid flowing through the adjacent inflow microchannel 210 . The exchange of thermal energy results in cooling of the fluid from its residence chamber temperature as it flows through the outflow microchannel 215 . Moreover, the incoming fluid is preheated via the heat exchange as it flows through the inflow microchannel 210 prior to reaching the heaters 220 . In an embodiment, the fluid in the outgoing microchannel 210 is cooled to a temperature that is no lower than the lowest possible temperature that precludes bacterial infestation of the fluid. When the heat exchange system pasteurizes the fluid, bacteria in the fluid down to the desired level of purification are dead as the fluid exits the heat exchange system. In such a case, the temperature of the fluid after exiting the heat exchange system may be maintained at room temperature before use in dialysis. In another embodiment, the fluid exiting the heat exchange system is cooled to a temperature at or below normal body temperature.
[0043] Although an embodiment is shown in FIG. 2 as having an outlet channel sandwiched between an inflow channel, other arrangements of the channels are possible to achieve the desired degrees of heating and cooling and energy requirements of the heaters. Common to all embodiments, however, is that all fluid pathways within the system are designed to be traveled by a single fluid, without the need for a second fluid to add heat to or remove heat from the single fluid. In other words, the single fluid relies on itself, at various positions in the fluid pathway, to heat and cool itself.
[0044] The dimensions of the microfluidic heat exchange system 110 may vary. In an embodiment, the microfluidic heat exchange system 110 is sufficiently small to be held in the hand of a user. In another embodiment, the microfluidic heat exchange system 110 is a single body that weighs less than 5 pounds when dry. In another embodiment, the microfluidic heat exchange portion 350 of the overall system 110 has a volume of about one cubic inch. The dimensions of the microfluidic heat exchange system 110 may be selected to achieve desired temperature and dwell time characteristics.
[0045] As mentioned, an embodiment of the microfluidic heat exchange system 110 is made up of multiple laminar units stacked atop one another to form layers of laminae. A desired microfluidic fluid flow path may be etched into the surface of each lamina such that, when the laminae are stacked atop one another, microfluidic channels or flow fields are formed between the lamina. Furthermore, both blind etching and through etching may be used for forming the channels in the laminae. In particular, through etching allows the fluid to change the plane of laminae and move to other layers of the stack of laminae. This occurs in one embodiment at the outlet of the inflow laminae where the fluid enters the heater section, as described below. Through etching allows all laminae around the heater section to participate in heating of the fluid instead of maintaining the fluid only in the plane of the inlet laminae. This embodiment provides more surface area and lower overall fluid velocity to facilitate the heating of the fluid to the required temperature and ultimately contributes to the efficiency of the device.
[0046] The microchannels or flow fields derived from blind and/or through etching of the laminae form the fluid flow pathways. FIG. 3A shows a plan view of an exemplary embodiment of an inlet lamina 305 that forms at least one inlet pathway where fluid flows in an inward direction (as represented by arrows 307 ) through the heat exchange system 110 . FIG. 3B shows a plan view an exemplary embodiment of an outlet lamina 310 that forms at least one outlet pathway where fluid flows in an outward direction (as represented by arrows 312 ) through the heat exchange system 110 . The inlet pathway and the outlet pathway may each comprise one or more microchannels. In an embodiment, the inlet and outlet pathway comprise a plurality of microchannels arranged in parallel relationship.
[0047] FIGS. 3A and 3B show the lamina 305 and 310 positioned adjacent each other, although in assembled device the lamina are stacked atop one another in an interleaved configuration. FIG. 3C shows the inlet lamina 305 and outlet lamina 310 superimposed over one another showing both the inlet pathway and outlet pathway. The inlet lamina 305 and outlet lamina 310 are stacked atop one another with a fluid conduit therebetween so fluid may flow through the conduit from the inlet pathway to the outlet pathway, as described more fully below. When stacked, a transfer layer may be interposed between the inlet lamina 305 and the outlet lamina 310 . The transfer layer is configured to permit heat to transfer from fluid in the outlet pathway to fluid in the inlet pathway. The transfer layer may be any material capable of conducting heat from one fluid to another fluid at a sufficient rate for the desired application. Relevant factors include, without limitation, the thermal conductivity of the heat transfer layer 110 , the thickness of the heat transfer layer, and the desired rate of heat transfer. Suitable materials include, without limitation, metal, metal alloy, ceramic, polymer, or composites thereof. Suitable metals include, without limitation, stainless steel, iron, copper, aluminum, nickel, titanium, gold, silver, or tin, and alloys of these metals. Copper may be a particularly desirable material. In another embodiment, there is no transfer layer between the inlet and outlet laminae and the laminae themselves serve as the thermal transfer layer between the flow pathways.
[0048] The inlet lamina 305 and outlet lamina 310 both include at least one inlet opening 320 and at least one outlet opening 325 . When the inlet lamina 305 and outlet lamina 310 are stacked atop one another and properly aligned, the inlet openings 320 align to collectively form a fluid pathway that extends through the stack and communicates with the inlet pathway of the inlet laminae 305 , as shown in FIG. 3C . Likewise, the outlet openings 325 also align to collectively form a fluid pathway that communicates with the outlet pathway of the outlet laminae 310 . Any quantity of inlet lamina and outlet lamina can be stacked to form multiple layers of inlet and outlet pathways for the heat exchange system 110 . The quantity of layers can be selected to provide predetermined characteristics to the microfluidic heat exchange system 110 , such as to vary the amount of heat exchange in the fluid, the flow rate of the fluid capable of being handled by the system, etc. In an embodiment, the heat exchange system 110 achieves incoming liquid flow rates of at least 100 ml/min.
[0049] In another embodiment, the heat exchange system 110 achieves incoming liquid flow rates of at least 1000 ml/min. Such a heat exchange system may be manufactured of a plurality of laminae in which the microfluidic pathways have been formed using a masking/chemical etching process. The laminae are then diffusion bonded in a stack, as described in more detail below. In an embodiment, the stack includes 40-50 laminae with a flow rate of 2-3 ml/min occurring over each lamina. Higher flow rates can be achieved by increasing the number of pairs of stacked laminae within the heat exchanger. In other embodiments, much higher flow rates can be handled through the system.
[0050] In operation, fluid flows into the inlet pathway of the inlet lamina 305 via the inlet opening 320 . This is described in more detail with reference to FIG. 4 , which shows an enlarged view of an inlet region of the inlet lamina 305 . The inlet opening 320 communicates with an inlet conduit 405 that guides the fluid to the inlet pathway. The inlet opening 320 may configured with a predetermined size relative to the size of the inlet conduit 405 , which may have a diameter of 2-mm. For example, in an embodiment, the inlet opening 320 has an associated hydraulic diameter that may be about ten to fifteen times larger than the hydraulic diameter of the inlet conduit 405 . Such a ratio of hydraulic diameters has been found to force fluid to distribute relatively evenly among the multiple inlet laminae. In another embodiment, for a 2-mm wide inlet flow path, a hydraulic diameter ratio of greater than 10:1, such as 15:1, may be used to ensure an even distribution of fluid flow over the stack.
[0051] With reference still to FIG. 4 , a downstream end of the inlet conduit 405 opens into the inlet pathway, which flares outward in size relative to the size of the inlet conduit 405 . In this regard, one or more flow separation guides, such as fins 410 , may be positioned at the entryway to the inlet pathway. The flow separation fins are sized and shaped to encourage an even distribution of fluid as the fluid flows into the inlet pathway from the inlet conduit 405 . It should be appreciated that the size, shape, and contour of the inlet conduit 405 and inlet pathway may vary and that the embodiment shown in FIG. 4 is merely exemplary. By way of example only, this region of the system could also comprise a flow field of pin-shaped members (of the sort disclosed in U.S. Provisional Patent Application No. 61/220,177, filed on Jun. 24, 2009, and its corresponding utility application entitled “Microfluidic Devices”, filed Jun. 7, 2010, and naming Richard B. Peterson, James R. Curtis, Hailei Wang, Robbie Ingram-Gobel, Luke W. Fisher and Anna E. Garrison, incorporated herein by reference) around which the fluid flows.
[0052] With reference again to FIG. 3A , the inlet pathway and outlet pathway each include a heat exchange region. The heat exchange regions are referred to collectively using the reference numeral 350 and individually using reference numeral 350 a (for the inlet pathway) and reference numeral 350 b (for the outlet pathway). The heat exchange regions 350 are the locations where the colder fluid (relative to the fluid in the outlet pathway) of the inlet pathway receives heat transferred from the hotter fluid (relative to the fluid in the inlet pathway) of the outlet pathway. As discussed above, the relatively colder fluid in the inflow pathway is positioned to flow in thermal communication with the relatively hotter fluid in the outflow pathway. In this layered embodiment, the inflow pathway is positioned immediately above (or below) the outflow pathway when the lamina are stacked. Heat transfers across the transfer layer from the fluid in the outflow pathway to the fluid in the inflow pathway as a result of the temperature differential between the fluid in the inflow pathway and the fluid in the outflow pathway and the thermal conductivity of the material separating the two pathways. Again rather than comprising a series of microchannels, the heat exchange regions may also comprise a microfluidic flow field as described above.
[0053] With reference still to FIG. 3A , the fluid in the inflow pathway flows into a heater region 355 from the heat exchange region 350 . A plurality of pins 357 may be positioned in the inlet flow pathway between the heat exchange region 350 and the heater region 355 . The pins 357 disrupt the fluid flow and promote mixing, which may improve both fluid flow and heat distribution. FIG. 5 shows an enlarged view of the heater region 355 . In an embodiment, the inflow pathway bifurcates into at least two flow pathways in the heater region 355 to accommodate a desired flow rate. Alternatively only one flow path through the heater region may be utilized, or three or more flow paths may be selected. The heater region 355 includes one or more heaters 220 that thermally communicate with fluid flowing through this region, but are hermetically isolated from the flow path. The heaters 220 add heat to the incoming fluid sufficient to raise temperature of the fluid to the desired temperature, which may include a pasteurization temperature. The incoming fluid was previously preheated as it flowed through the heat exchange region 350 . This advantageously reduced the energy requirements for the heaters.
[0054] The laminae in the stack may include through-etches at entry locations 505 to the heater region 355 such that fluid entering the heater region can pass through all the laminae in the stack. Through etching allows all laminae around the heater section to participate in heating of the fluid instead of maintaining the fluid only in the plane of the inlet laminae. This provides more surface area between the fluid and the heaters and also provides lower overall fluid velocity to facilitate the heating of the fluid to the required temperature.
[0055] As mentioned, the inflow pathway may bifurcate into multiple flow pathways. Each pathway may include one or more heaters 220 arranged within the pathway so as to maximize or otherwise increase the amount of surface area contact between the heaters 220 and fluid flowing through the pathways. In this regard, the heaters 220 may be positioned towards the middle of the pathway such that the fluid must flow around either side of the heaters 220 along a semicircular or otherwise curvilinear pathway around the heaters 220 . The heaters 220 can vary in configuration. In an embodiment, the heaters 220 are conventional cartridge heaters with a ⅛-inch diameter which can be run in an embodiment at a combined rate of between about 70,000 and 110,000 W/m2, which results in energy usages of less than 100 W in one embodiment, and less than 200 W in another embodiment, for the entire stack running at about 100 mL/minute. In an embodiment, the system uses six heaters in a configuration of three heaters per flow pathway wherein each heater uses about 70 W for a 100 ml/min flow rate. In an embodiment the fluid is forced to flow around the heaters in paths 1.6 mm wide.
[0056] With reference again to FIG. 3A , the inflow pathway transitions from the heater section 355 to the residence chamber 360 . By the time the fluid flows into the residence chamber 360 , it has been heated to the desired temperature, such as the pasteurization temperature, as a result of the heat transfer in the heat exchange region 350 and/or by being heated in the heater section 355 . In the case of multiple laminae being stacked, the residence chamber 360 may be a single chamber that spans all of the layers of laminae in the stack such that the fluid from each inlet lamina flows into a single volume of fluid in the residence chamber 360 . The residence chamber 360 is configured such that fluid flow ‘shortcuts’ are eliminated, all of the fluid is forced to travel a flow pathway such that no portion of the fluid will reside in the residence chamber for the less than the desired duration at a specified flow rate, and the fluid is maintained at or above the pasteurization temperature for the duration of the time (i.e., the dwell time) that the fluid is within the residence chamber 360 . In effect, the residence time is a result of the dimensions of the flowpath through the residence area and the flow rate. It will thus be apparent to one of skill in the art how to design a residence pathway for a desired duration.
[0057] FIG. 6 shows an enlarged view of the region of the residence chamber 360 for the inlet lamina 305 and outlet lamina 310 . For clarity of illustration, FIG. 6 shows the inlet lamina 305 and outlet lamina 310 positioned side-by-side although in use the laminae are stacked atop one another such that the residence chambers align to form a residence chamber that spans upward along the stack. In an embodiment, the residence chamber 360 incorporates a serpentine flow path as shown in the enlarged view of the residence chamber of FIG. 6 . The serpentine flow path provides a longer flow path to increase the likelihood of the liquid spending a sufficient amount of time within the residence chamber 360 .
[0058] After the fluid has reached the end of the serpentine flow path, it passes (represented by arrow 610 in FIG. 6 ) to the outlet pathway of the outlet lamina 310 . With reference now to FIG. 3B , the outlet pathway passes between the heaters 220 , which act as insulators for the fluid to lessen the likelihood of the fluid losing heat at this stage of the flow pathway. The heated fluid of the outlet pathway then flows toward the heat exchange region 350 b . The outlet flow pathway expands prior to reaching the heat exchange region 350 b . A set of expansion fans 367 directs the fluid into the expanded heat exchange region 350 b of the outlet pathway, where the fluid thermally communicates with the cooler fluid in the inflow pathway. As discussed, heat from the fluid in the hotter outflow pathway transfers to the cooler fluid in the inflow pathway. This results in cooling of the outflowing fluid and heating of the inflowing fluid. The fluid then flows from the heat exchange region 350 b to the outlet opening 325 . At this stage, the fluid is in a cooled, pasteurized state.
[0059] In an embodiment, laminae having a thickness of 350 microns with an etch-depth of 175 microns, with 2.5-mm wide channels having a hydraulic diameter of 327 microns were utilized. Each pair of laminae was able to handle a fluid flow rate of approximately 3.3. mL/min of fluid, which thus required 30 pairs of laminae in order to facilitate a flow of 100 mL/min, with only a 15-mm long heat exchanger section. In an embodiment, the fluid flowpaths are designed in smooth, sweeping curves and are substantially symmetrically designed along the longitudinal axis of the stack; if the flow paths are not designed symmetrically, they are designed to minimize differences in the path line or lengths so as to evenly distribute the flow, the heating of the fluid and the various dwell times.
[0060] The width of the ribs separating channels in the heat exchange portion can be reduced, which would have the effect of increasing the available heat transfer area and reducing the length of the heat exchange portion required for the desired energy efficiency level of the device. Energy efficiency levels of at least about 85%, and in some embodiment of at least about 90% can be achieved, meaning that 90% of the thermal energy from the outgoing fluid can be transferred to the incoming fluid stream and recaptured without loss.
[0061] In this manner, a heat exchange system may be constructed to provide pasteurized water continuously at a desired flow rate for real-time mixing of dialysate in a dialysis system, without the need either to heat, purify and store water in batched quantities or to provide bags of pure water or of premixed dialysate for use by the patient.
[0062] FIG. 7A shows a plan view of another embodiment of an inlet lamina 705 that forms at least one inlet pathway where fluid flows in an inward direction (as represented by arrows 707 ) through the heat exchange system 110 . FIG. 7B shows a plan view another embodiment of an outlet lamina 710 that forms at least one outlet pathway where fluid flows in an outward direction (as represented by arrows 712 ) through the heat exchange system 110 . The flow pathway in this embodiment generally follows a different contour than the flow pathway of the embodiment of FIGS. 3A and 3B . In actual use, the inlet lamina 705 and outlet lamina 710 are stacked atop one another.
[0063] The fluid enters the inlet pathway of the inlet lamina 705 at an inlet 720 . The inlet pathway then splits into multiple pathways at the heat exchange region 750 a , which thermally communicates with a corresponding heat exchange region 750 b of the outlet lamina 710 . In another embodiment, the inlet pathway does not split into multiple pathways but remains a single pathway. The inlet pathway could also be at least partially formed of one or more microfluidic flow fields as disclosed in U.S. Provisional Patent Application No. 61/220,177, filed on Jun. 24, 2009, and its corresponding utility application entitled “Microfluidic Devices”, filed Jun. 7, 2010, and naming Richard B. Peterson, James R. Curtis, Hailei Wang, Robbie Ingram-Gobel, Luke W. Fisher and Anna E. Garrison, incorporated herein by reference. After the heat exchange region 750 a , the inlet pathway transitions to an arc-shaped heater region 760 that thermally communicates with a heater 765 , such as a 150-Watt McMaster-Carr cartridge heater (model 3618K451). The heater region serves as both a region where the heater 765 heats the fluid and as a residence chamber where the fluid remains heated at or above the desired temperature for a predetermined amount of time.
[0064] From the heater region 760 and residence chamber of the inlet lamina 710 , the fluid flows to the outlet lamina 710 at an entrance location 770 . The fluid then flows into the heat exchange region 750 b of the outlet lamina 710 , where the fluid transfers heat to the incoming fluid flowing through the heat exchange region 750 a of the inlet lamina 705 . The fluid then exits the outlet lamina at an outlet 775 . In embodiment, the lamina 705 and 710 are about 600 μm thick and the microfluidic flow pathways have a depth of about 400 μm to 600 μm. In each of the embodiments disclosed herein, the fluid flow path completely encircles each of the heaters so that any shim material conducting heat away from the heater will have fluid flowing over it to receive the heat, thereby minimizing heat loss to the environment. In addition, ideally, the flowpaths around each heater will be relatively narrow so that non-uniform heating due to separation from the heaters will be avoided.
[0065] As mentioned, the microfluidic heat exchange system 110 may be formed of a plurality of lamina stacked atop one another and diffusion bonded. Additional information concerning diffusion bonding is provided by U.S. patent application Ser. Nos. 11/897,998 and 12/238,404, which are incorporated herein by reference. In an embodiment, the stack includes multiple sets of lamina with each set including an inlet lamina 305 juxtaposed with an outlet lamina 310 . Each set of juxtaposed inlet lamina and outlet lamina forms a single heat exchange unit. The stack of lamina may therefore include a plurality of heat exchange units wherein each unit is formed of an inlet lamina 305 coupled to an outlet lamina 310 . The flow pathways for each lamina may be formed by etching on the surface of the lamina, such as by etching on one side only of each lamina. When the laminae are juxtaposed, the etched side of a lamina seals against the unetched sided of an adjacent, neighboring lamina. This may provide desirable conditions for heat exchange and separation of the incoming fluid (which is not pasteurized) and the outgoing fluid (which is pasteurized).
[0066] FIG. 8 shows a perspective view of an exemplary stack 805 of laminae. The stack 805 is shown in partial cross-section at various levels of the stack including at an upper-most outlet lamina 310 , a mid-level inlet lamina 305 a , and a lower level inlet lamina 305 b . As mentioned, the stack 805 is formed of alternating inlet lamina and outlet lamina interleaved with one another. The heaters 220 are positioned within cut-outs that extend through the entire stack 805 across all the laminae in the stack 805 . The residence chamber 360 and the aligned inlet openings 320 and outlet openings 325 also extend entirely through the stack 805 . The laminae may also include one or more holes 810 that align when the lamina are stacked to form shafts through which alignment posts may be inserted.
[0067] The quantity of laminae in the stack may be varied to accommodate desired specifications for the microfluidic heat exchange system 110 , such as the heating specifications. The heating specifications may be dependent on flow rate of fluid, heater power input, initial temperature of incoming fluid, etc. In an embodiment, the stack 805 is less than about 100 mm long, less than about 50 mm wide at its widest dimension, and less than about 50 mm deep, with a volume of less than about 250 cubic centimeters, although the dimensions may vary. In another embodiment, the stack 805 is about 82 mm long, about 32 mm wide at its widest dimension, and about 26 mm deep, with a volume of about 69-70 cubic centimeters, and a weight of about five pounds when dry, although the dimensions may vary.
[0068] The lamina 305 and 310 may be any material capable of being patterned with features useful for a particular application, such as microchannels. The thickness of the lamina may vary. For example, the lamina may have a thickness in the range of about 200 μm to about 100 μm. In another embodiment, the lamina may have a thickness in the range of about 500 μm to about 100 μm. Some suitable lamina materials include, without limitation, polymers and metals. The lamina may be manufactured of any diffusion bondable metal, including stainless steel, copper, titanium alloy, as well as diffusion bondable plastics. Because of the operating pressures and temperatures involved, the need to avoid leaching of the lamina material into the heated fluid, such as water, and the desirability of multiple uses of this device before disposal, it has been found that manufacturing the heat exchange system from stainless steel, such as 316L stainless steel, has proven adequate, although other materials may be used as long as they withstand the operating conditions without degradation.
[0069] The laminae are stacked in a manner that achieves proper alignment of the lamina. For example, when properly stacked, the inlet openings 320 of all the lamina align to collectively form an inlet passage for fluid to flow into the system and the outlet openings 325 align to collectively form an outlet passage, as shown in FIG. 8 . The properly-aligned stack of lamina may also include one or more seats for coupling the heaters 220 in the stack. One or more features can be used to assist in proper alignment of the lamina in the stack, such as alignment posts and/or visual indicators of proper alignment. The stack may include a top cover positioned on the top-most lamina and a bottom cover positioned on the bottom-most lamina. The stack may also include an external insulation wrap to prevent heat loss to the outside environment.
[0070] FIG. 9 shows a perspective view of an example of an assembled microfluidic heat exchange system 110 . The stack 805 of inlet/outlet laminae includes chemically etched upper and lower covers that seal the stack 805 against the atmosphere. These covers typically are thicker than the laminae, and may be about 1 mm or more in thickness in an embodiment to withstand damage and the operating pressures necessary to maintain the fluid in a single state. The cartridge heaters 220 are mounted in cavities that extend through the entire stack 805 . A plate 910 is secured (such as via bolts) to the stack and provides a means of securing an inlet port 915 and an outlet port 920 to the stack 805 . The inlet port 915 and outlet port 920 can be piping having internal lumens that communicate with the inlet openings 320 and outlet openings 325 .
[0071] Before assembly of the stack, each hole of each lamina that is to accept a cartridge heater is designed slightly smaller than the diameter of the cartridge heater itself. After assembly of the entire stack, the hole is enlarged for a clearance fit between the hole inner diameter and the cartridge heater outer diameter, taking into account thermal expansion of the heater during operation, to provide a uniform surface for optimum heat transfer from the heater to the pasteurizer. This method avoids any potential issues with misalignment of the shims if the holes in each shim were to be properly sized to the cartridge heater prior to assembly.
[0072] A second plate 925 is also secured to the stack 805 . The plate 925 is used to couple one or more elongated and sheathed thermocouples 930 to the stack 805 . The thermocouples 930 extend through the stack 805 and communicate with the laminae in the stack 805 in the region of the dwell chamber for monitoring fluid temperature in the dwell chamber. The thermocouples that are to be inserted into solid sections of the stack utilize a slip fit for installation. The thermocouples that enter into the fluid flow paths require a seal to prevent fluid leakage. In these cases, the holes for accepting the thermocouples are generated after the stack is assembled by electrical discharge machining (EDM), because this technique generates very small debris that can easily be flushed out of the system, as compared with traditional drilling, which could result in larger debris blocking some of the flow paths. Any of a variety of sealing members, such as o-rings or gaskets, may be coupled to the stack to provide a sealed relationship with components attached to the stack, such as the plates 910 and 925 , thermocouples 930 , and inlet port 915 and outlet port 920 . It should be appreciated that the assembled microfluidic heat exchange system 110 shown in FIG. 9 is an example and that other configurations are possible.
[0073] In an exemplary manufacture process, a stack of lamina is positioned in a fixture or casing and is then placed into a bonding machine, such as a high temperature vacuum-press oven or an inert gas furnace. The machine creates a high temperature, high pressure environment that causes the lamina to physically bond to one another.
[0074] In an embodiment, the weight of the overall stack can be reduced by removing some of the excess material from the sides of the stack, thereby eliminating the rectangular footprint in favor of a more material-efficient polygonal footprint.
[0075] FIG. 11 shows a schematic, plan view of another exemplary embodiment of the microfluidic heat exchange system 110 . FIG. 11 is schematic and it should be appreciated that variations in the actual configuration of the flow pathway, such as size and shape of the flow pathway, are possible. The embodiment of FIG. 11 includes a first flow pathway 1105 and a second flow pathway 1110 separated by a transfer layer 1115 . Fluid enters the first flow pathway at an inlet 1120 and exits at an outlet 1125 . Fluid enters the second flow pathway at an inlet 1130 and exits at an outlet 1135 . The first and second flow pathways are arranged in a counterflow configuration such that fluid flows through the first flow pathway 1105 in a first direction and fluid flows through the second flow pathway 1110 in a direction opposite the first direction. In this regard, the inlet 1120 of the first flow pathway 1105 is located on the same side of the device as the outlet 1135 of the second flow pathway 1110 . Likewise, the outlet 1125 of the first flow pathway 1105 is located on the same side of the device as the inlet 1130 of the second flow pathway 1110 . The flow pathways may be least partially formed of one or more microchannels, although utilizing microfluidic flow fields as disclosed in U.S. Provisional Patent Application No. 61/220,177, filed on Jun. 24, 2009, and its corresponding utility application entitled “Microfluidic Devices”, filed Jun. 7, 2010, and naming Richard B. Peterson, James R. Curtis, Hailei Wang, Robbie Ingram-Gobel, Luke W. Fisher and Anna E. Garrison, incorporated herein by reference, for portions of the fluid flow pathway is also within the scope of the invention.
[0076] With reference still to FIG. 11 , fluid enters the first flow pathway 1120 at the inlet 1120 and passes through a heater region 1140 . A heater is positioned in thermal communication with the heater region 1140 so as to input heat into the fluid passing through the heater region 1140 . Prior to passing through the heater region 1140 , the fluid passes through a heat exchange region 1145 that is in thermal communication (via the transfer layer 1115 ) with fluid flowing through the second flow pathway 1110 . In an embodiment, the fluid flowing through the second flow pathway 1110 is fluid that previously exited the first flow pathway 1105 (via the outlet 1125 ) and was routed into the inlet 1125 of the second flow pathway 1110 . As the previously-heated fluid flows through the second flow pathway 1110 , thermal energy from the previously-heated fluid in the second flow pathway 110 transfers to the fluid flowing through the first flow pathway 1120 . In this manner, the fluid in the second flow pathway 1110 pre-heats the fluid in the heat exchange region 1145 of the first flow pathway prior to the fluid reaching the heater region 1140 .
[0077] In the heater region 1140 , the heater provides sufficient thermal energy to heat the fluid to a desired temperature, which may be the pasteurization temperature of the fluid. From the heater region 1140 , the fluid flows into a residence chamber 1150 where the fluid remains heated at or above the desired temperature for the residence time. The fluid desirably remains flowing, rather than stagnant, while in the residence chamber 1150 . From the residence chamber 1150 , the fluid exits the first flow pathway 1105 through the outlet 1125 and is routed into the inlet 1130 of the second flow pathway 1110 .
[0078] The fluid then flows through the second flow pathway 1110 toward the outlet 1135 . As mentioned, the second flow pathway 1110 is in thermal communication with the first flow pathway 1105 at least at the heat exchange region 1145 . In this manner, the previously-heated fluid flowing through the second flow pathway 1110 thermally communicates with the fluid flowing through the first flow pathway 1105 . As the previously-heated fluid flows through the second flow pathway 1110 , thermal energy from the heated fluid transfers to the fluid flowing through the adjacent heat exchange region 1145 of the first flow pathway 1105 . The exchange of thermal energy results in cooling of the fluid from its residence chamber temperature as it flows through the second flow pathway 1110 . In an embodiment, the fluid in the second flow pathway 1110 is cooled to a temperature that is no lower than the lowest possible temperature that precludes bacterial infestation of the fluid.
[0079] In another embodiment of the device of FIG. 11 , the fluid flowing into the second flow pathway 1110 is not fluid re-routed from the first flow pathway 1105 but is rather a separate fluid flow from the same source as, or from a different source than, the source for the first fluid flow pathway 1105 . The fluid in the second flow pathway 1110 may or may not be the same type of fluid in the first flow pathway 1105 . For example, water may flow through both pathways; or water may flow through one flow pathway and a non-water fluid may flow through the other flow pathway. In this embodiment where a separate fluid flows through the second pathway relative to the first pathway, the separate fluid has desirably been pre-heated in order to be able to transfer heat to the fluid in the first flow pathway 1105 at the heat exchange region 1145 .
[0080] As in the previous embodiments, the embodiment of FIG. 11 may be made up of multiple laminar units stacked atop one another to form layers of laminae. In addition, the embodiment of FIG. 11 may have the same or similar specifications as the other embodiments described herein, including materials, dimensions, residence times, and temperature levels.
[0081] In another embodiment shown in FIG. 12 , a microfluidic heat exchange system 110 purifies a single fluid. FIG. 12 represents an exemplary flow pathway configuration for a single lamina. A plurality of such laminae may be interleaved to form a stack of lamina as described above for other embodiments. The purification of the fluid may comprise pasteurizing the fluid although pasteurization is not necessary such as where the device is not used for dialysis. The heat exchange system receives a stream of incoming fluid 1205 , which splits before entering the heat exchange system. A first portion of the stream of incoming fluid 1205 a enters at a first inlet 1210 a on one end of the system and a second portion of the stream of incoming fluid 1205 enters at a second inlet 1205 b on the other, opposite end of the system. The two streams of incoming fluid 1205 are distributed across the stacked laminae in alternating fashion such that there is no direct contact between the two fluid streams.
[0082] Each stream of incoming fluid 1205 enters a flow pathway 1207 and flows along the flow pathway toward an outlet 1215 . One stream of fluid enters via the inlet 1205 a and exits at an outlet 1215 a positioned on the same end of the system as the inlet 1210 b , while the other stream of fluid enters via the inlet 1205 b and exits at an outlet 1215 b on the same end of the system as the inlet 1210 a . Each flow pathway 1207 includes a first heat exchange region 1220 where heat is exchanged through a transfer layer between the incoming fluid and the previously-heated outgoing fluid flowing through a lamina immediately above (or below) the instant lamina in the stack. As the fluid flows through the heat exchange region 1220 it receives heat via the heat transfer and is pre-heated prior to entering a heater region 1225 .
[0083] For each flow pathway 1207 , the fluid then flows into the heater region 1225 , which thermally communicates with at least one heater, and preferably multiple heaters, for communicating heat into the flowing fluid. The fluid is heated under pressure to a temperature at or above the desired threshold pasteurization temperature as described above for other embodiments. The heater region 1225 also serves as a residence chamber. The fluid flows through the residence chamber while held at or above the desired temperature for the desired residence time. The desired residence time may be achieved, for example, by varying the flow rate and/or by employing a serpentine flow path of the required length within the heater region 1225 . After leaving the heater region 1225 , the outgoing fluid enters a second heat exchange region 1230 where the outgoing fluid exchanges heat with the incoming fluid flowing through a lamina immediately above (or below) the instant lamina in the stack. The outgoing fluid then exits the flow pathways through the outlets 1210 a and 1210 b . The two streams of outgoing fluid then recombine into a single stream of outgoing fluid 1235 before continuing on to the ultrafilter to remove all or substantially all of the dead bacteria killed by the pasteurization process.
[0084] FIG. 13A shows another embodiment of an inlet lamina that forms a spiral inlet pathway where fluid flows in an inward direction through the heat exchange system. FIG. 13B shows a corresponding outlet lamina that forms a similar spiral pathway where fluid flows in an outward direction. A plurality of such inlet and outlet laminae may be interleaved to form a stack of laminae as described above for other embodiments. The laminae are shown having a circular outer contour although the outer shape may vary as with the other embodiments.
[0085] With reference to FIG. 13A , the inlet lamina has a header forming an inlet 1305 where incoming fluid enters the inlet pathway. The inlet pathway spirals inward toward a center of the pathway, where a heating chamber 1310 is located. The heating chamber 1310 also serves as a residence chamber for the fluid, as described below. One or more heaters are positioned in thermal communication with the heating chamber 1310 to provide heat to fluid flowing in the heating chamber 1310 . The heating chamber 1310 extends across multiple laminae in the stack and includes a conduit that communicates with the outlet lamina shown in FIG. 13B . The fluid enters the outlet lamina from the heating chamber 1310 . The outlet lamina has an outflow pathway that spirals outward from the heating chamber 1310 toward an outlet 1320 .
[0086] In use, the fluid enters the inlet pathway of the inlet lamina through the inlet 1305 shown in FIG. 13B . The fluid then flows along the spiral inlet pathway toward the heater chamber 1310 . As in the previous embodiments, the incoming fluid is at a temperature that is less than the previously-heated fluid flowing through the outlet lamina, which is positioned immediately above or below the inlet lamina. As the fluid flows through the inlet pathway, the fluid receives heat from the previously-heated fluid flowing through the outlet pathway of the outlet lamina. This serves to pre-heat the fluid prior to the fluid flowing into the heating chamber 1310 . The fluid then flows into the heating chamber 1310 where the fluid receives heat from the one or more heaters.
[0087] While in the heating chamber 1310 , the fluid is heated under pressure to a temperature at or above the desired threshold pasteurization temperature as described above for other embodiments. As mentioned, the heating chamber 1310 also serves as a residence chamber. The fluid flows through the residence chamber while held at or above the desired temperature for the desired residence time. As in other embodiments, the desired residence time may be achieved, for example, by varying the flow rate and/or by employing a serpentine flow path of the required length within the heater chamber 1310 . After leaving the heater chamber, the outgoing fluid enters the outlet pathway of an outlet lamina such as shown in FIG. 13B . The outgoing fluid flows outward from the heating chamber 1310 along the spiral flow pathway toward the outlet 1320 . The spiral pathway of the inlet lamina thermally communicates with the spiral pathway of the outlet lamina across a transfer layer As the outgoing fluid flows along the spiral pathway, it exchanges heat with the incoming fluid flowing through an inlet lamina immediately above (or below) the instant lamina in the stack. The outgoing fluid then exits the stack of lamina via the outlet 1320 before continuing on to the ultrafilter to remove all or substantially all of the dead bacteria killed by the pasteurization process.
Control System
[0088] The microfluidic heat exchange system 110 may include or may be coupled to a control system adapted to regulate and/or control one or more aspects of the fluid flow through the system, such as fluid flow rate, temperature and/or pressure of the fluid, chemical concentration of the fluid, etc. FIG. 10 shows a schematic view of an exemplary heater control system 805 communicatively coupled to the microfluidic heat exchange system 110 . The heater control system 1005 includes at least one power supply 1015 communicatively coupled to a heater control unit 1020 , which communicates with a control logic unit 1025 . The heater control unit 1020 is adapted to control the power supply to the heaters, either on an individual basis or collectively to a group of heaters. This permits temporal and spatial control of heat supplied to the microfluidic heat exchange system 110 .
[0089] The heater control system 1005 may include one or more temperature sensors 1010 positioned in or around the microfluidic heat exchange system 110 for sensing fluid temperature at one or more locations within the fluid flow path. The type of sensor can vary. In an embodiment, one or more thermocouples are used as the sensors 1010 . The sensors 1010 communicate with the heater control unit 1020 and the control logic unit 1025 to provide a temperature feedback loop. The heater control system 1005 provides for feedback control of fluid temperature in the system to ensure, for example, that fluid is being heated to the required pasteurization temperature and/or that the fluid is not overheated or underheated. For example, the heater control unit 1020 in conjunction with the control logic unit 1025 may adjust power to one or more of the heaters based on a sensed temperature in order to achieve a desired temperature profile in one or more locations of the fluid flow path. The heater control system 1005 may include other types of sensors such as, for example, pressure sensors, flow rate sensors, etc. to monitor and adjust other parameters of the fluid as desired.
[0090] The heater control system 1005 may also be configured to provide one or more alarms, such as a visual and/or audio indication and/or a telecommunications signal, to the user or a remote monitor of system functions to inform such parties when the temperature is at an undesired level. For example, the control unit 1020 may comprise one or more temperature set limits within which to maintain, for example, the residence chamber temperature. If a limit is exceeded—i.e., if the temperature falls below the lower operating limit or above the upper operating limit, the control system may bypass the heater, set off an alarm and cease operation of the overall water purification system until the problem can be diagnosed and fixed by the operator. In this regard, the control system 1005 may include a reporting unit 1030 that includes a database. The reporting unit 1005 is configured to log and store data from the sensors and to communicate such data to a user or monitor of the system at a remote site.
Exemplary Fluid Purification Procedure
[0091] With reference again to FIG. 1 , an exemplary configuration for purifying fluid using the fluid purification system is now described including a description of a fluid flow path through the system. It should be appreciated that the description is for example and that variations to the flow path as well as to the arrangement of the subsystems and hardware are possible. The fluid purification system is described in an exemplary context of being a component of a dialysis system. In this example, the fluid purification system is used to purify water that is used by the dialysis system. The fluid purification system is not limited to use for purifying water in dialysis systems.
[0092] As shown in FIG. 1 , water enters the system via an entry location 105 , flows along a flow pathway, and exits the system via an exit location 107 . The flow pathway may be formed by any type of fluid conduit, such as piping. The piping may include one or more sample ports that provide access to water flowing through the piping. One or more subsystems, including the microfluidic heat exchange system 110 , are positioned along the pathway for processing the water prior to the water exiting the system. As mentioned, the subsystems may include, for example, a sediment filter system 115 , a carbon filter system 120 , a reverse osmosis system 125 , an ultrafilter system 130 , an auxiliary heater system 135 , a degassifier system 140 , or any combination thereof.
[0093] The fluid purification system may also include hardware and/or software to achieve and control fluid flow through the fluid purification system. The hardware may include one or more pumps 150 and a throttling valve or other devices for driving fluid through the system, as well as sensors for sensing characteristics of the fluid and fluid flow, such as flow sensors, conductivity sensors, pressure sensors, etc. The hardware may communicate with a control system that controls operation of the hardware.
[0094] Upon entering the system, the water flows through at least one sediment filter system 115 , which includes one or more sediment filters that filter sediment from the water flowing therethrough. The water then flows through a carbon filter system 120 , which includes one or more carbon filters that filter organic chemicals, chlorine and chloramines in particular from the water. One or more pumps may be positioned at various locations along the water flow pathway such as between the filter subsystems. In addition, a conductivity sensor may be coupled to the pathway downstream of the carbon filter system 120 and downstream of the reverse osmosis system to determine the percentage of dissolves solids removed. The water flows from the carbon filter system 120 to a reverse osmosis system 125 configured to remove particles from the water pursuant a reverse osmosis procedure. The sediment filter 115 removes particulate matter down to 5 microns or even 1 micron. The carbon filter 120 removes chlorine compounds. The reverse osmosis system 125 usually removes greater than 95% of the total dissolved solids from the water.
[0095] The sediment filter system 115 , carbon filter system 120 , and reverse osmosis system 125 collectively form a pre-processing stage that removes a majority of dissolved solids, bacteria contamination, and chemical contamination, if any, from the water. The water is therefore in a somewhat macro-purified state prior to reaching the heat exchange system 110 . Thus, the preprocessing stage supplies relatively clean water to the downstream pumps and also to the heat exchange system 110 . This reduces or eliminates the potential for scale build-up and corrosion during heating of the water by the heat exchange system 110 .
[0096] After the water passes the pre-processing stage, a pump 150 may be used to increase the water pressure to a level higher than the saturation pressure encountered in the heat exchange system 110 . This would prevent phase change of the water inside the heat exchange system 110 . Thus, if the highest temperature reached in the heat exchange system 110 is 150 degrees Celsius where the water would have a saturation pressure of 475 kPa (approximately 4.7 atmospheres or 69 psia), the pressure of the water coming out of the pump would exceed the saturation pressure. The pump desirably increases the water pressure to a level that is at or exceeds the saturation pressure to ensure no localized boiling. This can be important where the heat exchange system is used to pasteurize water and the water is exposed to high temperatures that may be greater than 138 degrees Celsius, i.e., well above the boiling point of water at atmospheric pressure.
[0097] The water, which is now pressurized above, or significantly above, the saturation pressure, enters the heat exchange system 110 , which pasteurizes the water as described in detail above. The heat exchange system 110 may be encased in insulation to reduce the likelihood of heat loss of the water passing therethrough. After leaving the heat exchange system 110 , the water passes into a throttling valve 160 , which maintains the pressure though the water path from the pump 150 to outlet of the heat exchange system 110 . The throttling valve 160 and the pump 150 may be controlled and adjusted to achieve a flow rate and a desired pressure configuration. The pump 150 and the throttling valve 160 may communicate with one another in a closed loop system to ensure the required pressure is maintained for the desired flow rate and temperature. A degassifier system 140 may also be incorporated into the flow path for removing entrained gas from the water.
[0098] After the water leaves the throttling valve 160 , it passes to an ultrafilter system 130 that removes macromolecules and all or substantially all of the dead bacteria killed by the pasteurization process from the water to ensure no endotoxins remain in the water before mixing the dialysate. Where the water is used in a dialysis system, the presence of macromolecules may be detrimental to the dialysis process. The water then passes through a heater system that may heat the water to a desired temperature, such as to normal body temperature (98.6 degrees Fahrenheit). Where the water is used for dialysis, the water is then passed to a mixer 170 that mixes the clean water with a supply of concentrate solutions in order to make dialysate.
Startup and Shutdown of Fluid Purification System
[0099] Where the fluid purification system is used for dialysis, it is important to avoid bacterial contamination of the fluid flow path, both within the heat exchanger system 110 and throughout the components downstream of the heat exchanger system 110 . In this regard, the heat exchanger system 110 , which serves as a pasteurizer, is desirably operated in a manner that ensures clean fluid flow upon startup of the fluid purification system and also avoids bacterial contamination of the downstream components, or at least mitigates the contamination effects, upon shut down (i.e., when the heaters 220 are de-powered).
[0100] In an embodiment, clean fluid flow upon startup is achieved by initially flowing a sterilizing liquid through the heat exchanger system 110 while the heaters 220 are being powered up. The sterilizing liquid then flows through all the components downstream of the heat exchanger system 110 until the heat exchanger system 110 attains a desired operating temperature. Upon the heat exchanger system 110 reaching the desired operating temperature, fluid flow to the heat exchanger system 110 switches to water from the reverse osmosis system 125 . The water passes through the heat exchanger system 110 (which has achieved the desired operating temperature) to flush the sterilizing liquid out of the flow pathway of the heat exchanger system 110 . Various sterilizing solutions may be used. The solution, for example, can be a 1% chlorine in water mixture, or some other widely recognized water additive that can kill bacteria.
[0101] The fluid purification system may be shut down as follows. The heaters 220 are de-powered while fluid flow through the heat exchanger system 110 is maintained. Alternatively, a sterilizing liquid may be flowed through the heat exchanger system 110 until the heat exchanger system 110 attains near room temperature conditions. In this manner, the flow pathway is maintained in a sterilized condition as the heat exchanger system 110 shuts down. The flow pathway of the heat exchanger system 110 is then closed or “locked down” with sterilizing liquid present in the flow pathway of the heat exchanger system 110 . The presence of the sterilizing liquid greatly reduces the likelihood of bacterial contamination during shutdown.
[0102] In another embodiment, one or more valves are positioned in the flow pathway of fluid purification system wherein the valves allow a circulating flow of solution to loop through the pump 150 , heat exchanger system 110 , and downstream components in a recirculation loop until desired pasteurization conditions are achieved during startup. The valves are then set to allow the sterilizing liquid to be flushed from the system. An auxiliary component, such as a microchannel fluid heater (without heat exchange capability), can also be incorporated to provide the ability to circulated a warmed (e.g., less than 100 degrees Celsius) sterilizing liquid through the downstream components and/or through the unpowered heat exchanger system 110 . The sterilizing liquid can be used during either a start-up or shut-down process for keeping the flow pathway and components clean over the span of weeks and/or months. The use of a recirculation loop for sterilizing liquid at start up is another manner to prevent bacteria from entering the fluid purification system before the heat exchanger system 110 achieves operating temperatures. A timing control logic may be used with a temperature sensing capability to implement a process that ensures quality control over the start-up and shut down processes. The control logic may be configured to initiate flow only after the heat exchanger system 110 or a heater attains a preset temperature.
[0103] The flow path may include one or more bypass circulation routes that permit circulation of cleaning and/or sterilization fluid through the flow path. The circulation route may be an open flow loop wherein fluid flowing through the circulation route is dischargeable from the system after use. In another embodiment, the circulation route may be a closed flow loop wherein fluid flowing the circulation route not dischargeable from the system. Alternately, the system may include both open and closed circulation routes.
[0104] The present specification is related to subject matter disclosed in U.S. patent application entitled “Dialysis System with Ultrapurification Control,” filed on Jun. 7, 2010, naming James R. Curtis, Ladislaus F. Norm, and Julie Wrazel, and “Dialysis System,” filed on Jun. 7, 2010, naming Julie Wrazel, James R. Curtis, Ladislaus F. Norm, Richard B. Peterson, Hailei Wang, Robbie Ingram-Govel, Luke W. Fisher, Anna B. Garrision, M. Kevin Drost, Goran Jovanovic, Todd Miller, Bruce Johnson and Alana Warner-Tuhy, which are incorporated herein by reference in their entirety.
[0105] While this specification contains many specifics, these should not be construed as limitations on the scope of an invention that is claimed or of what may be claimed, but rather as descriptions of features specific to particular embodiments. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or a variation of a sub-combination. Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results.
[0106] Although embodiments of various methods and devices are described herein in detail with reference to certain versions, it should be appreciated that other versions, embodiments, methods of use, and combinations thereof are also possible. Therefore the spirit and scope of the appended claims should not be limited to the description of the embodiments contained herein.
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Disclosed are systems and methods of preparing dialysate for use in a home dialysis system that is compact and light-weight relative to existing systems and consumes relatively low amounts of energy. The method includes coupling a household water stream to a dialysis system; filtering the water stream; heating the water stream to at least about 138 degrees Celsius in a non-batch process to produce a heated water stream; maintaining the heated water stream at or above at least about 138 degrees Celsius for at least about two seconds; cooling the heated water stream to produce a cooled water stream; ultrafiltering the cooled water stream; and mixing dialysate components into the cooled water stream in a non-batch process.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for extracting hydrocarbons from the earth. More particularly, this invention relates to a method for recovering especially viscous hydrocarbons, e.g. bitumen, from a subterranean formation using at least two wells for injection and production, and which includes critical manipulative steps with heated fluid.
2. Description of the Prior Art
In many areas of the world, there are large deposits of viscous petroleum, such as the Cold Lake, Athabasca and Peace River regions in Canada, the Jobo region in Venezuela and the Edna and Sisquoc regions in the United States. These deposits are generally called "tar sand" and "heavy oil" deposits due to the high viscosity of the hydrocarbons which they contain and may extend for many miles and occur in varying thickness of up to more than 300 feet. Although these deposits may lie at or near the earth's surface, generally they are located under a substantial overburden which may be as great as several thousand feet thick. Tar sands located at these depths constitute some of the world's largest presently known petroleum deposits.
The tar sands contain viscous hydrocarbon material, commonly referred to as bitumen, in an amount which ranges from about 5 to about 20 percent by weight. Bitumen is usually immobile at typical reservoir temperatures. For example, at reservoir temperatures of about 48° F., bitumen viscosity frequently exceeds several thousand poises. At higher temperatures, such as temperatures exceeding 200° F., bitumen generally becomes mobile with a viscosity of less than 345 centipoises.
Since most tar sand deposits are too deep to be mined economically, a serious need exists for an in situ recovery process wherein the bitumen is separated from the sand in the formation and recovered through production means, e.g. wells drilled into the deposit.
In situ recovery processes known in the art include emulsification drive processes, thermal techniques (such as fire flooding), in situ combustion, steam flooding and combinations of these processes.
Any in situ recovery process must accomplish two functions: (1) the viscosity of the bitumen must be reduced to a sufficiently low level to mobilize, e.g. fluidize, the bitumen under the conditions prevailing; and (2) sufficient driving energy must be applied to that treated bitumen to induce it to move through the formation to a production well.
As previously noted, among the various methods that have been proposed for recovering bitumen in tar sand deposits are heating techniques. Because steam is generally the most economical and efficient thermal energy agent, it is clearly the most widely employed.
Several steam injection processes have been suggested for heating the bitumen. One method involves a steam stimulation technique commonly called the "huff and puff" process. In such a process, steam is injected into a well for a certain period of time. The well is then shut in to permit the steam to heat the oil. Subsequently, formation fluids, including bitumen, water and steam, are produced from the well. Production is later terminated and steam injection is preferably resumed for a further period. Steam injection and production are alternated for as many cycles as desired. A principle drawback to the "huff and puff" technique is that it does not heat the bulk of the oil in the reservoir and consequently reduces the oil recovery.
Another method of recovering viscous petroleum materials from subterranean formations is through the use of thermal drive techniques. Typically, thermal drive techniques employ an injection well and a production well which extend into the reservoir formation. In operation, a hot fluid (usually steam) is introduced into the formation through the injection well. Upon entering the formation, the hot flowing fluid lowers the viscosity of the petroleum materials therein and subsequently drives the lower viscosity fluid to a production well.
It has been found that conventional thermal drive processes generally are not commercially effective in recovering bitumen from tar sands. The basic problem in high viscosity hydrocarbon formations, such as tar sands, is restricted fluid mobility in the reservoir. One reason for this is that the bitumen tends to cool and increase in viscosity as it moves away from the injection well where the steam or hot fluid is most effective. Once the bitumen attains a high enough viscosity, it banks up and forms an impermeable barrier to further flow toward production wells.
Another problem with steam drive is that the driving force of the steam flooding technique is ultimately lost when breakthrough occurs at the production well. Steam breakthrough occurs when the steam front advances to a production well and steam pressure is largely dissipated through the production well. Fluid breakthrough causes a loss of steam driving pressure characterized by a marked diminuation in the efficiency of the process. After steam breakthrough, the usual practice, as suggested in U.S. Pat. No. 3,367,419 (Lookeren) and U.S. Pat. No. 3,354,954 (Buxton), is to produce without steam drive until further steam injection is necessitated or production is terminated.
U.S. Pat. No. 3,259,186 (Dietz), for example, appears to have an early teaching of conventional "huff and puff." The patent discloses a method for recovering viscous oil from subterranean formations by simultaneously injecting steam into several adjacent injection wells to heat the formation. Formation fluids are then produced from the injection wells. After several cycles, steam drive can be established by injecting steam into one injection well while using another for production. U.S. Pat. No. 3,280,909 (Closmann, et al) discloses a conventional steam drive comprising steam injection to produce interconnecting fractures, but insufficient to produce oil, followed by steam drive at conventional pressures and rates.
Several variations of steam stimulation have been tried, each with its own distinct sequence of steps. U.S. Pat. No. 3,796,262 (Allen, et al) teaches a method of injecting steam at a rate greater than the production rate but less than the rate needed to fracture the formation. The injection is stopped when live steam breaks through to the production well, but production continues at a high rate until the pressure drops.
U.S. Pat. No. 4,182,416 (Trantham, et al) discloses a method of pattern injection and production wherein steam is injected at the injection wells until it breaks through to one of the production wells which is then shut-in while injection continues. Later, the injection well communicating with the production well is shut-in, and the production well is produced for a period of time.
Also, U.S. Pat. No. 4,130,163 (Bombardieri) teaches a method of simultaneous injection of steam into the injection and production wells. After the hydrocarbons are sufficiently mobilized, the injection well is shut-in, and the production well is opened. Finally, steam is again injected into the injection well, but at a restricted rate, to help drive the oil to the production well.
While all of the above methods are of interest, the technology has not generally enabled cost effective recovery of oil for commercial development of tar sands. There is a continuing need for an improved thermal system for effectively recovering viscous hydrocarbons from subterranean formations such as tar sand deposits.
SUMMARY OF THE INVENTION
The invention is a method of recovering oil from subterranean formations wherein there is at least one injection well and one production well which are in fluid communication with each other through said formation. A heated fluid, such as steam, is injected via the injection well at a rate which is less than what is necessary to fracture the formation. This rate varies with the formation conditions, but must be sufficient to drive the heated oil to the production well. When breakthrough of the heated fluid occurs, the production well is shut-in, and injection through the injection well is increased to a level which is at least sufficient to fracture the formation, i.e. the injection pressure is greater than the overburden pressure. After the reservoir is sufficiently heated, the injection well is shut-in and the production well is opened for production. Once the production rate declines below the rate that existed before breakthrough, the production well can be shut-in, and the injection process repeated.
By practicing the method according to the invention, viscous hydrocarbons are sufficiently fluidized to be induced to flow out to a formation while avoiding excessive losses of heat. The primary advantage of this invention over continuous injection is that the heat is more efficiently transmitted to the formation. Still another advantage is that the oil does not have to complete with the injected fluid for a flowing path to the producer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of wells illustrating the state of two wells in the early stages of the process of this invention.
FIG. 2 is a diagrammatic representation similar to FIG. 1 illustrating the process of the invention at a later stage.
FIG. 3 is similar to FIGS. 1 and 2 and illustrates the process of the invention at still a later stage.
FIG. 4 is a graphic illustration of the injection and production results in an actual field test of the invention.
DETAILED DESCRIPTION OF INVENTION
The essence of this invention is the discovery that production from viscous hydrocarbon formations can be improved by following a critical sequence of injection and production steps. After two wells are in communication through one or more heated channels, a heated fluid, such as steam, is injected into the injected well at a rate less than the rate needed to fracture the formation, and oil is produced from the production well until the heated fluid breaks through at the production well. After breakthrough, the production well is shut-in to prevent excessive losses of heat, and the injection rate is increased to a value at least sufficient to fracture the formation. After the formation is suitably heated, the injection well is shut-in, and the production well is reopened to production of the heated fluids.
Referring to FIGS. 1 through 3 of the drawings, two wells are represented in varying phases of operation in the practice of the invention. The wells represented by a circle are injection wells, those which are solid circles are production wells, and those having a superimposed "x" mark are shut-in wells. While only two wells are illustrated in the drawings, it is understood that the invention is not limited to any particular number or pattern of wells.
A preferred embodiment of the invention is carried out in the following manner. Referring to FIG. 1, a heated fluid is injected into a viscous hydrocarbon formation through at least one well in said formation. Viscous hydrocarbons mobilized in the formation are produced at a second well. One well is referred to herein as an injection well, and the other well is referred to herein as a production well. In most cases, the injection of the hot fluid will occur simultaneously with the production of the mobilized hydrocarbons. This process continues until breakthrough of the heated fluid occurs at the production well.
As will be described in more detail later, a number of fluids can be used in the practice of this invention. However, steam is especially preferred because it is the most convenient to use. This embodiment will therefore be discussed in terms of steam although it is not so limited.
Initially, steam is injected into the formation at a rate which is less than the rate needed to fracture the formation and at a temperature in the range of about 465° F. to about 600° F., preferably about 500° F. to 550° F. Steam may be saturated or supersaturated. Generally, in most field applications the steam will be saturated with a quality of approximately 65 to 80 percent. Optimization of the injection rates, steam temperature and steam quality is well within the skill of petroleum engineers of ordinary skill in their art or can be readily determined by routine experimentation or computer modeling.
Steam may be injected into tubing or annulus depending on capacity of the steam system and type of well completion. Ordinarily, steam is injected either through the casing or through the tubing with a packer set between tubing and casing above the pay. With the latter arrangement, heat losses, increases in casing temperature, and resulting thermal stresses are minimized. The injection period varies between 45 to 75 days depending on the permeability of the reservoir and the boiler capacity. In any event, treatment time can be readily determined by one skilled in the art or by actual experience in a particular field.
During this first stage, production of fluids from the production well is not restricted, and fluid production is allowed to proceed without restriction so long as only liquids are produced at the production well. Once live or vapor phase steam breaks through at the production well, the first stage is ended and the second stage is begun.
Referring to FIG. 2 for the second stage, the production well is shut-in, and the rate of steam injection into the injection well is increased to a rate at least sufficient to fracture the formation. An injection rate of 5000 to 25,000, preferably 10,000 to 20,000, pounds of steam per hour is often satisfactorily for formations ranging in depth from 1200 to 1700 feet. Another way of expressing the injection rate is: 400 to 800 pounds per foot of open interval in the well. These high rates of injection result in the fracturing of the formation. By ceasing production and increasing the injection rate of steam, the formation is heated more efficiently than with other methods.
Several factors affect the volume of steam injection. Among these are the thickness of the hydrocarbon containing formation, the viscosity of the oil, the porosity of the formation, amount of formation face exposed and the saturation level of the hydrocarbon and water in the formation. Generally, the total steam volume injected during this step will vary between 30,000 to 60,000 barrels. Moreover, the steam may be mixed with other fluids, e.g. gases or liquids, to increase its heating efficiency. It may also be mixed with air and other oxygen containing gases to utilize a combustion front.
Steam is ideal for raising the temperature of a reservoir because of its high heat content per pound. Saturated steam at 350° F. contains 1192 BTU per pound compared with water at 350° F. which has only 322 BTU per pound or only about 1/4 as much as steam. The big difference in heat content between the liquid and the steam phases is the latent heat or heat of vaporization. Because the amount of heat released when steam condenses is very large, oil reservoirs can be heated much more efficiently by steam than by either hot liquids or noncondensable gases.
Generally, the formation should be heated radially at least 10 feet and up to 150 feet from each wellbore. Because the producing well has been shut-in during the second phase, the reservoir temperature and pressure are simultaneously increased.
The steam to be used in our invention is preferably of the highest quality available. As the injection pressure increases due to increased reservoir pressure, the steam generator conditions are adjusted to maintain high quality steam output.
Referring to FIG. 3 for the third stage, after the formation around the wells has been suitably heated, steam injection into the well is discontinued, and the production well is opened to production of the heated fluids. The removal of hydrocarbons from the formation via the production well may be accomplished by any of the known methods. The lifting of the hydrocarbons to the surface may also be effected by pumping or gas lifting. The recovery apparatus is not described in detail because such production methods are well known.
During stage three, production will continue in the production well at a declining rate over a given production cycle. The pressure within that part of the formation which is in contact with the steam gradually reduces to a value that is lower than the fracture pressure of the formation. When the production rate declines below the rate that existed during stage one, stage two can be repeated to increase the rate of production.
It is desirable that pressure and temperature measuring devices be placed in the bottom of the wells to record this information during shut-in and production periods. These pressure and temperature devices can be monitored to determine when each stage should be begun. During oil production, the actual production rates will be an additional factor in determining when the process should be repeated.
The term "heated fluid" as used herein is understood to means a fluid having a temperature considerably higher than the temperature of the formation into which it is injected (e.g. 150° F. to 1,000° F.) It could be heated gas or liquid, such as steam or hot water, and it could contain surfactants, solvents, oxygen, air, inert inorganic gases, and hydrocarbon gases.
Although the heated fluid in the initial and subsequent injection sequences described above was steam, these fluids may differ. For example, the initially injected fluid may be steam, and the second injected fluid may be hot water, or vice versa. As a further example, the initial fluid may be hot water, and the subsequent fluid may be superheated steam. Any suitable agent for increasing the mobility of the viscous hydrocarbons may be added to the heated fluid. The method of the present invention is not restricted to a particular well pattern, but it can be employed in oil fields in which the wells are arranged according to previously existing patterns. The injection, shut-in and production periods for two equivalent sets of wells may coincide.
While this steam injection process is particularly suitable for thick deposits of heavy viscous hydrocarbons, such as bitumen and tar sands, it should be understood that this invention may be employed to recover hydrocarbons of much higher API gravity, e.g. 25° to 40° API. Thus, it is also within the scope of this invention to employ the method described herein to recover liquids from any subterranean strata which may be thermally stimulated.
ACTUAL FIELD EXAMPLES
The invention is further illustrated by referring to the following examples based on field tests which are offered only as illustrative embodiment of the invention and are not intended to be limited or restrictive thereof. An index for comparing the performance of several experimental sites is provided in the following tables I and II:
TABLE I______________________________________STEAM FLOODINGTEST SITE OSR WOR CDOR______________________________________A 0.13 5.43 4.81B 0.30 3.31 6.83C 0.13 8.52 4.49D 0.10 10.92 3.10E 0.26 2.56 9.66______________________________________
TABLE II______________________________________COMBINED REPLACEMENT DRIVETEST SITE OSR WOR CDOR______________________________________A 0.15 5.21 5.01B 0.31 3.28 6.90C 0.15 7.91 4.98D 0.10 10.97 3.21E 0.28 2.87 9.90______________________________________ OSR = Oil/Stream Ratio WOR = Water/Oil Ratio CDOR = Cumulative Daily Oil Recovery (m.sup.3 /day)
Tests A through D were conducted at May pilot project, Cold Lake, Alberta, and test E was conducted at Leming pilot project, Cold Lake, Alberta. Test A and B each used one injection well and two production wells, and test C, D, and E used one injection well and one production well. Test periods ranged from six months to three years.
Tables I and II show the cumulative production data for the test sites and do not show the large differences that can occur over shorter periods of time. FIG. 4, on the other hand, details the production performance of test site B over a six-month period. The increase in oil recovery when steam injection ceased is particularly significant.
The principle of the invention and the best modes in which it is contemplated to apply that principal have been described. It is to be understood that the foregoing is illustrative only and that other means and techniques can be employed without departing from the true scope of the invention as described in the following claims.
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Performing steam drive operations in critical manipulative steps can improve the recovery of viscous hydrocarbons from tar sand deposits. Steam is injected into an injection well at a rate that is less than the rate needed to fracture the formation, and fluids are simultaneously produced from a communicating production well. When steam breakthrough occurs at the production well, the production well is shut-in, and the injection rate is increased to a rate at least sufficient to fracture the formation. After the reservoir is sufficiently heated, injection ceases and production resumes. Once the production rate declines to a rate that is no longer efficient, the process can be repeated.
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BACKGROUND OF THE INVENTION
The invention is directed to a knitting machine, in particular a crochet galloon machine having a plurality of knitting needles and a plurality of thread guides associated with the knitting needles and supported on a driveable guide bars.
There are a great many known knitting machines or crochet galloon machines of the type mentioned above, e.g., see DE-A-30 34 253. A problem occurring in these knitting machines consists in that the area above the knitting needles is relatively confined so that only a limited number of guide bars and corresponding thread guides can be arranged. Accordingly, the pattern possibilities in such a knitting machine are also limited.
The object of the present invention is to improve a knitting machine, in particular a crochet galloon machine, of the type mentioned above.
SUMMARY OF THE INVENTION
This object of the invention is achieved by providing a knitting machine in which the number of guide bars and corresponding thread guides which can be provided within the available space is increased in that there is at least one group of at least two guide bars which are arranged one on top of the other. This results in the decisive advantage that either the accessibility of the guide bars is improved given the same number of guide bars or a substantially greater number of guide bars can be provided within the same space. When the guide bars are arranged one above the other in groups of two, the number of guide bars and accordingly the number of possible patterns is doubled. If the groups are formed by three guide bars arranged one above the other, the number of guide bars is tripled.
As was mentioned above, the advantages of the invention are provided even if only some of the guide bars are combined in groups of guide bars arranged one above the other. However, combining a a majority of the guide bars in groups of guide bars arranged one above the other is especially advantageous.
In principle, it is possible for the thread guides of a group of guide bars to act on different offset lines or racking lines. Associating the guide bars of a group with the arms offset line is more advantageous in that adjustment work is substantially facilitated.
Advantageously, the guide bars of a group contact each other and, preferably, are guided reciprocally. The reciprocal guiding of the guide bars of a group results in an optimal and precise guidance of the guide bars and thread guides. Bending of the guide bars is reduced to a minimum by the reciprocal support. Accordingly, high knitting speeds of up to 2000 rpm can be achieved. The reciprocal guidance of the guide bars also obviates the need to secure the guide bars against relative rotation resulting in a simpler and accordingly more economical construction. The stability of the arrangement and its accessibility are further improved by forming the guide bars as upright guide bars having substantially flat profile. Although, there are a number of different possible constructions for the reciprocal guidance of the guide bars, the construction, in which one of the guide bar is provided with a web lying in the main plane of the guide bars and the other guide bar has a complimentary groove, is particularly advantageous.
There is also a variety of possible constructions and arrangements of the thread guides. For instance, the thread guides of the lower guide bar of one group can be attached from the bottom and the thread guides of the upper guide bar can be attached from the top. However, attaching the thread guides of both the lower and upper guide bars from the top is more advantageous, since all thread guides are accessible from the top in this case and access to the thread guides for adjustment and/or for the purpose of repairing the thread is made possible in the simplest manner and without restricting space.
The feeding of the yams or threads to the thread guides is substantially improved by a further development of the knitting machine according to the thread guides are formed as a clip having a head portion with a guide eyelet for the thread. This has considerable importance particularly when the quantity of guide bars and thread guides is especially large.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, embodiment examples of the invention are described more fully with reference to the drawings.
FIG. 1 shows the knitting location of a knitting machine in cross section;
FIG. 2 shows two groups of guide bars with thread guides in section;
FIG. 3 shows another knitting machine in section and in a side view of the guide bars;
FIG. 4 shows the knitting machine of FIG. 3 in section along IV--IV of FIG. 3;
FIG. 5 shows the knitting machine of FIG. 3 in section along V--V of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the knitting location of a knitting machine, in particular a crochet galloon machine. Knitting needles 4 which are guided in traversing or reciprocating motion at a knockover bar 6 are fastened to a knitting needle bar 2 which is guided in reciprocating motion. A guide rail 8 is supported in front of the knockover bar 6 and, together with the latter, forms a guide gap 10 through which the knitted fabric 12 is guided to take-off rollers 14, 16. Warp guide needles 20 which carry out a swiveling movement about the knitting needles and insert warp threads 22 into the respective knitting needles 4 are arranged in front of the knitting needles 4 at a warp guide bar 18.
An individual guide bar 24 with a thread guide 26 which feeds a thread 28, e.g., an elastic thread or rubber thread, to the knitting needles 4 via a guide needle or eye needle 30 of the thread guide 26 is arranged above the knitting needles 4. Thread guides 36 and 38 with tube needles 40 are fastened to groups G 1 to G 7 of guide bars 32, 34 which are arranged one above the other in pairs. The thread guides 36 and 38 are designed as clips which can be attached from above and cooperate with either the upper guide bar or lower guide bar 32, 34. For this purpose, each thread guide 36, 38 has a locking part 44 engaging in lock recesses 42 of the guide bar 32, 34 and a bridge part 46 which bridges the other respective guide bar. Every thread guide 36, 38 has a catch projection 48 at its back by means of which it engages in a locking groove 50 in the guide bar 32, 34 so as to prevent unwanted detaching of the thread guide. The head part 52 of the thread guides 36, 38 also contains a guide 54 in the form of a guide eye to guide the fed thread 56. As will be seen particularly from FIG. 2, thread guides 36 are connected with the lower guide bar 32 and thread guides 38 are connected with the upper guide bar 34, the thread guides of a group G 1 and G 2 , respectively, being guided along an offset line or racking line 58, 60 in each instance.
The guide bars 32, 34 of each group G 1 to G 7 have a flat construction and are supported by one another. To this end, the lower guide bar 32 contains a cross-piece or web 62 which projects upward in the principle plane of the guide bar and engages in a corresponding groove 64 of the adjacent guide bar 34. The guide bars which move back and forth in their longitudinal direction are supported at their respective ends in a bearing block 66 in order to place the thread 28, 56 in the form of a filling yarn over at least one knitting needle by means of their reciprocating motion. Further, the bearing block 66 executes an up-and-down movement in order to move the thread guides from a position located above the knitting needles 4 into a position below the knitting needles.
The guide bars 24, 32, 34 are driven in a conventional manner, e.g., analogous to the embodiment example in DE-A-30 34 253 which was already cited above.
FIGS. 3 to 5 show another embodiment example of a knitting machine in section. In this case, the guide bars 68, 70 which are arranged in pairs are arranged one above the other but do not contact one another. As will be seen particularly from FIG. 3, the guide bars 68, 70 are again guided in bearing blocks 72 in their end region and are actuated at one side by rocker arms 74 which are swivelable about an axis 76 and are driven by a pattern chain 78. The rocker arms 74 cooperate with end pieces 80 of the guide bars 68, 70 which are tensioned against the rocker arms on the other side of the knitting machine by springs 82. The bearing blocks 72 are again guided and driven so as to move up and down in a manner which is not shown in more detail.
FIGS. 4 and 5 show the guide bars 68, 70 in cross section. FIG. 4 shows the lower thread guide 36 cooperating with the lower guide bar and FIG. 5 shows the upper thread guide 38 cooperating with the upper guide bar 70. Every thread guide contains a locking part 44 cooperating with locking recesses 42 of the associated guide bar 68, 70 and a bridge part 46 which bridges the respective guide bar 70 (FIG. 4) and 68 (FIG. 5) which is not contacted. Every thread guide 36, 38 contains a head part 52 and a rear locking projection 48 which engages in a corresponding locking groove 50 of the guide bar 68, 70. A guide 54 with a guide eye is provided at the head part 52 of the thread guide 36, 38.
With regard to the embodiment examples shown in the drawings it should be added that only some of the guide bars may be arranged in groups if desired. Moreover, the guide bars may be arranged one above the other not only in pairs, but also in groups of three or, in any case, in groups of four guide bars.
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Guide bars (24, 32, 34) with thread guides (26, 36, 38) are arranged above the knitting needles (4). At least one group (G1 to G7) of at least two guide bars (36, 38) which are arranged one above the other is provided to increase the number of possible guide bars and/or to improve the accessibility of the guide bar region. This arrangement is effected in such a way that the thread guides of the guide bars (32, 34) arranged one above the other do not intersect.
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This application is a continuation-in-part of application Ser. No. 323,278 filed Jan. 10, 1973, having the same inventorship and ownership. The technology of the parent application is hereby incorporated herein for reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the roofing and siding art and more particularly to improved interlocking simulated shingle construction.
2. Description of the Prior Art
The conventional types of shingles, such as wood, concrete or clay tiles or asphalt, have generally not proven to be completely satisfactory in all applications. In general, the comparatively small size of the individual conventional shingles requires a comparatively lengthy time for covering an entire roof or wall. Further, such shingles require periodic maintenance in order to maintain them in satisfactory condition. These shingles, of course, have not proven to be effective thermal insulators and normally some other form of packing or insulation material has been utilized in the roof, ceiling or wall structure to provide the necessary thermal insulation.
Therefore, there have heretofore been developed various types of simulated shingles attemtping to solve these problems. For example, conventional wood shingles were utilized on metallic carriers, such as those shown in U.S. Pat. Nos. 3,418,777 and 3,232,020. Such arrangements often require separate elements, such as clips or the like, for complete installation. Utilization of such metallic carriers for holding conventional shingles did little to either decrease the cost of installing a shingle roof or improve the thermal or structural integrity of the shingles.
Other types of roofing or siding structures have incorporated various plastic laminates combined with one or more ridged members for installation as a simulated shingle on roofs or on walls as sidings. In certain of these prior art simulated shingle arrangements the nail heads were exposed to the environment thereby requiring utilization of corrosive resistant steel, or other similar materials resistant to environmental effects, in order to avoid rusting or the like. One such arrangement is shown in U.S. Pat. No. 2,352,236. Such exposed nails or screws detracted from the true simulated shingle structural appearance of the roof or wall. Other U.S. Patents, such as U.S. Pat. Nos. 3,626,439; 3,605,369; 638,802; 3,111,787 and 2,110,579 show various shingle arrangements.
In other simulated shingles the utilization of metallic elements not only increased the cost but required cutting tools, generally not available to the roofer, for sizing the simulated shingle elements to the particular roof or wall being covered. Thus, special saws or shears were required to cut through such metallic elements. Additionally, in utilization of metallic elements the weight of the load on the roof was thereby increased thus increasing the required strength of the supporting structure.
Further, the lower edge of most prior art shingles rested on the top edge of the adjacent course of shingles leaving a void between the sheeting and the shingles, thus resulting in fractures of the shingles and increased fire hazard.
One type of simulated shingle heretofore sold by National Pacific Roofing Products, a Division of Stephan Chemical Company, 8748 Remmet Avenue, Canoga Park California, utilized fiberglass shingle panels which were heavy, expensive and difficult to trim to size and then install in the field. Further, while providing a water tight seal between adacent shingles in the same course, such a seal was not interlocked between adjacent courses resulting often in wind forces loosening an entire panel.
While certain of the prior art simulated shingles have utilized various forms of interlock between simulated shingles in adjacent courses, such interlocks have generally not been of the type allowing a rapid slide fit of one course into the immediately previously installed course. Further, there has been no provision, in general, in prior art simulated shingles for a water tight sealing interlock between adjacent shingles in the same course. In the patent application referred to above a unique improved interlocking shingle construction is provided for simulating a plurality of shingles of foamed plastic and having wood portions and are secured to the sheeting members of a roof. The construction of the herein application is entirely new and unique in that while utilizing, in part, the principle of the prior application, the panels or courses of shingle members made of plastic are now integrated to the boards or wooden members that constitute the sheeting itself of the roof so that in making the construction, that is applying the roof, the shingles are integrated with the sheeting members and become applied at the same time to the roof rafters and are in sealed interlocking relationship both as between parallel courses from the top or ridge pole to the eves. Also, where courses or panels are joined at their lateral ends, they are also sealed. A preferred form of the construction is described in detail hereinafter.
SUMMARY OF THE INVENTION
It is a primary object of the invention to provide an improved integrated shingle and sheeting construction comprised of integrated panels or courses made up of foamed plastic shingle members bonded to a sheeting member or board which is securable to the rafters of a pitched roof.
It is a further object to provide such an improved integrated roof member wherein sealed interlocking relationship is provided between adjacent courses or panel members.
It is another object to provide integrated members as described which are directly attachable in any suitable way on building members such as rafters whereby the roof is completed.
It is a further object to provide a roof contruction as described which is rapidly and easily constructed or installed without special tools or other implements.
It is a further object to realize an integrated product as described which eliminates the need for having separate sheeting members and shingle members to be applied separately and further to provide an integrated product which is extremely inexpensive, easy to fabricate and economical to produce and install or utilize.
These and other objects of the invention are realized in a preferred embodiment as described in detail hereinafter.
In the preferred form the integrated roof member is in the form of an elongated body member preferably molded of a foamed plastic such as polyurethane foam, the body member having upper and lower surfaces, a forward or front surface, a rear surface and a pair of side surfaces similar to these parts of the shingle member of the prior application. The surfaces may be textured to simulate the appearance of shake shingles, or other external roof constructions. The body member of the integrated roof member may be provided with indentations in a spaced relationship to simulate, if desired, known sizes of shingles. In the preferred construction the product is formed from the molded foamed plastic and is bonded directly to the wooden sheeting member normally utilized for constructing a roof. Exposed parts of the foamed plastic are coated with weather proofing coating as described more in detail hereinafter.
Adjacent courses are constructed to have interlocking dovetail or tongue and groove relationship to provide complete sealing along the elongated length thereof as well as on the ends. The courses are formed in panels of various lengths which may be the length of the sheeting member normally nailed to the rafters of a pitched roof.
The integrated members interlock together as described thus simulating shingles, such as shake shingles, from the external view thereof and, as stated, the entire integrated member is nailed directly to the rafters, or to the joists or studs forming the siding of a wall and the attachment or securement can be by way of nails or other suitable securing or bonding means. When the plastic part of the integrated body member is fabricated from a polyurethane foam suitable exterior coating is applied thereon to prevent environmental deterioration due to exposure of the polyurethane foam to the ultraviolate radiation contained in sunlight. All exposed surfaces may be suitably coated with a protective coating during the manufacture of the integrated roof member in accordance with the herein invention. Where it is necessary to trim the integrated roof member to fit a particular installation, the exposed edges may be quickly and easily coated at the job site.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and additional advantages of the invention will become apparent from the following detailed description and annexed drawings wherein:
FIG. 1 is a perspective view of a section of a preferred form of one of the integrated roofing products;
FIG. 2 is a sectional view in the direction from ridge pole towards the eves of adjacent integrated roofing or shingle products in assembled interlocking relationship on a roof;
FIG. 3 is a "side" view of one of the integrated products, that is a view at the end of one of the panels;
FIG. 4 is a view of the upper side, that is the forward side towards the ridge pole of a section of one of the integrated panels;
FIG. 5 is a view of the lower side of two of the integrated panels as installed on a roof;
FIG. 6 is a side view of a preferred form of joining shingle product for purposes of providing joint between adjacent sides of shingle products of the type described in FIGS. 1 through 5;
FIG. 7 is a view of the bottom side of the joining product of FIG. 6;
FIG. 8 is an isometric view primarily of the bottom side of the product of FIGS. 6 and 7; and
FIG. 9 is a sectional view illustrating the joining of two panels of the type shown in FIGS. 1-5 joined together by the joining shingle of FIGS. 6-8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the various figures of the drawings there is illustrated more particularly in FIG. 1 a perspective view of one embodiment of the integrated element or member of the invention generally designated at 10. As shown in the figures this embodiment is an integrated shingle or roofing product which in appearance simulates a shake shingle and has a slant width in the direction of the arrow 12 approximately equivalent to the exposed slant width of a single conventional wood shake shingle as installed. However the slant width may be made to simulate any desired number of shingles. Similarly, the lateral width in the direction of the arrow 13 may be made to simulate any desired number of adjacent shingles in the same course, the lateral width being the elongated dimension of the sheeting member 18. (The term slant width is used to identify the dimension in the direction from the ridge pole to the eves. The arrow 15 identifies the thickness dimension. The top end 20 is the end towards the ridge pole and the bottom end 22 is the end towards the eves. The lateral width identifies the dimension in the direction of the arrow 13 although this dimension may also be identified as length since the integrated product is constructed in panels of desired length.)
As may be seen in the drawings each of the integrated panel elements or members comprises a foamed plastic layer or panel that is designated at 16 which is secured by bonding to a wooden sheeting member or board 18, these parts having a configuration as may be seen in the sectional view of FIG. 2. As explained the product may be constructed in the form of elongated panels and in the drawings the top end of the panel is designated at 20 as may be seen in FIG. 4, the bottom end is designated at 22 as may be seen in FIG. 5.
The sheeting member 18 which attaches to the rafters of the building or the side members, that is the studs, is of well known design and is a flat member as shown which at the upper forward side 20 is cut away to form a shoulder shown at 28 and is cut away to form a shoulder at the lower side as designated at 30. The foamed plastic element 16 is bonded to the sheeting member 18 along the surface thereof as designated at 32. The foamed plastic element has a cross-sectional configuration as shown in FIGS. 2 and 3 having a slanted upper surface 34, top end surface 35 having an undercut 36 as shown and having a bottom end surface 37 with an undercut 38 providing a further surface 39 to define a lower overhang or tongue as shown. FIG. 2 illustrates the application of the integrated members to the rafters 49 of a pitched roof, and the line 50 designating the angle or line of the rafters to which the integrated roof members can be attached in any suitable manner such as by nails 53, or by bonding or otherwise. The nails 53 are driven through the end portions 18' and 18" of the sheeting 18 (as shown in FIG. 1) and into the rafters 49. Thus, the preferred lateral width in the direction of the arrow 13 of each panel 10 is the rafter 49 spacing, or an even multiple thereof. For example, the panels 10 may be 8 ft., 10 ft., 12 ft., or the like, depending on rafter spacing. The edges 18a and 18b may be positioned along the center line of the rafters to allow the next adjacent panel to be similarly positioned. The nails 53 are driven only through the sheeting 18 and not through the plastic layer 16 thus avoiding damage to the plastic layer 16 which could lead to environmental deterioration, loss of waterproofing, or the like.
The end portions 18' and 18" of adjacent panels 10 are covered and sealingly interconnected by a separate member, as described below in connection with FIGS. 6, 7, 8, and 9. Since the nails 53 are thus covered, no rust streaks or the like will occur.
FIG. 1, which is a perspective view, shows the top surface of one of the integrated panels illustrating the configuration of the end parts of one of the panels 10 according to the present invention showing the plastic layer 16 as bonded to the sheeting member 18. As may be seen, the sheeting member 18 in FIG. 1 extends beyond the lateral end walls 16a and 16b of the foamed plastic element 16 to form the end portions 18' and 18", respectively.
The plastic layer 16 is provided at each end of the panel 10 with substantially identical lateral end sealing means 16' and 16" as shown in FIG. 1. Numeral 52 designates a lateral end surface; numeral 51 designates a top surface; and numeral 55 an upstanding sealing ridge. The lateral end sealing means 16' and 16" as well as end portions 18' and 18" are covered by the connecting structure as described below. All exposed surfaces of foamed plastic are coated with a suitable coating to protect from ultraviolet rays and/or other environmental conditions as described.
To simulate a shake shingle, the foamed plastic 16 may be separated, that is provided with grooves running in the slant direction, on the upper surface 34 of the shingle simulating section 16" of the foam plastic layer 16, one of which is designated at 62 in FIGS. 1 and 4. The grooves may be of any desired cross-sectional shape, either rectilinear or wedge shaped as shown, and spaced apart throughout the width of the panel 10 in approximately one shingle spacing.
FIG. 2 shows a sectional view of the integrated members 10 and 10' in interlocking sealing relationship on a rafter 49 of a roof. It may be seen that the juncture or joint between panels in adjacent courses of integrated members is a tongue in groove type joint whereby effective sealing and waterproofing is realized. This type of joint is described in greater detail in the above-identified co-pending patent application. Shoulders 28 and 30' of the sheeting elements come together in the conventional abutment position of such sheeting members, as shown, whereas the overhang defined by topend surface 35 and undercut 36 of the foamed plastic part 16 of the member 10 overlaps into the space between bottom end surface 37' and undercut 38' and sheeting portion 18c' of panel 10'.
At the position of the eves preferably a starting member 70 may be provided, as in the parent application, and is shown in broken lines in FIG. 2. This starting member may be fabricated similarly to the panels 10 in the same lengths and may be directly attached to the rafters of the roof in the same manner as the panels 10. Starting member 70 has a cross-sectional configuration as shown having shoulders which interfit with the lower end 37 shoulder 39 of the plastic element 16 and the shoulder 30 of the wood member 18 and the overhang or lower surface 38 of the plastic member 16. As previously described the integrated members 10 may be constructed in elongated courses or panels of predetermined length which may have a configuration at each end as illustrated in FIG. 1. FIG. 5 illustrates the positioning of two adjacent panels 10 and 10' prior to the installation of the connecting member described in FIGS. 6 through 9.
As shown in FIG. 5 the panels 10 and 10' are nailed to the rafters 49 with the edges 18a and 18b at the center thereof. The spacing "A" between the walls 16a and 16b and the corresponding walls of the adjacent panels 10' is approximately the lateral length of a single shingle. As described below, the connecting member is positioned between the panels 10 and 10' to provide a sealing relationship therewith. The spacing "A" is slightly greater, in preferred embodiments than the lateral length of a shingle to allow a space between each connecting member and the walls 52 to simulate the spacing between shingles.
Preferred coatings for the foamed polyurethane that may be exposed to sunlight may be coatings such a polyester, adhesive, aggregate mixture, polyvinyl chloride, polyetheylene, vinyl weather resistant coating or the like. These coatings may be applied at the forming of the integrated product and also may be quickly applied at the job site during installation on exposed portion that may be cut in providing coverage on a given size roof. If desired, the striations and grooves may be provided in order to closely simulate the appearance of shake shingles. This appearance is accentuated by desirable positioning of the grooves 62.
It will be observed, of course, that the integrated product is tapered in the thickness direction designated by the arrow 15 in FIG. 1. The foamed plastic element 16 is in contact with and bonded to the wooden member 18 throughout the areas of contact therebetween. In the construction as shown in FIG. 2 wherein the integrared members are applied to a pitched roof building having a ridge pole or peak, a ridge construction member (not shown) may be provided similar to that of the above identified co-pending patent application.
In the structure as described and as illustrated in FIG. 5 as can be seen, side parts of the panels are constructed substantially identical, and in preferred embodiments, all shingle product panels are constructed alike, that is, being uniform with the configuration at the sides being the same. For purposes of joining and sealing the panels, a separate joining shingle is provided to form the joint between adjacent shingles. Such a joining product is illustrated in FIGS. 6, 7, 8 and 9. FIG. 6 shows a preferred cross-sectional configuration of such a connecting member or joining product generally designated 79 that can be used.
In the construction of the connecting member 79 in FIGS. 6 through 9 the foamed plastic part of the article is designated at 80 and in this product on the underside there is a relatively thin layer of wood, hardboard, plastic, or other rigid material such as the wood plate designated at 82. As in the previous embodiments the exterior of the foamed plastic is coated with an appropriate coating material as designated at 84. The bottom edge 86 is aligned with the edges 37 of the panels 10 when installed and the forward portion 88 overlaps the forward end 20 of the panel 10 in the next course, the projecting portion 82' of the wood plate 82 underlying the undercut 36 thereof to provide an interlocking connection therebetween. The wall 87 abuts the wall 35 of the panel 10 in the next course towards the eves and the top end 89 underlies the surface 38 of the lower portion 22 of the panel 10 in the next course towards the ridge pole with the surface 91 abutting the surface 39 thereof.
On the bottom side 93 of the connecting member 79, as shown in FIG. 7 there are formed shallow depressions extending lengthwise of the product as designated at 92 and 92' and then inwardly of these depressions are deeper straight sided depressions as designated at 94 and 94' which have lateral parts as designated at 96 and 96'.
FIG. 9 is a sectional view illustrating how the product of FIGS. 6 through 9 is adapted to join between the side edges of adjacent panels 10 and 10' as shown in FIG. 5, the adjacent panels being identical and each individual one have the same constructional configuration along both sides or side edges.
FIG. 9 shows panels 10 and 10' adapted to form a joint with the connecting member 79 of FIGS. 6 to 9. The transverse extending portion of the ridges 55 and 55' extend into depressions 94 and 94' and the laterally extending portions thereof extend into lateral parts 96 and 96'. The shallower depressions 92 and 92' overlay the surfaces 51 and 51' to effect a weaterproof joining therebetween. While the connecting member 79 is firmly retained by the panels 10 in the adjacent courses, nails may be utilized to secure the member 79 by nailing in the portion 89.
From the foregoing it can be seen that all of the products of the type illustrated in FIGS. 1 through 5 can be constructed to be exactly alike and where it may be necessary to make lateral joints, joints can be made by way of the product as described in FIGS. 6 through 9.
The foregoing disclosure is representative of a preferred form of the invention and is to be interpreted in illustrative rather than a limiting sense the invention to be accorded the full scope of the claims appended thereto.
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An integrated shingle construction in which shingles are constructed perferably of foamed plastic primarily, the construction being in the form of panels in which the foamed plastic shingle is integrated with a board or wooden roofing member such as a standard sized sheeting member that attaches directly to the rafters. The integrated shingle and sheeting members are applied in courses to a pitched roof, for example, the first course being at the top or adjacent the ridge pole and then proceeding downwardly to the eves. Adjacent courses are in interlocking sealing interconnection. The integrated shingle and sheeting members are formed in extended panels with the shingle portion simulating a plurality of individual shingles. Sealing and interconnecting or joining means are provided to sealingly join panel courses at their ends.
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FIELD OF THE INVENTION
This invention relates to image proofing systems, more particularly to a proofing apparatus and a proofing head assembly used to prepare color correct samples of printed materials.
BACKGROUND OF THE INVENTION
In the printing industry, it is common to provide a sample of an image to the customer for approval prior to printing a large number of copies of the image using a high volume output device such as a printing press. The sample image is known as a “proof”. The proof is used to ensure that the consumer is satisfied with the contents, composition and color gamut and tone characteristics of the image.
It is not, however, cost effective to print the proof using high volume output devices of the type used to print large quantities of the image. This is because it is expensive to set up high volume output devices to print an image. Accordingly, it has become the practice in the printing industry to use digital color printers to print proofs. Digital color printers render color prints of images that have been encoded in the form of digital data. This data includes code values indicating the colors to be printed in an image. When the color printer generates the printed output of an image, it is intended that the image recorded on the printed output will contain the exact colors called for by the code values in the digitally encoded data.
In practice, it has been found that the colors in the images printed by digital color printers do not always match the colors printed by high volume output devices. One reason for this is that variations in ink, paper and printing conditions can cause a digital color printer to generate images with colors that do not match the colors produced by a high volume output device using the same values. Therefore, a proof printed by a digital color printer may not have colors that match the colors that will be printed by the high volume output device.
Accordingly, digital color printers have been developed that can be color adjusted so that they can mimic the performance of high volume output devices. Such adjustable color printers are known in the industry as “proofers”. Two types of adjustments are commonly applied to cause proofers to produce visually accurate proofs of an image: color calibration adjustments and color management adjustments.
Color calibration adjustments are used to modify the operation of the proofer so that the proofer prints the colors called for in the code values of the images to be printed by the proofer. These adjustments are necessary to compensate for the variations in ink, paper and printing conditions that can cause the colors printed by the proofer to vary from the colors called for in the code values. To determine what color calibration adjustments must be made, it is necessary to determine how the proofer translates code values into colors on a printed image. This is done by asking the proofer to print a calibration test image. The calibration test image consists of a number of color patches. Each color patch contains the color printed by the proofer in response to a particular code value. The stand-alone calibration device measures the colors in the test image. The color of each color patch is compared to code values associated with that patch and the comparisons are used to determine what adjustments must be made to the proofer to cause the proofer to print desired colors in response to particular color code values.
Color management adjustments are used to modify the operation of the proofer so that an image printed by the proofer will have an appearance that matches the appearance of the same image as printed by a high volume output device. The first step in color management is to determine how the high volume output device converts color code values into printed colors. This is known as characterization. To characterize a high volume output device it is necessary to obtain a characterization test image. The characterization test image can be printed by the high volume output device. However, if it is known that the high volume output device converts code values into printed colors in accordance with an industry standard proofing system such as MatchPrint ™ or Cromalin ™, then a test image printed in accordance with that standard can be used for characterization purposes.
In either case, the characterization test image is submitted to the stand-alone color management device. The color patches on the characterization test image are compared to the color code values associated with the patches. This comparison is used to determine the adjustments that must be made to cause the proofer to print images having the same color gamut and tone characteristics as the images printed by the high volume output device. The proofer is then adjusted accordingly.
In this manner, the proofer is adjusted so that the proofer is properly calibrated to render images having the colors called for in the code values in the image to be proofed and is also adjusted to modify the code values in the image to be proofed in accordance with the profile for the output device. Thus, the proofer renders images having the colors that will appear the same as the colors in the images printed by output device.
It will be recognized that both calibration adjustments and color management adjustments are based upon objective measurements of the color gamut and tone characteristics of the test images printed by the proofer and by the high volume output device.
Various devices are used to measure the color content of an image. The most common devices are the densitometer and the color scanner. These devices typically analyze the color content of the light reflected by an image by dividing light into a set of primary colors, such as red, green and blue. These devices divide light into primary colors by passing the light through a set of colored filters. By measuring the intensity of the light in each primary color, it is possible to objectively measure the color content of an image.
A special form of densitometer, the colorimeter, can also be used to objectively measure the color gamut and tone characteristics of an image. Colorimeters are designed to objectively measure the color of a sample in a way that approximates human visual response. This is accomplished by the use of filters that are chosen to mimic human visual response.
A more accurate device for measuring color for calibration and color management purposes is the spectrophotometer. The spectrophotometer measures the reflectance or transmittance of an object at a number of wavelengths throughout the visible spectrum. More specifically, a spectrophotometer exposes a test image to a known light source and then analyzes the light that is reflected by the test image to determine the spectral intensity of the sample. A typical spectrophotometer is capable of measuring a group of pixels in an image and includes an apparatus that measures the light that is reflected by a portion of an image at a number of wavelengths throughout the visible spectrum to obtain data that reflects the true spectral content of the reflected light. Because the spectrophotometer measures color with greater accuracy than do the other measurement devices discussed above, the spectrophotometer is preferred.
Thus, densitometers, colorimeters, color scanners, and spectrophotometers can be used for color measurement. However, these are typically stand-alone devices and the use of such devices during proofing is very costly. Part of this cost is created by the inherent redundancy of many of the systems used in these devices. For example, a stand-alone spectrophotometer, has an “X-Y” table to move the test image relative to the spectrophotometer. A digital color printer or proofer also contains an “X-Y” displacement mechanism for moving the paper and printing element or printhead. Similarly, both the spectrophotometer and the proofer contain separate electrical control systems, motors and other components. Thus, the total cost of the proofing system including a separate stand-alone color measurement device and a proofer is high and can be in excess of more than U.S. $10,000.00.
Installation and maintenance costs are also high because two separate devices, typically manufactured by different vendors, must be separately purchased, installed, and maintained. Finally, there is a significant labor cost associated with making calibration and color management adjustments to the proofer using a stand-alone color measurement device.
Accordingly, there are substantial cost and efficiency penalties associated with stand-alone proofing combinations and what is needed is an integrated proofing apparatus.
Special printers having integrated color scanners or densitometers for color calibration purposes exist. Examples of color calibration and correction systems of this type can be found in commonly assigned U.S. Pat. Nos. 5,053,866, and 5,491,586. These patents show specially designed printing systems for generating a color image and adjusting the color content of subsequent images based upon the colors printed in the color image. However, these specially designed systems also use redundant structures for printing and color measurement and do not teach or suggest color management capabilities.
It will also be recognized that many high quality color digital printers exist. However, these printers are not designed with integral proofing capabilities. Thus, what is also needed is a proofing head having calibration and color management capabilities and that can be readily integrated into an existing printer.
Accordingly, it is an object of the present invention to provide a proofer that is low in cost and is easily maintained.
It is also an object to provide a proofer that substantially automates the proofing process.
It is also an object of the present invention to provide a proofing head that can be readily incorporated into a printer of conventional design to permit the printer to act as a proofer.
SUMMARY OF THE INVENTION
The present invention resides in a proofing printer for generating a proof and a proofing head assembly. The proofing head assembly comprises a color light analyzer and a color printhead joined by a housing that directs the color light analyzer and the printhead at a media. A controller is provided to drive the color light analyzer to make color measurements of an image and to instruct the printhead to render images on a receiver media. The controller can adjust the colors printed by the printhead so that an image printed by the printhead will match the appearance of the same image as printed by another output device. The proofing printer assembly of the present invention combines the proofing head with a media advance and translation mechanism. Certain embodiments of the proofing printer self-calibrate and automatically characterize another output device. One embodiment of the proofing head of the present invention is adapted to be incorporated into color printers without color calibration and color management capabilities.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a drawing of the proofing process using a stand-alone color measurement device according to the prior art.
FIG. 2 shows a schematic diagram of a proofer of the present invention.
FIG. 3 shows an expanded view of the proofer of FIG. 1 with various components exhibited in cross section.
FIG. 4 shows a detailed view of a portion of the proofer of FIGS. 2 and 3 .
FIG. 5 shows a diagram of another embodiment of the present invention.
FIG. 6 shows an embodiment of the proofing head of the present invention for use with a conventional printer.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a drawing of the proofing process using a stand-alone color measurement device according to the prior art. The process of making calibration adjustments to the proofer 10 begins when the proofer 10 renders a calibration test image 16 . Calibration test image 16 contains a multiplicity of color patches 17 . Each of color patches 17 contains the color printed by proofer 10 in response to a particular color code value. The color content of the color patches 17 of test image 16 are measured using stand alone color measurement device 12 . The color measurements are compared to the code values associated with the color patches 17 . A set of calibration adjustments is determined using these comparisons. The operation of the stand-alone proofer 10 is then adjusted so that the stand-alone proofer 10 renders a proof having the colors called for in the color code values for the proof.
The process of making color measurement adjustments to proofer 10 begins by obtaining a characterization test image 18 . Characterization test image 18 is printed by high volume output device 14 or otherwise printed in accordance with a standard color proofing system such as MatchPrint ™. Characterization test image 18 also contains a set of color patches 19 . Each of color patches 19 is associated with a color code value. The location of each of patches 19 on characterization test image 18 are defined by convention or by an industry standard e.g. American National Standards Institute standard IT8.7/3.
Characterization test image 18 is submitted to color measurement device 12 . The color content of color patches 19 are measured and compared to the color code values associated with color patches 19 . Comparison of the color code values to the colors printed in color patches 19 forms the foundation for building a mathematical model that predicts the color that high volume device 14 will print as a function of input code values. This mathematical model is inverted to allow prediction of image code values as a function of colorimetric values. These two mathematical models relating code values to the color output of high volume output device 14 comprise the primary elements in what is known as a device profile. The device profile for high volume output device 14 is used to adjust proofer 10 to convert the code values in the image to be proofed into modified code values. Proofer 10 prints the proof using the modified code values.
It will be appreciated that substantial operator involvement is required to make calibration and color management adjustments using the stand alone devices. For example, an operator using a stand-alone color measurement device 12 is required to cause the high volume output device 14 to print test image 18 . The operator must then wait for the test image 18 to be printed and convey test image 18 from the high volume output device 14 to the stand-alone color measurement device 12 . The operator must then insert the characterization test image 18 into the color management device 12 to initiate the color measurement. Then the operator must wait for stand-alone color measurement device 12 to complete making the color measurements. Finally, the operator must adjust proofer 10 using the information from stand-alone color management device 12 to determine the adjustments that must be made to the proofer and to make those adjustments.
FIG. 2 shows a proofer 26 according to a preferred embodiment of the present invention. Proofer 26 comprises a proofing head 50 having a color light analyzer 20 , a color printhead 56 and a housing 40 which joins light analyzer 20 to printhead 56 . Printhead 56 may use any of several known technologies, such as, for example, ink jet, laser, impact, etc.
Housing 40 can comprise any of a box, closed frame, continuous surface or any other enclosure defining an interior chamber 41 . In the embodiment of FIGS. 2 and 3 , housing 40 comprises a housing that holds both color light analyzer 20 and printhead 56 . Housing 40 directs printhead 56 so that a donor material such as an ink 52 ejected by printhead 56 is directed onto media 30 . Housing 40 also directs the light analyzer 20 so that it receives light reflected by media 30 .
The proofing head 50 is advanced along an X-axis by a translation unit 60 . In the embodiment shown in FIG. 2 , translation unit 60 comprises a motor 62 and a belt 64 . Belt 64 is aligned along an X-axis relative to the media and supported at one end by a freely rotating support pinion 66 and a drive pinion 68 . Drive pinion 68 is operated by motor 62 . Housing 40 of proofing head 50 is fixed to belt 64 and moves in accordance with the motion of belt 64 . Y-axis displacement of media 30 relative to proofing head 50 is provided by media advance 70 . Media advance 70 can comprise any number of well-known systems for moving media 30 within a printer including but not limited to a motor 72 driving pinch rollers 74 , a motorized platen roller (not shown). Of course, other mechanical arrangements may be used to provide relative translation of proofing head 50 and media 30 .
A controller 80 is provided and, as will be discussed in greater detail below, controller 80 drives the operation of printhead 56 , light analyzer 20 , translation unit 60 , and media advance 70 during calibration, color management and printing operations. Controller 80 can comprise any of a programmable digital computer, a programmable logic controller, a series of electronic circuits or a series of electronic circuits reduced to the form of an integrated circuit.
FIG. 3 shows another view of proofer 26 with proofing head 50 shown in partial cross section. As is seen in this view, housing 40 comprises an interior chamber 41 that contains both color light analyzer 20 and printhead 56 . An opening 42 in housing 40 permits ink 52 to flow from printhead 50 during printing operations to form an image on a media 30 positioned in a media plane 37 .
Opening 42 in housing 40 also permits light to pass between a media 30 positioned in a media plane 37 and color light analyzer 20 during color management and calibration operations. In one embodiment, housing 40 directs the printhead 56 so that ink ejected by the print head flows onto one portion of a media. In this embodiment, the housing 40 directs the color light analyzer to collect light reflected by a second portion of the media 30 . The first portion is adjacent to the second portion. However, in an alternative embodiment the first and second portion are separate.
Printhead 56 preferably comprises ink jet nozzles 54 for ejecting colored ink droplets 52 onto media 30 . In such a design, colored ink is supplied to the printhead 50 by a suitable reservoir (not shown). Printhead 56 may be caused to eject droplets of ink 52 by a thermal mechanism or by an electro-mechanical mechanism. Printhead 56 may also use continuous ink flow technology.
Color light analyzer 20 preferably includes a light source 22 that emits a light beam 24 having a known spectral composition. Light beam 24 is directed at media 30 and is reflected by the media. Color light analyzer 20 receives the reflected light via sensor 28 . The color content of the reflected light is then measured and a signal representing the color content is transmitted from color light analyzer 20 to controller 80 . The color light analyzer 20 can be a densitometer, calorimeter, color scanner or spectrophotometer. In the embodiment of FIG. 3 , color light analyzer 20 comprises a spectrophotometer.
The process of making calibration and color management adjustments to proofer 26 will now be described with reference to FIGS. 2 and 3 .
In the first step of the calibration process, controller 80 causes media advance 70 to position media 30 into position for printing. Controller 80 then accesses an electronic representation of a test image used for calibration. This electronic representation is stored in a controller memory 82 . This electronic representation contains particular code values defining the colors to be printed at particular X-Y positions on media 30 to form test image 32 . Alternatively, the electronic representation of test image 32 to be used for calibration can be stored on a device such as a data disk (not shown) or a computer network (not shown) and accessed by way of communication interface 84 . Controller 80 positions printhead 56 at particular X-Y coordinates on media 30 by the action of translation unit 60 and media advance 70 . The controller 80 causes printhead 56 to eject ink droplets 52 to form the color patches 34 on the test image 32 in accordance with the code values in the electronic representation of the calibration test image 32 .
In the second step of the calibration process, controller 80 actuates the media advance 70 and translation unit 60 so that the color light analyzer 20 can scan each of the color patches 34 . The color light analyzer 20 measures the spectral reflectance of each of the patches 34 . Controller 80 receives the measurement data from each of the color patches 34 . Controller memory 82 contains code values associated with each of the patches of the characterization test image. Controller 80 then compares the color measured at each of patches 34 against the color code values associated with each of patches 34 . From this comparison controller 80 then determines the adjustments that must be made to cause printhead 56 to generate a particular color on media 30 . Controller 80 then makes the calibration adjustments so that the printhead 56 renders images having the colors associated with the code values for the images.
Color management adjustments are made to the operation of proofer 26 using a characterization test image (not shown). The characterization test image can be printed by the high volume output device or printed in accordance with a standard color proofing system. In either case, the characterization test image contains a number of color patches with each patch associated with a particular code value. The characterization test image is inserted into the media advance 70 . Controller 80 then advances the color light analyzer 20 to each of the color patches and measures the color of each patch.
Controller memory 82 contains code values associated with each of the patches of the characterization test image. The colors measured at each of the patches by color light analyzer 20 are transmitted to controller 80 and compared to the code values associated with the patches. Controller 80 uses these comparisons to build a device profile that predicts how the high volume output device will convert code values to colors on a printed image. Controller 80 then makes the color management adjustments in accordance with the profile.
To print the proof using proofer 26 , the data representing an image, Ir, to be proofed is provided to interface 84 which converts this data into a form that is usable by controller 80 . Controller 80 receives this data and modifies this data to reflect calibration adjustments and profile adjustments. Controller 80 then transmits printing instructions to the printhead 56 in accordance with the adjusted data so that so that an image printed by the printhead 56 will visually match the appearance of the same image as printed the high volume output device.
It will be understood that it is also possible to accomplish the same result by using the calibration data and color adjustments to modify the way in which controller 80 transforms color code values into printing instructions or by using calibration and color management adjustments to modify the way in which the printhead 56 transforms printing instructions into the release of ink 52 .
It will also be understood that the time required to perform color calibration measurements can be reduced by using color light analyzer 20 to measure the color patches 34 of test image 32 during the printing of test image 32 .
Accordingly, both calibration and characterization of the proofer 26 is accomplished in the present invention with greatly reduced operator involvement and equipment cost as compared to the stand-alone color proofer arrangement of FIG. 1 .
FIG. 4 shows a detailed embodiment of controller 80 of the present invention. In this embodiment, independent processors are used for image processing ( 120 ), color management ( 130 ), calibration ( 150 ), and control purposes ( 160 ). Each of the independent processors of FIG. 4 can comprise any of a programmable digital computer, a programmable logic controller, a series of electronic circuits or a series of electronic circuits reduced to the form of an integrated circuit. It will readily be understood that it is possible to practice the present invention using other combinations of processors and electrical circuits to perform the required functions.
In the embodiment of FIG. 4 , a media advance 70 and translation unit 80 , as generally described above, are provided for maneuvering proofing head 50 and media 30 . Controller 160 operates media advance 70 and translation unit 60 to position the proofing head 50 at particular X-Y co-ordinates relative to media 30 .
To make calibration adjustments, a test image 32 is generated by the proofer 26 . Controller 160 maneuvers color light analyzer 20 into position to measure the color content of the color patches 34 of calibration test image 32 . The measurements are provided to a color calibrator 150 . Color calibrator 150 calculates color density at particular patches 34 and compares these densities to the color densities that the printhead 56 was instructed to print. From this, the color calibrator 150 generates a calibration look up table (CaLUT). The CaLUT correlates color code values in the electronic image data to the color code values that must actually be used during printing to cause the printhead 56 to generate the desired colors in the printed image. During printing, color calibrator 150 modifies the code values in the data representing the image to be printed in accordance with the CaLUT.
To make color management adjustments, a characterization test image (not shown) having color patches printed by the high volume output device or printed in accordance with an industry standard, is inserted into the media advance 70 . Controller 160 causes media translation unit 60 to color light analyzer 20 into positions to measure color content of the color patches of the characterization test image. The measurements are provided to color image processor 130 . Color image processor 130 generates a color profile of the data measured from the test image using one or more profiling techniques known in the art. Examples of software embodying these techniques include CompassProFile ™ software sold by Color Savvy Systems, Ltd. of Springboro, Ohio, and KODAK COLORFLOW ICC Profile Editor sold by Eastman Kodak Company of Rochester, N.Y. The profile takes the form of a three or four dimensional Look Up Table (ChLUT), depending upon the number of color channels in the image. The color image processor 130 can comprise a trilinear or quadlinear interpolation processor (not shown) to modify the color code values in the electronic data representing an image in accordance with the ChLUT.
During proofing operations, electronic data representing the image to be proofed is transmitted to the proofer 26 . This data, Ir, is accepted by the proofer 26 by way of an image source 110 . Image source 110 can comprise any convenient interface for accepting Ir from an external source and making Ir available for processing and printing by the proofer 26 . Image source 110 can include systems for receiving and decoding magnetic or optical disk drives and flash memory cards. Image source 110 can also include systems for receiving electronic signals from computers, computer networks, and other devices. These signals may take the form of raster image data, outline image data in the form of a page description language or other forms of digital representation.
Image source 110 is coupled to an image processor 120 that converts the image data Ir from image source 110 into a pixel-mapped page image Ipm. Color image processor 130 processes the pixel-mapped image Ipm, using the ChLUT to form a processed image Ip. This modifies the image, Ip, so that the color gamut and tone characteristics of the code values in the processed image Ip match the color gamut and tone characteristics of the output of the high volume output device that has been profiled. After processing, the processed image Ip is stored in memory 140 until the processed image, Ip, is needed for printing.
To print the proof, processed image Ip is fed from memory 140 to previously mentioned calibrator 150 . Calibrator 150 modifies the processed image Ip using the CaLUT to produce a calibrated image Ic. This calibrated image Ic is then fed to the printer controller 160 . Printer controller 160 determines, from this data, the colors to be used in the image, and where these colors are to be deposited on a receiver media 30 . Controller 160 advances the printhead 56 and media 30 to any X-Y coordinate by operation of the translation unit 60 and media advance 70 . Printer controller 160 then applies a time-varying electrical pulse to the printhead 56 to eject a combination of ink droplets 52 from printhead 56 in accordance with the calibrated image Ic.
The proofer 26 of FIG. 4 , therefore, modifies image data twice before printing: once to ensure that the colors of the printed image properly reflect the calorimetric characteristics of a high volume output device and once to ensure that the printhead 56 creates the desired colors on a particular receiver media 30 .
It will also be appreciated that proofer 26 can be configured to automatically execute both calibration adjustments and color management adjustments with a minimum of operator involvement. In the system shown in FIG. 5 , the media advance 70 can be supplied by a media supply source such as a tray 78 . Tray 78 is configured to contain more than one sheet of media 30 , and to supply the media 30 to the media advance 70 in an orderly fashion. With this arrangement, a user can insert a receiver media 30 and a second media 31 having a test image 33 printed by a high volume output device into the tray 78 . Controller 80 is programmed to execute both calibration and color management adjustments using these images. After calibration and color management adjustments, the proofer 26 is ready to generate a visually accurate proof.
It will be understood that printing conditions can change during the printing of the proof. These changes can alter the color content of an image printed by printhead 56 on a receiver media 30 . To prevent this, proofer 26 of the present invention can be configured so that the light reflecting from colors printed by printhead 56 on a media 30 is measured by the color light analyzer 20 during printing. Controller 80 can then make printer calibration adjustments in response to real-time color measurements.
It will also be understood that circumstances may arise wherein the printhead 56 cannot be made to print the desired colors on the media 30 . For example, this can occur because a supply of an ink is exhausted or because the printhead 56 is clogged or damaged. In such circumstances, no adjustment of the calibration can compensate for the problem, thus, controller 80 can be programmed to stop printing or to provide the user with a warning that calibration errors occurred during printing. This warning can comprise a written warning printed on the image, an interruption of the printing process or other forms of aural or visual notification.
As is shown in FIG. 6 , one particularly valuable application of the proofing head 50 of the present invention is for a proofing head 50 that can be installed into a conventional printer 200 , having a predefined printhead mounting area 210 . Printer controller 212 controls the operation of printer media advance 230 and printhead translation unit 220 . An electrical connection 214 is also defined between printer controller 212 and printhead mounting area 210 to allow the printer controller 212 to govern the operation of a conventional printhead to 216 (not shown). Media advance 230 comprises a media roller 232 and pinch roller 234 . A motor 236 drives the operation of roller 232 to advance a sheet of media 240 along a Y-axis. Translation unit 220 can movably position the mounting area 210 relative to the media along an X-axis by rotating drive pinion 268 to drive belt 264 and pinion 266 . The printer 200 operates as does any conventional printer and, does not have any inherent structure for performing calibration or characterization operations.
Proofing head 50 is installed in the predefined printhead mounting area 210 . To accommodate this, housing 40 is shaped to fit into printhead mounting area 210 . In this embodiment, housing 40 comprises an inner chamber 41 that contains controller 80 , printhead 56 and color light analyzer 20 . In this embodiment, the controller 80 is electrically connected to controller 212 by way of the electrical connection 214 . In this manner, the printing instructions transmitted by the printer controller 212 are received by the controller 80 of the proofing head 52 .
Once installed into the printhead mounting area 210 , proofing head 50 is used to execute printer calibration and characterization adjustments. In this respect, controller 80 of proofing head 50 is connected to printer controller 212 to cause printer controller 212 to operate translation unit 220 and media advance 230 to allow for the creation of a calibration test image and to allow for the color measurement of calibration and characterization test images as generally described above. Alternatively, printer 200 can be connected to an external computer 250 , which directs printer controller 212 to maneuver proofing head 50 to particular locations in order to allow the proofer to perform calibration and characterization operations, as generally described above.
During printing, the printer controller 212 transmits printing instructions to controller 80 . Controller 80 modifies the printing instructions in accordance with color calibration and color management adjustments so that an image printed by printer 200 will have the same visual appearance as the same image when printed by a high volume printer or output device. In one embodiment of the present invention, controller 80 uses color light analyzer 20 to ensure that the colors that are printed by printhead 56 onto a media 240 during printing match the colors that the controller 80 has instructed the printhead 56 to print. If these colors do not match, controller 80 modifies the operation of the printhead 56 .
Thus, as is shown and described, the proofing head 56 can be incorporated into a conventional printer to provide calibration and proofing capabilities to such a printer 210 without substantial modification to the existing printer design.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
PARTS LIST
10 stand-alone proofer
12 stand-alone color measurement device
14 high volume output device
16 calibration test image
17 color patches
18 characterization test image
19 color patches
20 color light analyzer
22 light source
24 light beam
26 proofer
28 sensor
30 media
31 second Media
32 calibration test image
33 characterization test image
34 color patches
37 media plane
40 housing
42 opening in housing
50 proofing head
52 ink
56 printhead
60 translation unit
62 motor
64 belt
66 support pinion
68 drive pinion
70 media advance
72 motor
74 pinch rollers
76 media supply source
78 tray
80 controller
82 controller memory
84 controller interface
110 image source
120 image processor
130 color image processor
140 image memory
150 color calibrator
160 printhead controller
200 conventional printer
210 predefined printhead mounting area
212 printer controller
214 electrical connection
216 conventional printhead
220 translation unit
230 media advance
232 media roller
234 pinch roller
236 motor
250 conventional computer
264 belt
266 support pinion
268 drive pinion
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The present invention discloses a proofing head apparatus and a proofing printer for generating a proof. The proofing head assembly comprises a color light analyzer and a color printhead joined by a housing to align the color light analyzer and to direct both the printhead and the color light analyzer at a media. In certain embodiments a controller is provided to drive the color light analyzer to make color measurements of an image and to instruct the printhead to render images on a receiver media. The controller can adjust the colors printed by the printhead so that an image printed by the printhead will match the appearance of the same image as printed by another printer. The proofing printer assembly of the present invention incorporates the proofing head with a media advance and translation mechanism.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to specialized carrier or transport devices, and in particular to a belt clip support mechanism for a hand-carried rigid container, such as an infant carrier seat or similar device for transporting the device from one location to another.
[0002] One type of common infant carrier ( FIG. 1 a ) uses a rigid handle that attaches to the sides of the carrier and forms an arch above the carrier with a handgrip centered above the infant. This type of carrier is frequently combined with a base unit strapped to a car seat to form a combination car seat carrier. The handle for these carriers is perpendicular to the baby's body making it awkward to carry at the user's side. Because of the handle's orientation, the user's arm is twisted so the palm faces either forward or backward placing a strain on the elbow. Furthermore, the width of the carrier forces the hand to be held away from the body, increasing the strain on the elbow, shoulder, and back ( FIGS. 1 b and 1 c ). The weight of the baby plus the weight of the carrier would typically be in the 15 to 25 lb range. This requires substantial strength by the user and is only practical for a limited duration. A hand-carried basket found in grocery stores is a similar carrier device with similar problems. A device is needed to shift the weight to the hip region to reduce the strain on the arm and back while transporting the loaded carrier.
SUMMARY OF THE INVENTION
[0003] In a preferred embodiment, the present invention provides a simple and easily manufactured device to help support the weight of an infant carrier, grocery basket, or similar rigid carrier. The device clips on to a belt and has a hook-like protrusion upon which a lip of the carrier rests. Below the hook is a support cross member to further distribute the weight by pressing against the user's hip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The accompanying drawings illustrate by way of example the principles of the invention.
[0005] FIG. 1 a shows a typical infant carrier.
[0006] FIG. 1 b shows a typical infant carrier in the transport position.
[0007] FIG. 1 c is a oblique view of a typical infant carrier in the transport position.
[0008] FIG. 2 is a perspective view of the infant carrier support.
[0009] FIG. 3 is a front view of the device.
[0010] FIG. 4 is a side view of the device.
[0011] FIG. 5 is a rear view of the device.
[0012] FIG. 6 shows the device attached to a belt.
[0013] FIG. 7 is a detailed side view of the device.
[0014] FIG. 8 is a detailed perspective view of the device.
[0015] FIG. 9 a is a diagram showing an infant carrier held out to the side.
[0016] FIG. 9 b is a diagram showing an infant carrier supported by the belt clip.
[0017] FIG. 9 c is a diagram showing a grocery basket supported by the belt clip.
DETAILED DESCRIPTION
[0018] The present invention enhances the usefulness of infant carriers, hand-carried grocery baskets, and similar devices having a rigid or semi-rigid structure. The apparatus makes it easier for a person to transport such a carrier by shifting a significant amount of weight to the user's hip region.
[0019] The apparatus may be viewed as having three sections: a clip for attaching the device to a belt, a rigid hook attached to the lower exterior end of the belt clip, and a support cross member extending below the hook to further distribute the weight against the user's hip. The apparatus would, however, be manufactured as a single object of any lightweight malleable material, such as plastic. FIGS. 2-5 show a perspective view, a side view, and front and rear views of the apparatus, respectively. FIG. 6 shows the device attached to a belt.
[0020] A detailed side-view diagram of the infant carrier support is shown in FIG. 7 . As depicted in this figure, the belt-clip section is generally in the shape of an inverted “U” that slips over the user's belt. The inner side to the belt clip 21 is about 2 to 3 inches in length while the outer side 22 in total extends 5 to 6 inches in length to encompass the hook and support cross member. The width of the belt clip section is about 1½ to 2 inches. The inner and outer sides of the belt clip are connected at their top ends 23 and open at their bottom ends to form a slot 24 to accommodate a belt. The slot is approximately 1¼ to 1¾ inches in height and approximately ¼ inch in width, sufficient to fit most belts. The entry to the slot 25 may be somewhat offset from the vertical axis of the slot. The inner side of the belt clip 21 at its bottom end may have a rounded knob 26 . This knob 26 and the slot offset tend to secure the belt within the slot.
[0021] The outer side of the belt clip 22 has a hook-like projection 27 attached to its outer surface at about half way down its length (about 3 inches from its top end). The hook-like projection 27 extends outwards approximately 1 inch at an upward angle 28 of from 5 to 30 degrees and preferably about 10 degrees with respect to the perpendicular to the outer side of the belt clip 22 . The hook-like projection 27 ends in a rounded knob 29 . The hook-like projection extends the width of the outer belt clip side 22 and further has an open slot 30 down the middle to accommodate a structural feature found on the outer lip of many infant carriers (see the detailed perspective view of FIG. 8 ). The upward angle 28 of the hook-like projection and the knob 29 at its end tend to secure the carrier device.
[0022] Below the hook-like projection 27 , the outer side 22 is initially curved back toward the inner side 21 ( 31 in FIG. 7 ) and then is bent outwards at about a 10-degree angle ( 32 in FIG. 7 ) with respect to the plane of the upper portion of the outer belt clip side 22 . The outward bent portion 33 is increased in width to form a support cross member. When the edge of an infant carrier or other device engages the hook, it not only presses downward on the belt but also tends to rotate the belt outwards. The support cross member then presses against the user's hip, further distributing the carrier weight to the hip region.
[0023] FIG. 9 demonstrates a method of carrying an infant carrier seat or similar carrier by attaching it to a person's belt. FIG. 9 a shows one method of carrying an infant seat without assistance. FIG. 9 b shows a method of supporting an infant carrier seat in which the foot end of the infant carrier seat is attached to a person's belt, transferring a significant amount of weight to the hip region and reducing strain on the arm, back, and shoulder of the person carrying the seat. In this case, the means for attaching the carrier to a belt is to rest the foot edge of the infant carrier upon the hook-like projection of the belt clip. The side of the carrier could also be attached to the belt clip rather than the foot end as an alternative method of support. FIG. 9 c shows a grocery carrier supported by the belt clip.
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A belt mounted infant carrier support device comprising a belt clip, an attached upward projecting hook-like protrusion upon which the lip of an infant carrier rests and a support cross member below the hook.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a brassiere, the blank for making the brassiere and to the methods for making the brassiere and the blank. More particularly, this invention relates to producing a brassiere blank on a circular knitting machine, producing a brassiere from the blank having seams only at the shoulder straps.
(2) Description of the Prior Art
Brassieres having fabric areas to define breast cups have been produced by full fashioned and reciprocating knitting machines, but blank and brassiere production is slow and inefficient unless circular knitting is used. One such improved circular knitting process is disclosed in Richards U.S. Pat. No. 4,531,525 wherein a brassiere blank is made on a circular knitting machine which includes producing a cylindrical tubular blank having a torso portion with a pair of breast cups and straps knit integrally with the torso portion and having turned welt portions at each end of the cylindrical blank. The tubular blank is slit on one side, laid flat for cutting neck and arm openings and seaming at each side to form the brassiere.
SUMMARY OF THE INVENTION
It an object of this invention to provide a circular knit, cylindrical tube blank from which a brassiere may be made.
Another object of this invention is to provide a method for manufacturing a brassiere blank which has a fabric construction shaped to contours desired for the finished brassiere so as to minimize the manufacturing steps required for completion of the brassiere.
A further object of this invention is to provide a method of manufacturing a brassiere from a single circular knit, cylindrical tubular blank to produce a brassiere having a torso engaging portion and straps integrally knit with the torso portion.
Yet another object of this invention is to provide a brassiere fabricated from circular knit fabric and in which differential stitch structures in coursewise directions accomplish the principle shaping of the finished brassiere.
An even further object of this invention is to provide a brassiere from a single piece of circular knit fabric having sewn only at the shoulder strap seams and the banding.
In accordance with the present invention there is described a method of manufacturing a circular knit blank which includes knitting a series of courses defining a cylindrical tubular fabric torso encircling portion which includes a first or lower torso portion in the form of a turned welt. The torso encircling portion also includes a second or upper torso portion comprising a series of courses defining a cylindrical tubular fabric portion having a pair of breast cups on the front of the upper torso portion defined by two areas in which the fabric is in simple knit courses with the areas being separated one from another, the courses defining the front torso portion differentially shaping the breast cups. A rear torso portion knit to the rear portion of the turned welt and in which the fabric is in simple knit coursed. The first several courses of the upper torso portion provide a series of tucks around the torso portion, immediately above the turned welt portion. To the upper torso portion, a shoulder portion having a cylindrical tubular front and back fabric straps are knit. Each strap forms an elongated area in which the courses are simple knit with the areas being divided by an elongated panel area in which succeeding courses are also simple knit. Lastly, the circular knit tubular blank is completed by knitting several courses forming a non-raveling edge.
In a preferred embodiment of the circular knit blank of this invention, the breast cups are separated one from the another by a central area of gathered panels in which succeeding courses vary between simple knit and welt knit courses.
The brassiere of the present invention is made from a circular knit tubular blank by cutting the fabric of the blank along the neck lines and arm hole lines. The waste fabric is removed to define pairs of front and rear shoulder straps. Banding and the like are added to finish off the brassiere. Lastly, the shoulder straps are sewn together. There is thus provided a brassiere made from a blank of knit construction which is shaped to the contours of a finished brassiere, thereby minimizing the steps of completing the finished brassiere.
Other objects, features and advantages of the present invention will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating an embodiment of a brassiere in the present invention made from the blank shown in FIG. 2 as it is worn;
FIG. 2 is a front elevation view of an embodiment of a circular knit cylindrical blank in accordance with the present invention and from which the brassiere of FIG. 1 is manufactured;
FIG. 3 is a front elevation view of another embodiment of a circular knit cylindrical blank in accordance with the present invention and from which the brassiere of FIG. 4 is manufactured; and
FIG. 4 is a perspective view of a brassiere made from the circular knit blank of FIG. 3 and illustrating another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 shows a preferred embodiment of the finished brassiere of the present invention represented generally at 10. The brassiere 10 includes a cylindrical tubular torso encircling portion 20 including a first or lower portion in the form of a turned welt portion 22 and an upper torso portion comprising a series of courses defining a cylindrical tubular fabric portion defining a front torso portion 27 and a rear torso portion 28 knit to the turned welt portion 22. The front torso portion 27 has a pair of breast cups 26 defined by areas in which the courses are simple knit and have succeeding courses varying between simple knit and welt knit courses. Following the turned welt portion 22, the first several courses of the front torso portion 27 and rear torso portion 28 include a series of tucks gathering the upper torso portion to the turned welt, shown in FIG. 2. The courses defining the front torso portion 27 differentially shape the breast cups 26. The torso portion includes a rear portion above the turned welt and in which the fabric is in simple knit courses. A pair of front shoulder straps 29 are each knit to the front torso portion and a pair of back shoulder straps are each knit to the rear torso portion and in which the fabric is in simple knit courses with patterns. The back shoulder straps are like the back straps 131 shown in the embodiment of FIG. 4.
In a preferred embodiment of this invention, the breast cups 26 are defined by areas in which the courses are simple knit with the breast cup areas 26 being separated by a center gathered panel area 25 shown in FIGS. 1 and 2, in which the courses varying between simple and welt knit courses. The gathered portion 25 is made by pulling the cams away from the butts allowing the shorter button needles to pass through underneath the cams to hold the stitch for a predetermined number of courses, say 3 to 20 and preferably 10 to 12, then the needles are raised to clear the stitch to form a pleat, then the process is repeated until the gather is formed. The cams are then returned to the cylinder so that the button needles will rise.
Turning now to FIG. 2, there is shown a brassiere blank 30, made on a high speed circular knitting machine, from which the brassiere 10 is produced. The blank 30 is a cylindrical tube having portions which correspond to the portions of the brassiere described in FIG. 1. The reference characters corresponding to those used with reference to FIG. 1 will be applied in FIG. 2, with the addition of prime notation. Thus, the torso portion 20', in the blank 30, includes a turned welt portion 22' as is produced on circular knitting machines in well known ways and the upper torso portion comprising front portion 27' and rear portion 28'. The differentially shaped breast cups 26' are defined on the front panel of the torso portion 20'. The straps 29', 31' are shown on the knitted portion above the torso portion. A non-raveling edge 21' formed of several courses tops off the brassiere blank 30. Tucks 23' are formed in the upper torso portion immediately above the turned welt portion 22', in a manner known to those skilled in the knitting art.
The various portions of the circular knit tubular brassiere blank 30 are integrally knit together and have stitch constructions as described hereinabove. Thus, the method of manufacturing the blank will become more clearly understandable and may be characterized as knitting a series of courses defining a first cylindrical tubular portion in the form of a turned welt 22', and then knitting to the first turned welt portion a series of courses defining a cylindrical upper tubular torso portion 20' having a series of tucks 23' where the courses start immediately above the turned welt 22'. The front torso portion 27' has a pair of breast cups 26' defined by two areas in which the courses are simple knit with the areas being separated one from the other by areas of gathered panels 25' in which succeeding courses vary between simple knit and welt knit courses, the knitting of courses defining the front torso portion differentially shaping the breast cups with respect to the gathered panels. As will be understood, the degree of shaping will vary, and may be taken into account in accomplishing sizing of the brassiere. Then knitting to the front torso portion a series of courses defining a cylindrical tubular fabric shoulder strap 29' and rear torso portion having an elongated shoulder strap areas 31' in which the courses are simple knit, and the knitting to the upper portion several courses forming a non-raveling edge 21'.
In manufacturing the brassiere 10 from the blank 30 the fabric of the blank 30 as shown in FIG. 2 is cut along a pair of neck lines 33, and a pair of arm hole lines 35 and waste fabric is removed so as to define the front shoulder straps 29' and the rear shoulder straps 31' which are sewn together along a seam (not shown). Banding and the like may be added to finish off the brassiere. The brassiere is of a circular knit construction, with the turned welts 22 extending in a coursewise direction. The first several courses of the upper torso portion are knit so as to provide a series of tucks, shown at 23' in FIG. 2, around the upper torso portion 20, immediately above the turned welt portion 22'. When the brassiere is worn, as shown in FIG. 1, the knit fabric fits snugly to the body and the tucks are not evident. Thus, the fabric construction is the upper torso portion is such that the coursewise direction of the knit fabric is generally circumferential of the body of the wearer of the brassiere 10. The courses are knit in such a way as to shape the breast cup 26. In particular, the fabric in the breast cups are a simple knit, while the area between the cups 26 in the embodiment of FIG. 1 are formed by gathered fabric having successive courses varying between simple knit and welt knit stitches.
Simple knit stitches used to distinguish those stitch constructions possible on a circular knitting machine and in which yarn is taken into a needle during each rotation of the cylinder, such as plain, purl, tuck and combinations thereof. Reference to welt knit is intended to encompass miss-stitch or float stitch constructions in which loops in certain courses are held without additional yarns being taken and then knit into subsequent courses, thereby gathering the courses together and providing the characteristic turned welt or panel effect referred to above.
In another embodiment, that shown in FIG. 3, a blank 130 is made similarly to the blank 30 in FIG. 2, but without the central gathered portion 25'. A cylindrical tubular fabric torso encircling portion 120' is knit in the form of a turned welt portion 122' and an upper torso portion comprising a front torso portion 127' and a rear torso portion 128'. The front torso portion 127' comprises a series of courses defining a cylindrical tubular fabric portion having a pair of breast cups 126' on the front portion defined by areas in which the courses are simple knit and having succeeding courses varying between simple knit and welt knit courses. The first several courses of the upper torso portion are knit so as to provide a series of tucks 123' around the upper torso portion immediately above the turned welt portion 122'. Then knitting to the torso portion a shoulder portion having a cylindrical tubular front and back fabric straps 129', 131' each having an elongated patterned area in which the courses are simple knit with the areas being divided by an elongated panel area in which succeeding courses vary between simple knit and welt knit courses. The blank 130 is completed by knitting several courses 121' forming a non-raveling edge.
The brassiere 110, shown is FIG. 4, is made from blank 130, shown in FIG. 3 by cutting along a pair of neck lines 133, and a pair of arm hole lines 135. The waste fabric is removed so as to define the front shoulder straps 129' and the rear shoulder straps 131' which are sewn together along seam 132. Banding and the like may be added to finish off the brassiere.
In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.
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This invention discloses methods of manufacturing brassiere blanks and brassieres, and the brassieres made therefrom. In particular, the methods and brassieres involve circular knitting operations in which a brassiere blank is produced on a circular knitting machine as a cylindrical tube, and thereafter cut and sewn only at the shoulders to produce a brassiere having shoulder straps knit integrally with a front torso portion having a pair of breast cups and a rear torso portion cooperating with the front torso portion in forming a torso encircling portion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing a p-halogenobenzophenone derivative useful as a monomer for heat-resistant polymers.
2. Description of the Related Arts
p-Halogenobenzophenone derivatives are recently especially noted as monomers for heat-resistant polymers such as polyether ketones and polythioether ketones and a development of a process for producing them at a low cost is eagerly demanded. Known processes for producing halogenobenzophenone derivatives include those wherein a halogenobenzene is directly acylated, such as (1) a process wherein chlorobenzoyl chloride is reacted with a halogenobenzene, (2) a process wherein a halogenobenzene is reacted with phosgene (see European Patent No. 147,299), and (3) a process wherein chlorobenzene is reacted with carbon monoxide (see Japanese Patent Laid-Open No. 221146/1986), as well as a process wherein a 1,1-dichloro-2,2-bis(halogenopheny)ethylene is oxidized with nitric acid, a process wherein p-chlorobenzotrichloride is reacted with chlorobenzene in the presence of a Lewis acid catalyst such as iron chloride or aluminum chloride (see French Patent No. 2,534,906) and a process wherein the reaction is conducted in the presence of a crystalline aluminosilicate (see Japanese Patent Laid-Open No. 121945/1990).
However, the above-described prior art processes have problems. Namely, the process wherein a halogenobenzene is directly acylated with phosgene or carbon monoxide is unfavorable to be conducted on an industrial scale, since phosgene and carbon monoxide are chemicals having a strong toxicity. The process wherein a 1,1-dichloro-2,2-bis(halogenophenyl)ethylene is oxidized with nitric acid has a problem in the production per se of the starting material, since the production of the starting material causes environmental pollution. Further the process wherein chlorobenzene is directly acylated with an acid chloride in the presence of a Lewis acid and the process wherein p-chlorobenzotrichloride is reacted with chlorobenzene in the presence of a Lewis acid catalyst such as iron chloride or aluminum chloride have a problem of catalyst removal and a problem of waste water treatment. Namely, when a Lewis acid catalyst soluble in the reaction system, such as iron chloride or aluminum chloride, is used, the whole reaction liquid must be washed with an acid and water after the completion of the reaction so that the catalyst migrates into the aqueous layer. This necessitates a complicated operation and, in addition, water used in a large quantity for washing posed a problem of environmental pollution if it is discharged as it is.
Although the process wherein p-chlorobenzotrichloride is reacted with chlorobenzene in the presence of crystalline aluminosilicate (zeolite) is a preferred process free from the above-described problems, it is yet unsatisfactory for conducting on an industrial scale, since the life of the catalyst is short and a complicated catalyst regeneration is necessary for the repeated use. In particular, the recovery of the activity thereof is slight when it is washed with a solvent and the conversion is sharply reduced when this catalyst is repeatedly used after mere washing with the solvent. Thus when zeolite is repeatedly used as the catalyst, a problem is posed that it must be frequently regenerated by heat treatment or the like.
Thus all the prior art processes involve problems when they are conducted on an industrial scale.
SUMMARY OF THE INVENTION
Therefore, the present invention aims at solving the above-described problems of the prior art processes. Namely, an object of the present invention is to provide a process for producing a p-halogenobenzophenone derivative of a high purity in a high yield at a low cost in the presence of a repeatedly usable catalyst having a long life and free from the problem of waste water treatment without using any chemical of a strong toxicity.
The inventors have completed the present invention after intensive investigations made for the purpose of finding a catalyst having a sufficiently long catalytic life and being repeatedly usable many times without being regenerated and also reusable by regeneration when used in place of the crystalline aluminosilicate as the catalyst for the above-described prior art process which comprises reacting p-chlorobenzotrichloride with chlorobenzene and in which no strongly toxic chemical is used and no problem of environmental pollution will occur, thus being relatively less problematic among other processes.
The constructive feature of the present invention resides in that an (un)substituted benzotrichloride of the following formula (I) is reacted with a halogenobenzene of the following formula (II) in the presence of a catalyst selected from the group consisting of alumina, nickel sulfate, zirconium oxide, amorphous silica/alumina and a mixture of two or more of them or a catalyst obtained by treating these compounds with an acid and the resulting bisphenyldichloromethane of the following formula (III) is hydrolyzed to give a p-halogenobenzophenone: ##STR2## wherein X represents a halogen atom or a hydrogen atom and Y represents a halogen atom.
The p-halogenobenzophenone derivatives produced by the present invention are benzophenone of the following formula having a halogen atom at the p-position of at least one benzene ring of the benzophenone: ##STR3## wherein X represents a halogen atom or a hydrogen atom and Y represents a halogen atom.
The term "amorphous silica/alumina" as used herein refers to an aluminum silicate having no X-ray diffraction pattern, such as silica/alumina obtained in the form of a hydrogel by the reaction of an aqueous silicate solution with an aqueous aluminum salt solution.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Now the detailed description will be made on the present invention.
The benzotrichloride of the formula (I) which is one of the starting materials to be reacted is a benzotrichloride in which the benzene ring is unsubstituted or substituted with a halogen atom such as a chlorine, fluorine, bromine or iodine atom. A benzotrichloride having a halogen atom at the p-position is preferably used.
In conducting the process of the present invention, the molar ratio of the starting benzotrichloride of the formula (I) to the halogenobenzene of the formula (II) ranges from 1:0.2 to 1:15. Usually a less expensive starting compound is used in excess. When a reaction solvent is used, the molar ratio ranges from 1:1 to 1:2, preferably from 1:1.1 to 1:1.2. The reaction solvent usable herein is, for example, 1,1,2,2-tetrachloroethane.
The catalyst used in the present invention is selected from the group consisting of alumina, nickel sulfate, zirconium oxide and amorphous silica/alumina or is a solid acid catalyst obtained by treating such a catalyst with an acid. The catalyst selected from the group consisting of alumina, nickel sulfate, zirconium oxide and amorphous silica/alumina may be used either singly or in the form of a mixture of two or more of them. The catalyst may be treated with an acid by immersing it in an acid such as sulfuric or hydrofluoric acid. By the acid treatment, the conversion or selectivity toward the p-isomer is improved. The amount of the catalyst used varies depending on the kind and shape of the catalyst and the type of the reaction (batchwise or continuous process) and the scale of the reaction. Therefore, the amount of the catalyst to be used is suitably determined depending on the catalyst used and the type of the reaction. It is usually an amount sufficient for obtaining an economical reaction velocity. When the reaction is conducted batchwise on a relatively small scale, the catalyst is used in an amount ranging from 10 to 200 g, preferably from 50 to 150 g, per mole of the benzotrichloride of the formula (I).
The catalyst used in the present invention is repeatedly usable. For example, the catalyst used in conducting the reaction batchwise and then separated from the reaction mixture can be subjected to the reaction of the next batch after merely washing it with a halogenobenzene which is one of the reactants. Reductions in the conversion and yield are only slight even after repeatedly using it several tens of times. Thus as compared with zeolite with which the conversion is sharply lowered after repeated use, the catalyst used in the present invention exhibits a remarkably excellent effect.
The reaction is conducted at a temperature ranging from 80° to 200° C., preferably from 100° to 150° C. When the reaction temperature is too low, the reaction hardly proceeds, while when it exceeds 200° C., high boiling compounds are formed as by-products in a large amount unfavorably. The reaction time is 0.2 to 20 hours, desirably 0.5 to 10 hours.
When the above-described starting materials are reacted as described above according to the present invention, a reaction liquid mainly comprising a bisphenyldichloromethane of the formula (III), i.e. bis(halogenophenyl)dichloromethane or halogenophenyl-phenyldichloromethane and its hydrolyzate, i.e. a mono- or dihalogenobenzophenone, as the main products is obtained. After cooling, the catalyst is separated from the reaction mixture by filtration and the filtrate is distilled to recover unreacted starting materials.
By hydrolyzing the distillation residue, a mono- or dihalogenobenzophenone can be quantitatively obtained. More specifically, for example, the distillation residue remaining after an unreacted matter has been removed is dissolved in a solvent mixture of methanol and dilute hydrochloric acid, the solution is heated under reflux to conduct hydrolysis, and the reaction mixture is left to cool to form crystals. The crystals are separated by filtration to give the intended p-halogenobenzophenone derivative of a quite high purity.
The present invention basically comprises reacting a benzotrichloride with a halogenobenzene in the presence of the above-described catalyst. As for such a reaction, an example wherein a crystalline aluminosilicate, i.e. zeolite, is used as the solid acid catalyst is disclosed in the Japanese Patent Laid-Open No. 121945/1990 as described above. However, the catalyst used in the present invention is characterized in that it is repeatedly usable merely by washing it with the starting material and that it has a long catalytic life unlike zeolite. It has been quite unexpectable that the amorphous silica/alumina which is one of the catalysts usable in the present invention might have the above-described excellent effects, though its components is similar to that of zeolite.
According to the process of the present invention, the p-halogenobenzophenone derivative can be produced in a yield of 80% or more and the isolated p-halogenobenzophenone derivative has a purity of as high as at least 99%. In addition, the solid acid catalyst can be separated by mere filtration after the completion of the reaction. The separated catalyst can be repeatedly used many times after the mere washing treatment. Thus the process of the present invention is free from the problem of waste water treatment as posed when the conventional soluble Lewis acid catalyst is used or the problem of the shortness of the catalyst life as posed when zeolite is used and, therefore, it is quite suitable as the industrial production process.
EXAMPLES
The following Examples will further illustrate the present invention.
EXAMPLE 1
In a 200-ml three-necked flask provided with a stirrer, 22.9 g (0.1 mol) of p-chlorobenzotrichloride, 90 g (0.8 mol) of chlorobenzene and 10 g of silica/alumina (3 mm×3 mm pellets of X-632HN, a product of Nikki Chemical Co., Ltd.) were placed and reacted at 124° to 125° C. for 4 hours. After the completion of the reaction, the catalyst was separated by filtration and washed with chlorobenzene for reuse. The obtained reaction liquid was analyzed by gas chromatography to find that the conversion was 52.0% and the total formation rate of bis(p-chlorophenyl)dichloromethane (A) and p,p'-dichlorobenzophenone (B) was 44.7% based on the fed p-chlorobenzotrichloride (molar ratio of A to B: 89/11). The yield was 86% based on the consumed starting materials. The ratio of the p,p'-compound to the o,p'-compound was 12.2:1.
The obtained reaction liquid was distilled under a reduced pressure (12 mmHg, 93° C. or below) to recover unreacted chlorobenzene and p-chlorobenzotrichloride. 10 ml of 1N hydrochloric acid and 90 ml of methanol were added to the residue and the mixture was refluxed for 30 minutes to hydrolyze. The hydrolysis reaction liquid was left to cool and crystals thus formed were separated by filtration and washed with a small quantity of methanol to give 10.10 g of crystalline p,p'-dichlorobenzophenone having a purity of 99.8%.
Methanol used for the washing as described above was concentrated and crystals thus formed were recrystallized from methanol/water to give 0.91 g of p,p'-dichlorobenzophenone having a purity of 98.5%. The total yield of isolation of the product was 84.2% based on the consumed p-chlorobenzotrichloride.
EXAMPLE 2
A similar reaction to that of Example 1 was repeated except that the silica/alumina catalyst was replaced by each catalyst listed in Table 1. The conversion and reaction yield of dichlorobenzophenone are given in Table 1.
TABLE 1______________________________________ Yield of Yield of p,p'- o,p'- Conversion compound compoundCatalyst (%) (%) (%)______________________________________nickel sulfate 59.4 79.3 17.2pulverized silica/alumina 61.3 87.1 6.9silica/alumina treated with 63.7 83.0 9.3sulfuric acidsilica/alumina treated with 42.5 87.3 6.9HFalumina 35.7 81.4 9.4zirconium oxide treated 69.6 82.9 11.5with sulfuric acid______________________________________ (Notes) nickel sulfate: prepared by calcining special grade nickel sulfate hexahydrate (a product of Kanto Chemical Co., Inc.) at 350° C. for 6 hours, pulverized silica/alumina: prepared by pulverizing X632HN (a product of Nikki Chemical Co, Ltd.) with a mortar and sieving through a 250mesh filter, silica/alumina treated with sulfuric acid: prepared by immersing X632HN ( product of Nikki Chemical Co., Ltd.) in 10% sulfuric acid for 6 hours and then calcining it at 500° C. for 3 hours, silica/alumina treated with HF: prepared by calcining No. E58LI (a produc of Nikki Chemical Co., Ltd.), at 150° C. for 3 hours, alumina: prepared by calcining neutral alumina for chromatography at 550° C. for 2 hours, zirconium oxide treated with sulfuric acid: prepared by treating zirconiu hydroxide with 1 N sulfuric acid calcining it at 500° C. for 3 hours.
EXAMPLE 3
The silica/alumina catalyst used in Example 1 was washed with 100 ml of chlorobenzene and subjected to the reaction under the same conditions as those of Example 1. The catalyst was repeatedly used for the reaction 20 times in the same manner as that described above. The conversion and reaction yield of p,p'-dichlorobenzophenone are given in Table 2.
TABLE 2______________________________________Number of times of Conversion Yieldrepetition (%) (%)______________________________________2 50.6 82.54 50.0 82.56 50.9 83.58 52.0 82.510 49.7 86.712 50.4 84.314 47.6 86.616 46.6 88.820 47.6 89.2______________________________________
EXAMPLE 4
The reaction was conducted in a similar manner to that of Example 1 except that p-chlorobenzo-trichloride was replaced by m-chlorobenzotrichloride. The conversion was 34.1%. The reaction yield of intended m,p'-dichlorobenzophenone was 89%.
EXAMPLE 5
The reaction was conducted in a similar manner to that of Example 3 except that the silica/alumina catalyst was replaced by alumina treated with sulfuric acid (i.e. alumina immersed in dilute sulfuric acid and then calcined at 600° C. for 3 hours) and that the reaction time was altered to 1 hour. The results are given in Table 3.
TABLE 3______________________________________Number of Rate of p,p'-compoundtimes of Conversion formation Yieldrepetition (%) (%) (%)______________________________________1 44.6 38.2 85.72 43.7 38.1 87.23 43.7 37.5 85.84 42.6 36.4 85.45 41.2 35.8 86.96 42.3 35.7 84.47 43.2 36.7 85.08 43.6 37.9 86.99 42.8 37.1 86.710 40.5 35.8 88.4______________________________________
COMPARATIVE EXAMPLE
The reaction was conducted in a similar manner to that of Example 3 except that the silica/alumina catalyst was replaced by zeolite. Since a lowering in the conversion during the repeated use of the catalyst was serious, the catalyst was repeatedly used only three times. The results are given in Table 4.
TABLE 4__________________________________________________________________________ Y-Zeolite Hyperstable HY-zeolite Mordenite H Conver- Rate of p,p'- Conver- Rate of p,p'- Conver- Rate of p,p'-Number of times sion compound sion compound sion compoundof repetition (%) formation (%) (%) formation (%) (%) formation (%)__________________________________________________________________________1 48.1 36.8 64.0 50.6 24.1 18.82 28.8 27.0 33.0 28.2 13.8 12.13 27.1 24.9 26.7 24.5 12.0 11.4__________________________________________________________________________
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The present invention provides a process for producing a p-halogenobenzophenone derivative of a high purity in a high yield at a low cost in the presence of a repeatedly usable catalyst having a long life and free from the problem of waste water treatment without using any chemical of a strong toxicity. According to the present invention, the p-halogenobenzophenone derivative is produced by reacting an (un)substituted benzotrichloride of the following formula (I) with a halogenobezene of the following formula (II) in the presence of a catalyst selected from the group consisting of alumina, nickel sulfate, zirconium oxide, amorphous silica/alumina and a mixture of two or more of them or a catalyst obtained by treating these compounds with an acid and hydrolyzing the resulting bisphenyldichloromethane of the following formula (III): ##STR1## wherein X represents a halogen atom or a hydrogen atom and Y represents a halogen atom.
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BACKGROUND OF THE INVENTION
A. Field of the Invention
A new design for a complete set of luggage consisting of several new innovations to accomplish the following:
1. Provide a method whereby a traveler can easily carry and transport a complete set of luggage on a built in dolly that can either be pulled along or pushed.
2. Provide at a convenient table top length three configurations of a travelers tote/carry on bag as follows:
A. Lap top computer work station B. Cosmetic case C. Casual open tote
3. Provide an optional piece of luggage as a bulk files trunk with an adjustable area for personal items and or garments.
4. Provide a firm divider board for each piece of luggage that would avoid the necessity to “stuff” luggage full in order to prevent garments from shifting and wrinkling plus allowed saved space to accommodate extra items purchased during travel.
All of the above will provide the traveler with an easily transported set of luggage, a means to easily access and work at a lap top or have a cosmetic station or have personal items and travel documents easily accessible, carry bulk file, prevent garments from wrinkling and provide an accessory bag for those personal items usually held in your hands during down times.
B. Prior Art
The concept of combining a desk surface with luggage has been around for many years and patents, which address this idea are found in the prior art. A representative example of this type of device is Johnson, U.S. Pat. No. 6,543,796. The Johnson device seeks to combine a desk surface with a luggage carrier. Another example in the prior art which seeks to combine dual functions in one device can be found at McNeil, U.S. Pat. No. 6,604,472 and claims a laptop computer support table. Another reference is also found at Ryburg, U.S. Pat. No. 6,736,073.
Because this device will be used by a business traveler it is anticipated that certain desk materials should be included. An example of that type of device in the prior art can be found at Terkildsen, U.S. Pat. No. 5,115,893.
None of the prior art references however combine the many features that are found in this application.
BRIEF SUMMARY OF THE INVENTION
This device will allow the business traveler or anyone to easily transport a complete set of luggage and to easily perform computer functions while at the same time stowing one's carry on luggage. It will be a combination dolly transport system, computer workstation, cosmetic desk and an open/casual tote, with a luggage compartment. The items that may be carried in the luggage portion of the tote device will be as varied as the traveler.
The basic tote will have retractable or telescoping legs to expand downward and secure one side of a bottom surface of the unit and a series of supports to secure the other side of the bottom surface of the device. Because the bottom surface is retractable the bottom surface will rest flush against the bottom of the luggage piece.
Wheels or rollers on one end of the telescoping legs support one end of the bottom surface, and a plurality of swivel wheels or feet on the front side of the bottom surface ensures that the device, once it has been placed in position, remains level. The leveling feet may be replaced by front swivel wheels to provide a means to push or pull the device when luggage is stowed in the space between the bottom of the main piece of luggage and the bottom surface of the unit.
On the top of the piece of luggage will be several zippered compartments. Underneath the top zippered compartments will be a stowing space, which will stow an expandable and removable briefcase, laptop computer and a flip out work surface. Protective padding is also provided to ensure that the computer is not damaged during transit.
On the bottom surface will be a flat, planar surface on which various items, particularly luggage may be kept and stored. When the bottom surface of the device is expanded, several vertical support members will rotate upward from the support members on the bottom surface to locking ports on the underside of the device. These vertical support members will secure the device in position and will provide a space between the bottom of the luggage and the grill surface, which is on the flat planar surface. The flat, planar surface will be large enough to stow other pieces of luggage in that section.
On the front or around the perimeter of the luggage will be several other pockets in which to stow commonly transported items, for instance, pens and pencils, a phone pocket, and traveling documents. This compartment will be built on a rigid flip down flap that will also provide a computer mouse pad on the back side.
In order to carry the device, there will be a shoulder strap, which may be adjustable, a carrying handle on the top as well as a retractable handle on the back side.
It is an object of this device to enable a business traveler to have a level laptop and working (desk type) surface on which to work while at the same time easily transporting a complete set of his or her luggage. It is a further object to protect all necessary equipment, including the computer and delicate electronic equipment during transit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the device with the bottom flush against the bottom of the carrying case.
FIG. 2 is an isometric view from the rear of the device with the bottom of the device flush against the bottom of the carrying case.
FIG. 3 is an isometric view from the front of the device depicting the grill on the device partially lowered.
FIG. 4 is an isometric view of the device from the front with the grill in place and the work space and computer exposed.
FIG. 5 is an isometric view of the front with the top zippered compartment open, showing the various storage spaces as well as work surfaces, briefcase lifted out of its' housing and expandable compartment to accommodate carrying the laptop within the briefcase.
FIG. 6 is a depiction of the device stowing another piece of luggage on the grill member.
FIG. 7 is another depiction of the device storing multiple pieces of luggage on the grill member.
DETAILED DESCRIPTION OF THE EMBODIMENTS
This is a device that will allow travelers to not only easily carry a complete set of luggage but also work at his or her computer during periods of down time, particularly in airports, courthouses, conference rooms and hotel rooms. It will be a complete set of luggage but will have several additional features.
The device 5 will be equipped with several ways to carry the device. One of the ways will be a shoulder strap 15 , which is adjustable. The shoulder strap 15 is attached or secured to both sides of the device, on the ends. A carrying handle 30 , which is located on the top surface of this device 5 will also be provided as an alternative means to carry the device. On one end of the device 5 will be a retractable handle 25 , which is secured in tubes for that purpose.
On the bottom of the device 5 will be a set of rollers 35 , which will allow the device 5 to be tilted backwards using the retractable handle 25 , and pulled using the rollers 35 . A variety of rollers 35 may be used but they should be sufficiently sturdy to support the weight that may be placed on the device 5 .
The rollers 35 will be secured to the outside edges of a bottom grill member 45 . The grill member 45 is the approximate dimensions of the bottom of the device and will move up and down, as desired. The grill member 45 should be constructed to support the weight and size of other pieces of luggage such as depicted in FIGS. 6 and 7 . This may require a double layer, flip out, or slide out extension to the grill member 45 to avoid larger pieces of luggage from tumbling off the grill member 45 (not depicted). On one end of the grill member 45 will be the rollers 35 and on the opposite end will be a set of leveling or swivel wheel devices 20 . These leveling devices 20 could either be leveling feet as depicted in FIG. 4 or another set of swivel wheels. The purpose of the swivel wheels leveling device is to insure a flat, level work surface for the user of this device. If swivel wheels are used as the leveling members, flip-up bicycle type handles (not depicted) may also be positioned on either side of the piece of luggage to allow an individual to push the device as you would a grocery cart or airport rental luggage cart. With the bicycle handles would also be a soft material bag with loops on each end to hang over the bicycle handles that would hold items such as magazines, water bottles, toys, snacks, etc. used during down time (not depicted).
Near the leveling devices 20 will be a set of vertical supports 50 , which are attached at one end to the grill member 45 . When the grill member 45 is flush with the bottom of the device 5 , the supports 50 are positioned parallel with the grill member 45 . When the grill member 45 is fully expanded, the supports 50 will rotate upward from the grill member 45 and be perpendicular relative to the grill member 45 . One end of the supports 50 will lock into support retainers 52 , which are located on the bottom front of each end of the piece of luggage. The support retainers 52 insure that the supports 50 remain in position.
On one end of the grill member 45 will be a pair of support members 40 . These support members 40 , which telescope when the grill member is lowered are housed in tubes 41 that are secured to the outside surface of the piece of luggage, one on each of the sides for the tubes for the telescoping handle 25 such as depicted in FIG. 2 .
It is anticipated that the support retainers will be an indentation or a means to firmly secure this device to the bottom of the device.
On the front surface of the device 5 will be various pockets to stow items that are commonly used by the business traveler. This may be a pen and pencil pocket 26 , a mobile phone pocket 28 or a traveling document pocket 27 . Other types of pockets may be anticipated in addition to those specifically mentioned or specifically depicted in the drawings. These compartments will be on a firm or solid platform that folds down to provide a computer mouse storage.
In order to gain access to the computer and workstation, which is located in the center of the device, a zipper or other means of access will be provided. By opening the top cover 10 the computer will be exposed. A separate zipper will provide access to the storage area 11 for clothing.
On one side of the interior of the device will be a work surface 70 , which is stowed in a compartment for that purpose inside the case. When the work surface 70 is pulled from the compartment it will rest roughly parallel to the ground and provide a surface on which to lay items. In the center of the interior will be a laptop computer 65 . On the opposite side from the work surface 70 will be an opening for a briefcase 60 and other miscellaneous items such as files 62 . The work surface 70 will be stowed in a cavity 72 for that purpose. The briefcase 60 may also have an expandable pocket for additional storage. The expandable computer pocket 61 on the briefcase 60 will also enable a laptop 65 to be stowed with the briefcase when the briefcase is carried separately as desired.
A variety of storage options and placement options are possible for the interior of the device in the area of the computer workstation. It is impossible to depict all possible storage arrangements but toiletry articles, small clothing items, etc. may be carried as a representative example.
In the lower part of the device 5 will be the area of the device to stow clothing, toilet articles and other items that are routinely taken by the traveler. Another set of zippers controls access to this area.
This device enables a computer workstation to be stored with this device. Because of the ability of the grill member 45 and telescoping legs 40 to move downward, adequate height is provided that various pieces of luggage may be stowed and transported with one device.
When the grill member 45 is fully extended such as shown in FIG. 6 another piece of luggage 81 may be stowed in the area between the bottom surface of the piece of luggage. In another configuration to show the versatility of the device, two pieces of luggage 80 , 81 may be stowed in the area between the bottom of the piece of luggage and the top of the grill member as depicted in FIG. 7 .
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This is a combination computer work station, cosmetic desk, casual/open tote and luggage set device. The device is easily transported and the area to push or pull luggage may be expanded to stow various pieces of luggage. Luggage may be partially filled yet secured by the divider device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an all terrain vehicle including a radiator mounted frontward of a vehicle body frame in a protective environment.
2. Description of the Related Art
In vehicles of the type including a radiator used to maintain the temperature of the engine coolant within a predetermined range, generally the radiator is mounted frontward of the vehicle body frame to increase cooling performance by flowing air. For example, in Japanese Unexamined Patent Application Publication No. 2006-103369, there is proposed a configuration including a radiator mounted frontward of cross pipes. More specifically, a front frame provided frontward of a vehicle body frame is configured into a U-shape in the plan view. The front frame includes left and right extending portions extending along a vehicle in a front-back direction, and cross portions that extend along the vehicle width direction which interconnect with rear ends of the respective left and right extending portions. Additional cross pipes are provided for interconnecting the left and right extending portions in the vehicle width direction. The radiator is mounted frontward of the cross pipes.
However, in the configuration as in the above-described conventional vehicle in which the radiator is disposed frontward of the cross pipes, while the radiator can be protected against external forces exerted from the vehicle lateral sides, there is a problem in that the radiator cannot be sufficiently protected against external forces exerted from the vehicle front side.
SUMMARY OF THE INVENTION
In view of the foregoing problem, an object of the present invention is to provide a vehicle that enables improving protection for a radiator against external forces exerted from both the vehicle lateral sides and vehicle front side.
According to one aspect of the present invention, an all terrain vehicle (ATV 1 ) includes a pair of left and right front wheels, a front panel provided rearward of the front wheels, a first front cross frame that is disposed in front of the front panel and extends generally across the vehicle in the width direction, a second front cross frame disposed forward and offset from the first front cross frame and also extending generally along the vehicle's width direction; a front left side frame and a front right side frame that respectively, are disposed on the left and right sides of the vehicle extending along the vehicle's front-back direction, and that respectively interconnect the first front cross frame and the second front cross frame. A first bracket is provided near a connection portion of the second front cross frame with the front left side frame, and supports a first cushion unit of a front wheel suspension system. A second bracket is provided near a connection portion of the second front cross frame with the front right side frame that supports a second cushion unit of a front wheel suspension system. These structures define a radiator cage having an interior. A radiator is mounted in a manner that is located in a rectangular space surrounded by the first front and second front cross frames and the left and right side frames.
According to the vehicle of the present invention, frame members include outer surfaces which define boundaries which the radiator does not pass. Hence, the first and the second front cross frames and the front left and right side frames function as protection members, thereby improving the protection performance against external forces exerted from both the vehicle lateral sides and vehicle frontward side.
Further, the first and the second brackets, respectively, for supporting the cushion units are provided near the connection portions of the second front cross frame with the front left and right side frames. Hence, external forces transmitted from the front wheels via the cushion units can be supported by the second front cross frame that has high stiffness, consequently it is possible to increase the support stiffness of the cushion units.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an all-terrain vehicle of one embodiment of the present invention;
FIG. 2 is a side view of a vehicle body frame of the vehicle to which a radiator is mounted;
FIG. 3 is a plan view of the vehicle body frame;
FIG. 4 is a side view of a front frame of the vehicle body frame;
FIG. 5 is a front view of the front frame;
FIG. 6 is a front view of an upper portion of the radiator; and
FIG. 7 is a side view of a lower portion of the radiator.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the present invention will be described with reference to the accompanying drawings.
FIGS. 1 to 7 are views of an all-terrain vehicle of one embodiment of the present invention. In the present embodiment, the front, rear, left, and right refer to the front, rear, left, and right in the state as viewed from a passenger who is sitting in a seat looking toward the front wheels unless otherwise specifically mentioned. Also, as shown in the Figures like parts are identified with the same numeral. The front wheels are the same on both the left and right sides, so they are referenced by like numeral 3 . In some instances only the left side of the vehicle is shown, but it is understood that similar items on the right side, while not shown, are of similar nature.
With reference to the drawings, all terrain vehicle 1 (ATV 1 ) includes a vehicle body frame 2 , a radiator 19 , an engine unit 3 , a pair of front wheels 4 , and a pair of rear wheels 5 . The radiator 19 is mounted in a front portion of the vehicle body frame 2 . The engine unit 3 is mounted in a central portion of the vehicle body frame 2 . The front wheels 4 are, respectively, disposed in left and right front end portions of the vehicle body frame 2 . The rear wheels 5 are, respectively, disposed in left and right rear end portions.
The ATV 1 further includes a first seat 6 disposed in a front portion of the vehicle body frame 2 , a second seat 7 disposed rearward of the first seat 6 , a first floor 8 disposed frontward of the first seat 6 , and a second floor 9 disposed between the first and the second seats 6 and 7 .
The engine unit 3 is disposed between the first and the second floors 8 and 9 . A cargo support 10 is disposed on the rear side of the second seat 7 of the vehicle body frame 2 substantially at the same height as a seat surface of the second seat 7 .
The vehicle body frame 2 preferably includes main body frame 2 a , pillar frames 2 b , and front frame 2 c . The left and right front wheels 4 and the engine unit 3 are disposed in the main body frame 2 a . The pillar frames 2 b are respectively elevationally formed on the left and right sides of the main body frame 2 a , thereby forming a passenger compartment A. The front frame 2 c is disposed frontward of passenger compartment A of the main body frame 2 a . The first and second seats 6 and 7 are disposed inside of the passenger compartment A.
Main body frame 2 a includes left and right center members 12 extending along the vehicle in a front-back direction, and front and rear cross members 14 F, 14 R that interconnect between left and right center members 12 . Plate-like cross members 13 interconnect midway portions of the respective center members 12 . Engine unit 3 is mounted to cross members 13 .
As shown in FIGS. 1 and 3 , pillar frame 2 b is connected to outer end portions 14 a of the front and rear cross members 14 , and includes left and right pillar members 15 and multiple roof members 16 . The left and right pillar members 15 have front and rear passenger entries 15 a and 15 b formed therein, and the roof members 16 interconnect between upper end portions of the left and right pillar members 15 L and 15 R.
The first seat 6 is separated into left and right seats 6 L and 6 R at a predetermined distance along the vehicle width direction. The left and right seats 6 include seat cushions 6 c , seat backs 6 d , and headrests 6 e . A steering wheel 17 is disposed frontward of the left seat 6 . The second seat 7 is disposed approximately at the same height as the first seat 6 , and includes a bench seat cushion 7 a and a seat back 7 b allowing two persons to be seated. A headrest 7 c is disposed above the seat back 7 b.
The ATV 1 further includes a partition wall 23 and a hood 25 . The partition wall 23 partitions the passenger compartment A from a front compartment B. The hood 25 is disposed frontward of the partition wall 23 and opens or closes an upper end portion of the front compartment B.
As shown in FIG. 4 , partition wall 23 includes an upper portion 23 a , a frontwardly declined portion 23 b , and a lower portion 23 c . The upper portion 23 a is disposed in a front end portion of pillar frame 2 b , and instruments (not shown), such as a speed meter, are disposed on it. The frontwardly declined portion 23 b extends obliquely downward and forward from the upper portion 23 a . The lower portion 23 c extends obliquely downward and rearward from the frontwardly declined portion 23 b . An accelerator pedal (not shown) and a brake pedal are disposed in the lower portion 23 c , and a front edge portion of the first floor 8 is connected to the lower portion 23 c.
A tunnel portion 24 extending rearward in continuation with the partition wall 23 is formed in a central portion of the partition wall 23 in the vehicle width direction. The tunnel portion 24 is formed convexly into an upwardly protruding shape, in which an upper end of the tunnel portion 24 is located at substantially the same height as the seat surface of the first seat 6 .
The front compartment B is a space located ahead of the partition wall 23 and below the hood 25 , and communicates with a space in the tunnel portion 24 . The engine unit 3 is disposed in the tunnel portion 24 located rearward of the partition wall 23 .
The engine unit 3 includes a water-cooled four-cycle engine 20 mounted in a central portion of the left and right center members 12 , 12 in the front-back direction, a V-belt type continuously variable transmission 21 that changes and the rotation of the engine 20 and outputs it, and a cooling unit 28 that cools the continuously variable transmission 21 . The engine 20 has a structure formed by overlay-coupling a cylinder body 20 g and a cylinder head 20 c on a crankcase 20 f . More specifically, the engine 20 is mounted in a manner that a crankshaft 20 a is oriented substantially horizontally along the vehicle width direction, and a cylinder axis line 20 b is oriented rearward and obliquely upward direction. The engine 20 is disposed so as to be located between the left and right seats 6 a and 6 b of the first seat 6 . As viewed from a vehicle lateral side, the engine 20 is disposed such that a portion of the engine 20 overlaps with the first seat 6 . More specifically, the engine 20 is disposed such that the cylinder head 20 c of the engine 20 overlaps with the seat cushions 6 c.
An intake pipe 30 extending forward the vehicle front direction from the front sidewall of the cylinder head 20 c is connected to the front sidewall, and an exhaust pipe 31 extending toward the vehicle rearward direction from a rear sidewall of the cylinder head 20 c is connected to the rear sidewall. In a top view, the intake pipe 30 and the exhaust pipe 31 are disposed substantially linearly on a substantially vehicle center line along the front-back direction.
The exhaust pipe 31 includes a first vertical tube portion 31 b , a transverse tube portion 31 c , a second longitudinal tube portion 31 d , and an extending portion 31 e . The first vertical tube portion 31 b extends substantially vertically and downward from a connection portion 31 a connected to the cylinder head 20 c . The transverse tube portion 31 c extends rearward below the second floor 9 from a lower end of the first vertical tube portion 31 b . The second longitudinal tube portion 31 d extends in such a manner as to elevate upward from a rear end of the transverse tube portion 31 c . The extending portion 31 e extends rearwardly from an upper end of the second longitudinal tube portion 31 d through a space between the second seat 7 and a rear wheel drive shaft 5 a of the rear wheels 5 . The exhaust pipe 31 includes a muffler 36 that is disposed in connection to a rear end of the extending portion 31 e and is disposed so as to be located rearward of the second seat 7 . The muffler 36 has a substantially ellipsoidal shape having a front-back direction dimension greater than a vertical direction dimension, and the axis line thereof is arranged in the vehicle width direction.
The intake pipe 30 is connected to the cylinder head 20 c by way of a throttle body 32 equipped with a fuel injection valve 33 . A surge tank 34 is interposed midway of the intake pipe 30 . The surge tank 34 is disposed frontward of the engine 20 in the tunnel portion 24 . An air cleaner 35 is connected to the surge tank 34 by way of an intake air introduction pipe 30 a . The surge tank 34 has a volumetric capacity greater than a volumetric capacity of the air cleaner 35 .
The air cleaner 35 is disposed in a central portion in the vehicle width direction. As viewed from the side, the air cleaner 35 is disposed between the partition wall 23 in the front compartment B and the hood 25 . An intake port 35 a is connected and formed to a rear wall of the air cleaner 35 . The intake port 35 a is located higher than upper ends 4 b of the respective front wheels 4 , and is opened towards the rear side in the front compartment B.
The continuously variable transmission 21 includes a transmission case 21 a , a drive pulley 21 b , a driven pulley 21 d , and a V belt 21 e . The transmission case 21 a is integrally coupled to a left side in the vehicle width direction of the engine 20 and extends frontward from the engine 20 . The drive pulley 21 b is housed in the transmission case 21 a and is mounted to the crankshaft 20 a of the engine 20 . The driven pulley 21 d is mounted to an output shaft 21 c parallel to the crankshaft 20 a . The V belt 21 e is wound around the drive pulley 21 b and the driven pulley 21 d.
Front and rear power transmission shafts 22 a and 22 b disposed towards the front-back direction are connected to the output shaft 21 c . The front and rear power transmission shafts 22 a and 22 b are, respectively, connected to front and rear wheel drive shafts 4 a and 5 a via front and rear differential unit 22 c and 22 d.
The cooling unit 28 includes a cooling air introduction duct 40 that introduces cooling air into the continuously variable transmission 21 , and a cooling air discharge duct 41 that discharges air after cooling. The cooling air introduction duct 40 is routed towards the vehicle's forward side from the transmission case 21 a . An air inlet 40 a of the cooling air introduction duct 40 is located higher than the upper ends 4 b of the front wheels 4 (same herein below), and is opened in the vicinity of a right wall of the air cleaner 35 in the vehicle width direction in the front compartment B. The cooling air discharge duct 41 is routed towards the vehicle front side from the transmission case 21 a . An air outlet 41 a of the cooling air discharge duct 41 is located higher than the upper edges 4 b of the front wheels 4 , and is opened downward and rearward in the front compartment B.
The left and right front wheels 4 are supported by the vehicle body frame 2 via front wheel suspension systems 37 so as to be vertically and pivotally moveable. The left and right front wheel suspension systems 37 respectively are connected to the front frame 2 c , and include upper and lower arm members 38 a and 38 b that supports the front wheels 4 to be vertically and pivotally, and rotatably moveable, and cushion units 39 that interconnects between the upper arm members 38 a and the front frame 2 c.
The front frame 2 c includes a first front cross frame 45 , a second front cross frame 46 , a first front side frame 47 , and a second side frame 48 . The first front cross frame 45 is disposed frontward of passenger compartment A higher than the main frame 2 a , and extends along the vehicle width direction. The second front cross frame 46 is disposed forward of and lower than the first front cross frame 45 , and extends along the vehicle width direction. The first and second front side frames 47 and 48 , respectively, are disposed so as to extend in the front-back direction on the left and right side in the vehicle width direction, and interconnect the first and the second front cross frames 45 and 46 forming a protective environment for radiator 19 .
The front frame 2 c further includes left and right front pillar members 50 and left and right rear pillar members 51 that, respectively, extend upward from left and right center members 12 of main body frame 2 a to interconnect with first and second front side frames 47 and 48
As shown in FIG. 4 , the various frame members of front frame 2 c are of differing height to provide an inclined upper frame profile. In application, first and second frit side frames 47 and 48 incline from a lowest point at their respective interconnections with front pillar members 50 to their highest point at their interconnection with first frame cross frame 45 . Along their respective lengths, second front cross frame is elevated in relation with front the front pillars and the rear pillars are elevated with respect to second front frame member.
In application, the first front cross frame 45 is formed of an angular pipe, and the left and right end portions thereof are respectively connected to the left and right pillar members 15 . A steering support bracket 45 a for supporting the steering wheel 17 is connected to the left end portion of the first front cross frame 45 .
The respective first and second front side frames 47 and 48 are formed of an angular pipe, and a rear end portion thereof is connected to the first front cross frame 45 and extends linearly along a frontward and downward direction from the first front cross frame 45 . In other words, the respective first and second front side frames 47 and 48 are disposed to extend rearward and upward so that a portion located more rearward in the vehicle front-back direction is located higher.
The second front cross frame 46 has a U-shaped cross section that is downwardly opened, and is connected to front end portions of the respective first and second front side frames 47 and 48 . Left and right end portions 46 a L, 46 a R of the second front cross frame 46 , respectively, protrude outward in the vehicle width direction from the first and the second front side frames 47 and 48 .
As shown in FIG. 5 , to provide further support to second front cross frame 46 , left and right front side members 52 and 53 extend along the front-back direction and are disposed on the outer sides of the first and the second front side frames 47 and 48 in the vehicle width direction. First and second front side frames 47 and 48 are inclined and in the preferred embodiment are inclined up to an angle of sixty-eight degrees as measured against a vertical axis along its length. The left and right side members 52 and 53 , respectively, have rear end faces connected to the first front cross frame 45 and front end portions connected to the left and right end portions 46 a of the second front cross frame 46 .
The left and right front side members 52 and 53 , respectively, are located at the same heights as the first and the second front side frames 47 and 48 , and are disposed so that the vehicle widthwise distance becomes narrower towards the vehicle front side.
As shown in FIG. 5 , a vehicle widthwise distance P 1 between the left and right center members 12 is set smaller than a vehicle widthwise distance P 2 between the first and the second front side frames 47 and 48 . This arrangement enables increasing arm lengths of the respective upper and lower arm members 38 a and 38 b on the left and right sides.
Further, with reference to FIG. 5 , as viewed from the vehicle front side, the front differential unit 22 c is disposed in such a manner as to bridge between the left and right center members 12 . It is formed in the manner that a vehicle-lateral dimension W 1 between the left and right center members 12 is smaller than a vehicle-lateral dimension W 2 inclusive of joint portions 22 e of the front differential unit 22 c to which the front wheel drive shaft 4 a is connected.
The front frame 2 c further includes first and second brackets 46 b , 46 b respectively provided near connection portions of the second cross frame 46 with the first and the second side frames 47 and 48 . The first and second brackets 46 b , 46 b , respectively, are formed integrally with left and right end portions 46 a of the second cross frame 46 . Upper end portions 39 a of the left and right cushion units 39 are, respectively, connected to the first and the second brackets 46 b.
As shown in FIG. 5 , the respective first and second front cross frames 45 and 46 in combination with first and second front side frames 47 and 48 define a radiator cage having an interior. Radiator 19 is mounted in a manner wherein it is located inside of a rectangular space B′ surrounded by the first and second front cross frames 45 and 46 and the first and second front side frames 47 and 48 . As is shown by the drawings, a key aspect of the radiator cage is that the radiator does not extend forwardly past the most outer structural surface area of second cross frame 46 and hence is protected from a frontal impact. Radiator 19 is configured as described in detail below.
The radiator 19 is a vertical type radiator that includes a core 55 , an upper head tank 56 , and a lower head tank 57 . The core 55 has a rectangular shape in which the vertical dimension is greater than the vehicle widthwise dimension. The upper head tank 56 is connected to an upper end of the core 55 , and temporarily stores coolant that is used to cool the engine 20 . The lower head tank 57 is connected to a lower end of the core 55 , temporarily stores the coolant cooled when flowing through the core 55 , and returns the coolant into the engine 20 . By providing the upper head tank 56 and the lower head tank 57 , the coolant can be flown evenly into the overall area of the core 55 . A radiator cap 56 a for opening and closing a filler port for the coolant is fitted to the upper head tank 56 . As shown in FIG. 4 , an electric fan 58 is disposed on a rear face of the core 55 .
As shown in FIGS. 5 and 6 , radiator brackets 59 are mounted to left and right side portions of the upper tank 56 , respectively. The left and right radiator brackets 59 are, respectively, fixed with bolts to the first and the second front side frames 47 and 48 . Thereby, the upper portion 19 a of the radiator 19 is supported by the first and the second front side frames 47 and 48 .
As shown in FIGS. 4 and 7 , a radiator projection portion 57 a projecting downward is formed to the lower head tank 57 . A fixing bracket 62 extending rearward to fix the front differential unit 22 c is mounted to the front pillar members 50 , and an upward U-shaped fixing bracket 60 which faces upward is fixed together with the fixing bracket 62 . A supporting hole 60 a is formed in a bottom portion 60 b of the fixing bracket 60 , and a grommet 61 is mounted to the supporting hole 60 a . The protruding portion 57 a is inserted into the supporting hole 60 a with the grommet 61 interposed there between. Thereby, a lower portion 19 b of the radiator 19 is resiliently supported by the front frame 2 c via a fixing bracket 60 so as not to be moveable along the front-back and lateral directions.
The radiator 19 is disposed in a manner that the upper portion 19 a thereof is located rearward of and near the second front cross frame 46 and projects upward from the first and the second front side frames 47 and 48 . The hood 25 is located upward of and near the upper head tank 56 .
Further, the radiator 19 is disposed in a manner that the lower portion 19 b thereof is located downward of the second front cross frame 46 , and the upper portion 19 a is located rearward of the second front cross frame 46 . More specifically, the radiator 19 is disposed in a rearwardly inclined state where a portion thereof is located more rearward as it is located more upward. While the invention is intended to providing for the inclination of the radiator from even a small five degree incline, in the preferred embodiment, radiator 19 is able to be inclined preferably at an angle up to fifteen degrees as measured against a vertical axis. Thereby, as viewed from the vehicle lateral side, the upper portion 19 a of the radiator 19 is rearwardly inclined so brackets 59 may join them with first and the second front side frames 47 and 48 .
According to the present embodiment, the upper portion 19 a of the radiator 19 is disposed inside the rectangular space B′. The rectangular space B′ is surrounded by the second and first front cross frames 46 and 45 , which extend in the vehicle width direction and are disposed in the front and rear portions spaced apart from each other ahead of the passenger compartment A, and the first and the second front side frames 47 and 48 , which extend along the vehicle front-back direction and interconnect the first and the second front cross frames 45 and 46 . Hence, the first and the second front cross frames 45 and 46 and the first and the second front side frames 47 and 48 function as protection members. This enhances the protection performance of the radiator 19 against external forces exerted from both the vehicle lateral sides and vehicle front side.
As described above, the first and the second brackets 46 b , 46 b respectively, for supporting the upper end portions 39 a of the cushion units 39 are provided near the connection portions of the second cross frame 46 with the first and the second front side frames 47 and 48 . Hence, input power transmitted from the front wheels 4 L and 4 R via the left and right cushion units 39 can be supported by the entirety of the front frame 2 c having a high stiffness, consequently enabling enhancing the support stiffness of the cushion units 39 . This is accomplished as the upper end portions 39 a are provided near the connection portions then first and second side frames 47 and 48 can assist in the support. If end portions 39 a were not provided near the connection portions, then side frames 47 and 48 could not provide much support.
Further, since the first and the second brackets 46 b , respectively, are formed integral with the second front cross frame 46 , the number of parts is not increased, therefore enabling inhibiting costs from increasing.
In the present invention, the configuration may be such that the first and the second brackets 46 b are formed independently of the second front cross frame 46 , and are disposed near the connection portions of the second front cross frame 46 .
In the present embodiment, the radiator 19 is disposed in a manner that the lower portion 19 b thereof is located downwardly of the second front cross frame 46 , and the upper portion 19 a thereof is located rearward of the second front cross frame 46 . As viewed from the vehicle lateral side, the radiator 19 is disposed in the rearwardly inclined state in which the upper portion 19 a thereof is located more rearward as it is located more upward; that is, the lower portion 19 b thereof is more frontward as it is located more downward. Consequently, the vertical dimension of the radiator 19 can be increased, and hence the cooling performance can be improved corresponding thereto. More specifically, since the hood 25 is located near the upper portion of the radiator 19 , in the case where, for example, the radiator 19 is disposed upright, the vertical dimension thereof has to be reduced to prevent interference with the hood 25 . In the present embodiment, the radiator 19 is rearwardly inclined, so that the size of the radiator 19 can be increased.
In the present embodiment, the radiator 19 is disposed to diagonally intersect with the first and the second front side frames 47 and 48 . From this respect as well, the size of the radiator 19 can be increased, thereby enabling the cooling performance to be enhanced.
In the present embodiment, the radiator 19 is the vertical type radiator in which the upper and lower head tank 56 and 57 are, respectively, connected to the upper and lower ends of the core 55 . Further, the lower head tank 57 is resiliently supported by means of the fixing bracket 60 of the front frame 2 c . Consequently, the size of the radiator 19 can be increased while preventing interference with the hood 25 , and hence the cooling performance can be improved. In other words, it is more advantageous in terms of the cost to increase the radiation area size by increasing the core length rather than increasing the number of cores. In the present embodiment, since the radiator 19 is of the vertical type, the radiation area size can be increased by increasing the core length.
In the present embodiment, the first and the second front side frames 47 and 48 are each inclined upwardly in an upward direction towards the vehicle rear so that it is positioned higher as it comes nearer to the vehicle rearward direction. Consequently, the inclination angle of the radiator 19 can be increased while preventing the interference with the hood 25 , and the size of the radiator 19 can be increased corresponding thereto.
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A vehicle including a main body frame having a length direction and a width direction includes a front frame carried by the main body frame. The front frame includes a first front cross frame having a generally height and extends along said main body's width direction. A second front cross frame is disposed frontward and offset from the first cross frame at an elevational height less than the first front cross frame. A first and second side frame interconnect with the first cross frame and the second cross frame to define radiator cage having an interior space. A radiator is disposed within the interior space of said radiator cage.
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This application is a divisional of U.S. Ser. No. 10/261,107 filed Sep. 30, 2002 now U.S. Pat. No. 6,767,455, which claims priority of provisional patent application Ser. No. 60/404,944 filed on Aug. 21, 2002, the disclosures of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to an airlift membrane device, an airlift membrane bioreactor containing same, and an airlift bioreactor process. The membrane device utilizes one or more multiple passageway porous monoliths as a microfiltration or ultrafiltration membrane support. The monolith-based membrane device provides a compact, low cost device that has well-controlled and efficient airlift for membrane flux maintenance. The use of a ceramic membrane offers a hydrophilic membrane resistant to fouling by the bioreactor biomass feed stock.
BACKGROUND AND PRIOR AND RELATED ART
The rapid emergence of the membrane bioreactor (MBR) has lead to the deployment of several types of membrane devices in such MBR's, in both “submerged membrane” and pumped “external loop” membrane module configurations. For the submerged membrane configuration, which is favored due to lower costs, there are primarily two membrane types employed: polymeric hollow fibers and polymeric plate devices. Descriptions of the state of the art for both submerged and external loop technology can be found in the following:
1. Articles in the June 2002 issue of Filtration+Separation, Vol. 39, no. 5, pages 26-35. 2. Proceedings of the Microfiltration III Conference, Costa Mesa, Calif., May 5-7, 2002. 3. “Membrane Bioreactors: Wastewater Treatment Applications to Achieve High Quality Effluent”, by Steven Till and Henry Mallia, presented at the 64 th Annual Water Industry Engineers and Operators' Conference, Sep. 5-6, 2001, Bendigo, Australia.
The last paper describes the two leading submerged systems, hollow fibers sold by Zenon (Canada) and plate devices sold by Kubota (Japan). The invention that is the subject of this patent application and that can be used in a submerged MBR is a substantially different membrane configuration, viz. a multiple passageway monolith membrane device. The structures covered by this invention have the characteristics of intrinsically low cost and a very high membrane surface area per unit volume of the device.
Similar devices in various structures when used as crossflow membrane modules, as could be used in external loop MBR's, have been disclosed in the following patents, specifically incorporated herein by reference:
1. U.S. Pat. No. 4,781,831 (Goldsmith), which discloses in FIG. 5 therein, and described in the patent Specification, a cluster of individual multiple passageway monoliths arranged to have “filtrate flow conduits” formed by the space among the monolith elements. 2. U.S. Pat. Nos. 5,009,781 and 5,108,601 (Goldsmith), which therein disclose in the Figures and Specification unitary monolith structures with filtrate conduits formed within the monoliths. 3. U.S. Pat. No. 6,126,833 (Stobbe, et al.), which discloses structures comprised of a collection of monolith segments containing both segment internal filtrate conduits and a filtrate conduit arrangement formed by the gap among the monolith segments.
Preferred embodiments of the monolith based membrane device would be fabricated from a porous ceramic monolith support and a finer-pored ceramic or polymeric membrane coating applied to the passageway wall surfaces of the monolith support.
Ceramic membrane microfiltration (MF) and ultrafiltration (UF) devices have been used in external MBR systems. Examples are found in an article by Wen, Xing, and Qian (“Ceramic Ultra Filtration Membrane Bioreactor for Domestic Wastewater Treatment”, Tsinghau Science and Technology, ISSN 1007-0214, 08/17, Vol. 5, No. 3, pp 283-287 (September 2000)) and an article by Fan, Urbain, Qian, and Manem (“Ultrafiltration of Activated Sludge with Ceramic Membranes in a Cross-Flow Membrane Bioreactor Process”, Water Science & Technology, Vol. 41, No. 10-11, pp 243-250 (2000)).
There has been little work using ceramic membranes in a submerged MBR configuration. A recent presentation by Xu, Xing, and Xu entitled “Design and Application of Airlift Membrane-Bioreactor for Municipal Wastewater Reclamation” describes the use of an airlift MBR using single tubular ceramic UF membrane elements and a five (5) channel multichannel UF membrane element (Presentation at the North American Membrane Society Meeting, May 11-15, 2002, Long Beach, Calif.).
SUMMARY OF THE INVENTION
This device features a submerged, vertically-mounted airlift membrane device. The device comprises a structure of one or more monolith segments of porous material, each monolith segment defining a plurality of passageways extending longitudinally from a bottom feed end face to a top retentate end face. The surface area of the passageways in the monolith segment is at least 150 square meters per cubic meter of monolith segment volume, and the porous material has a porosity of at least 30% and a mean pore size of at least 3 μm porous membrane with mean pore size below 1 μm is applied to the walls of the monolith segment passageways to provide a separating barrier. A gas sparger is located below the device to provide a gas-sparged liquid feed stock at the bottom end face to provide airlift circulation of the feed stock through the device, which separates the feed stock into filtrate and a residual gas-containing retentate that passes from the top end face of the device. At least one filtrate conduit is formed within the device for carrying filtrate from within the device toward a filtrate collection zone of the device, the filtrate conduit providing a path of lower flow resistance than that of alternative flow paths through the porous material. The device has at least one seal to separate feed stock and retentate from the filtrate collection zone.
In a preferred embodiment, the porous material of the membrane device is ceramic. The device structure can be comprised of a single monolith or an assembly of monolith segments. The membrane device can be contained in a housing for filtrate collection and the filtrate collection zone is the annular space between the device and the housing. Alternatively, the device can be isolated along the exterior surface and the filtrate can be withdrawn from an end face of the device.
The membrane used in the device can be a microfiltration membrane with a pore size from about 0.1 to about 1 micron or an ultrafiltration membrane with a pore size from about 5 nm to about 0.1 micron. Preferably, the membrane is a ceramic membrane.
The vertically mounted membrane device can contain a shroud extending below the bottom end face of the device and the gas is sparged into a cavity created by the shroud. Preferably, the hydraulic diameter of the passageways is from about 4 to 15 mm and the preferred hydraulic diameter of the monolith segments is greater than about 50 mm.
This membrane device can be used in a membrane bioreactor that includes, in addition to the cross flow membrane device, a membrane bioreactor feed tank with means of introduction of a liquid feed stock and a means to convey the filtrate from the filtrate collection zone of the device to the filtrate discharge point of the bioreactor.
The membrane device can be installed within a bioreactor feed tank in an internal airlift circulation loop, or it can installed external to the feed tank in an external airlift circulation loop. The sparged gas can be air or oxygen and the bioreactor can operate under aerobic conditions, or the sparged gas can have low or negligible oxygen content and the bioreactor can operate under anaerobic conditions.
This invention further features a bioreactor process that includes introducing a feedstock into a submerged airlift membrane bioreactor. Gas is sparged at a bottom feed inlet of at least one submerged, vertically-mounted membrane device to provide airlift circulation of the feedstock through the device, and the feed stock is separated into filtrate and residual gas-containing retentate which passes from the top end of the device. The device consists of a structure of one or more monolith segments of porous material each monolith segment defining a plurality of passageways extending longitudinally from a bottom feed end face to a top retentate end face, the surface area of the passageways in the monolith segment being at least 150 square meters per cubic meter of monolith segment volume. The porous material has a porosity of at least 30% and a mean pore size of at least 3 μm and a porous membrane with mean pore size below 1 μm is applied to the walls of the monolith segment passageways to provide a separating barrier. At least one filtrate conduit within the device carries filtrate from within the device toward a filtrate collection zone of the device, and the filtrate conduit provides a path of lower flow resistance than that of alternative flow paths through the porous material. The device has a means to separate feed stock and retentate from the filtrate collection zone. The filtrate collected in the filtrate collection zone is conveyed to the filtrate discharge point of the bioreactor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a potted membrane element in an enclosing housing in accordance with an embodiment of the present invention;
FIG. 2 is a perspective view of a segmented structure assembled around a central cavity in accordance with an embodiment of the present invention;
FIGS. 3 a and 3 b are top views of multiple membrane devices mounted vertically in a membrane bioreactor wastewater tank in accordance with an embodiment of the present invention;
FIG. 4 is a cross-sectional view of an aerobic membrane bioreactor wherein air is sparged at the bottom ends of the membrane devices in accordance with an embodiment of the present invention;
FIG. 5 is a cross-sectional view of an aerobic membrane bioreactor wherein air is sparged within shrouds at the bottom ends of the membrane devices in accordance with an embodiment of the present invention; and
FIG. 6 is a top view of banks of membrane modules in a bioreactor tank in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF INVENTION
The description which follows focuses on an airlift MBR. However, the membrane element that is the subject of the present invention can be used for any pressure-driven membrane process in which a liquid feed stock is separated into filtrate and retentate streams. The transmembrane pressure driving force can be applied by using a filtrate pump to create a filtrate pressure below that of the pressure of the feed stock. Alternatively, the filtrate can be withdrawn at a location physically below the level of the membrane element, in which case the elevation of the membrane element higher than the withdrawal point of the filtrate creates a gravity head transmembrane pressure. While processes in which the feed stock is essentially at atmospheric pressure are envisioned, a pressurized feed stock can also be used to create the necessary transmembrane pressure. Membrane processes for which this invention is especially applicable include microfiltration and ultrafiltration. However, if the necessary transmembrane pressure can be generated, the invention could be used for nanofiltration and reverse osmosis.
The present invention recognizes the potential use of large diameter monolith membrane devices in a submerged, airlift MBR, taking into account important requirements for an airlift MBR, viz.
1. Operation of the MBR at a relatively low transmembrane pressure (TMP), and the resultant requirement of having a monolith membrane support and membrane coating with high permeability; 2. Operation of the MBR with a high level of suspended solids (e.g., 10,000-20,000 mg/l), which can plug passageways below a minimum dimension; and 3. The need to have a membrane with a pore size sufficiently small to efficiently retain the MBR biomass.
In the present invention, one or more porous honeycomb monolith segments are used as membrane supports. The monolith material is preferably a ceramic, but can also be a porous metal, plastic, filled resin, resin-bonded glass or sand or metal, or other composites. For ceramics, preferred materials have been disclosed in the US Patents of Goldsmith and Stobbe, et al., cited above, as well as the reaction bonded alumina monolith disclosed in U.S. patent application Ser. No. 10/097,921 filed Mar. 13, 2002, the disclosure of which is hereby incorporated by reference.
The monoliths can have a circular, square, hexagonal, rectangular, triangular or other cross-section. The passageway hydraulic diameter should be 2 mm or greater, preferably in the range of about 4 to 15 mm, selected to be sufficiently large so as to resist blockage by solids under operating conditions in an airlift MBR. The monolith porosity should be greater than 30%, preferably greater than 40% to maximize permeability. The monolith passageway wall thickness should be sufficiently high to provide adequate strength and permeability, but not so high so as to deleteriously reduce the passageway wall area per unit volume. Typically, the monolith passageway wall thickness would be between 20% and 40% of the passageway hydraulic diameter. To minimize costs of the device, the hydraulic diameter of the monolith should be relatively large, preferably greater than about 50 mm.
The structure of the monolith support can be as disclosed in the cited patents of Goldsmith and Stobbe, et al. These include a single monolith with internal filtrate conduits, an assembly of monolith segments with the filtrate conduit formed by the space among segments, and the same with the segments having one or more internal filtrate conduits.
The monolith support (or supports) can be coated with a MF membrane or a UF membrane. The membrane could be ceramic, polymeric, or metallic. Membrane coating materials and procedures for coating tubular and monolith supports are well known in the membrane art. One category of preferred membranes includes MF membranes which have a pore size in the range of about 0.1 to 0.5 μm, and which are capable of having very high retention efficiency for microorganisms. A second type of membrane that can be employed is an UF membrane, with a pore size in the range of about 0.01 to 0.1 μm and which can also retain viruses with high efficiency.
The single or multiple monolith segment device, after coating with a membrane, becomes a membrane element that must be configured with a means to separate filtrate from the MBR feed contents. For the honeycomb monolith membrane element structures, means of filtrate withdrawal have been disclosed in the patents of Goldsmith, cited above and included herein by reference. One means is withdrawal of filtrate from along the sides of the monolith membrane element into an enclosing housing. One simple means to accomplish this is to pot the membrane element into a housing. As shown in FIG. 1 , an individual filter element 12 with internal filtrate conduits is potted into a housing 10 with potting compound 13 . The housing 10 includes a standoff ring 14 and a support ring 15 as shown. Another method of filtrate withdrawal is to extract filtrate from an end face of the membrane element. This can be accomplished, for example, with the segmented structures of Stobbe, et al., with the filtrate collection tubes of Goldsmith (U.S. Pat. No. 5,009,781), and to withdraw the filtrate from an end face of a multi-segment element. Such a structure is illustrated in FIG. 2 . In this example, “ring segments” 16 (eight shown) with their external surface sealed are assembled around a central cavity 17 for filtrate withdrawal. The segments 16 are wrapped with an impermeable sleeve or otherwise sealed to hold the assembly together and to prevent filtrate from exiting at the lateral circumferential surface of the structure. The central cavity 17 is connected to a filtrate withdrawal tube sealed in the cavity 17 but not shown), which need not run the length of the structure. The intersegment portion 18 and intrasegment portion 19 of the filtrate conduit are sealed at the end faces. The assembled segmented structure is appropriately sealed at the ends to prevent contamination of the filtrate by feed wastewater. The filtrate withdrawal tube can also serve as a mechanical support for the membrane element mounted vertically in a MBR waste treatment tank.
Structures of the type described above can have a very high membrane packing density. For example, for different passageway sizes and monolith wall thicknesses, assuming 80% utilization of the passageways for contacting a feed stock, the packing densities of Table 1 are achievable.
TABLE 1
Properties of Monolith Based Membrane Devices
Percentage
passageways
Approximate
Wall
used for
Membrane
Passageway
thickness
Feed stock
area/volume, sq
size, mm
@ 25%, mm
passageways
m/cu m
4
1
80%
510
6
1.5
80%
340
8
2
80%
255
10
2.5
80%
205
12
3
80%
170
A membrane element, provided with a means to separate filtrate and feed wastewater and a means to withdraw filtrate to an exterior point becomes a membrane device. The necessary transmembrane pressure (TMP) to drive filtrate can be achieved by either of the means normally employed in other submerged MBR's, viz. gravity head or a filtrate pump which pulls a partial vacuum on the filtrate side of the device.
Multiple membrane devices can be mounted vertically in a MBR wastewater tank in a closely packed array, such as shown in FIGS. 3 a and 3 b . FIG. 3 a illustrates a 2×8 array of square filter elements 12 ′. The elements can have filtrate withdrawn from the side of the enclosure (not shown) or end tubes can be connected to internal filtrate collection cavities. FIG. 3 b illustrates a 4×7 array of round filter elements 12 ″. The elements can have filtrate withdrawn from individual housing shells or end tubes from the top or bottom end faces. For an aerobic MBR, air (or oxygen) is sparged at the bottom ends of the membrane devices with a suitable sparger 21 in communication with a source of compressed air or oxygen and the rising gas 22 provides the airlift for liquid flow through the passageways and oxygen for the biological oxidation process (FIG. 4 ). It is possible to provide shrouds 23 around the lower part of the membrane devices and to have the air (or oxygen) sparged within the shroud to insure that all sparged gas will flow up through the device passageways (FIG. 5 ). This will provide the most efficient means of air or oxygen introduction in terms of efficient airlift mass transfer within the membrane devices since all of the gas will flow through the membrane devices with negligible bypassing as found, especially, in hollow fiber MBR contactors.
The same membrane device can be used for an anaerobic MBR, sparging with inert gas or a gas with low oxygen content.
The arrangement of membrane devices, as shown in FIG. 6 , has the spacing among banks of membrane devices 25 available for liquid downflow after disengagement of the gas and liquid at the top of the devices. The banks 25 are separated by open spaces for deaerated liquid downflow. Filtrate withdrawal depends on whether housings or internal cavities are used to remove filtrate. Aeration sparger(s) at the bottom of the device are not shown.
The advantages of the subject invention include the following. First, the compactness of the membrane devices provides a very high membrane area per unit volume of the submerged MBR reactor, comparable to those of hollow fiber and plate MBR's. Second, the hydrodynamic control of liquid in the device passageways will promote very high mass transfer, uniform throughout the device. The use of shrouds will insure all gas introduced is used for efficient airlift. This should provide high membrane flux and low compressed gas power per unit flux relative to other membrane devices. A preferred membrane will be ceramic, which will be very rugged and mechanically durable, and can be expected to have a long life relative to polymeric membranes used in hollow fiber and plate configurations. For ceramic membranes, in particular, it is possible to apply membrane coatings which are highly hydrophilic and will be weakly adsorptive of organic contaminants present in MBR's. This will reduce fouling and improve effectiveness of chemical cleaning. The devices are capable of cleaning by pressurized filtrate backflushing, pressurized gas backflushing, chemical solution backflushing, and circulation of chemical cleaning solutions in a normal operating mode, especially when operating without filtrate withdrawal. Cleaning agents can include acids, caustic and oxidants such as hypochlorite.
The use of large diameter monolith devices, as disclosed herein, is conducive to production of ceramic membrane devices that can be cost competitive with lost cost polymeric membranes. While the membrane devices may be more costly than polymeric hollow fibers per unit membrane area, the anticipated advantages of higher membrane flux, lower power consumption, and longer membrane life will offset a higher membrane area cost.
As an alternative to immersion of the membrane devices in the MBR feed tank, they can be utilized in an external airlift circulation mode. In this arrangement, the membrane devices are mounted external to the feed tank and the airlift gas in the membrane devices creates circulation between the feed tank and the external membrane devices.
Although specific features of the invention are described in various embodiments, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. Other embodiments will occur to those skilled in the art and are within the scope of the following claims:
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A submerged, vertically-mounted membrane device, the device receiving a gas-sparged feed stock at a bottom feed inlet to provide airlift circulation of the feed stock through the device and separating the feed stock into filtrate and residual gas-containing retentate which passes from the top end of the device. The device comprises a structure of one or more monolith segments of porous material each monolith segment defining a plurality of passageways extending longitudinally from a bottom feed end face to a top retentate end face. A porous membrane is applied to the walls of the monolith segment passageways to provide a separating barrier. At least one filtrate conduit within the device carries filtrate from within the device toward a filtrate collection zone of the device, and the filtrate conduit provides a path of lower flow resistance than that of alternative flow paths through the porous material. A seal is provided to separate feed stock and retentate from the filtrate collection zone.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an inkjet recording head and an inkjet recording apparatus for recording data on a material to be recorded by ejecting ink as liquid droplets. The present invention is applicable to apparatuses such as copy machines, facsimiles having a communication system, word processors having a print unit, and the like, and further to industrial recording apparatuses which are in complex combination with various processing apparatuses, in addition to ordinary printers.
[0003] In the specification, a term “print” (sometimes, also referred to as “recording”) not only means a case in which meaningful information of characters, graphics, and the like is formed but also widely means a case in which images, shapes, patterns, and the like are formed on a print medium or the print medium is processed so as to show them thereon regardless of that they are meaningful or meaningless and that they are made obvious so as to be visually recognized by a person or not. The term “print medium” used here not only means paper used in an ordinary printer but also widely means ink recipients such as cloth, plastic, film, metal sheet, glass, ceramics, wood, leather, and the like. Further, the term “ink” (sometimes, also referred to as “liquid”) must be widely interpreted similarly to the definition of the term “print” and means a liquid which can form images, shapes, patterns, and the like by being applied onto a print medium or a liquid used to process a print medium or ink (for example, to solidify color agents in ink or to make the color agents insoluble).
[0004] 2. Description of the Related Art
[0005] Recently, the performance of inkjet printers has been remarkably improved. Inkjet printers of late have realized a print speed as high as that of laser beam printers. Further, it is more and more required to increase a print speed of color images as a processing speed of personal computers is increased and the Internet becomes widespread.
[0006] A bubble jet recording system as one of inkjet recording systems is arranged such that ink is abruptly heated and vaporized by a heating element and the ink is ejected as liquid droplets from ejection ports (orifices) making use of the pressure of generated bubbles. Bubbles generated in a bubble jet recording head finally disappear because they are cooled by the ink in the vicinity of them and the vapor of the ink in the bubbles is condensed and returned to a liquid. The ink consumed by being ejected is refilled from an ink supply port through an ink supply path. Further, there is also available a recording system for abruptly heating and vaporizing ink by a heating element and ejecting generated bubbles by communicating them to the outside air.
[0007] A bubble jet recording heads according to a background art will be described. FIG. 6 is a schematic view showing a structure nozzles (ink flow paths to ejecting ports) of a first example of the bubble jet recording head according to the background art, and FIG. 7 is an enlarged schematic view showing traces of ink droplets recorded by the structure off the nozzles of the first example.
[0008] When an inkjet head as shown in FIG. 6 in which ink ejecting ports 3 and heaters (not shown), which are disposed inwardly of the ejecting port 3 , are disposed in a single row, respectively, no difference is caused in the refill of ink because the ink flow paths 6 in respective segments have the same length. However, when timeshared drive is executed, positions at which ink droplets arrive are off-set in correspondence a sequence of drive, by which a problem is arisen in the formation of an image. FIG. 7 shows a case in which linear image data is printed using even segments, wherein a straight line is printed as zigzag lines spaced apart from each other by a maximum of 42.3 μm.
[0009] Whereas, when the timeshared drive is not executed, a problem is arisen in that a value of a current which instantly flows to heaters and electrodes increases and a voltage is dropped, and thus a print fades when an image of high duty is printed.
[0010] Another background art of a bubble jet recording head will be described. FIG. 8 is a schematic view showing a nozzle structure as a second example of the bubble jet recording head according to the background art.
[0011] In FIG. 8, the nozzles have a density is 600 dpi. A heating element (not shown) and an ink ejecting port 3 are disposed in a nozzle at positions which are different on a segment 0 side (even segments) and on a segment 2 side (odd segments). That is, the ink flow paths 6 on the even number segment side are made longer in a sequence of the segment numbers 2 , 4 , 6 , 8 , and 0 , whereas the ink flow paths 6 on the odd number segment side are made shorter in a sequence of the segment numbers 3 , 5 , 7 , 9 , and 1 , whereby the above problem of the first example is solved. In FIG. 8, an ink supply path 1 is disposed vertically at a center, and ink is supplied to the respective nozzles from a segment 0 to a segment 255 through the ink flow paths 6 having a different length.
[0012] Since a lot of nozzles, that is, 256 nozzles are provided, a value of a current which flows instantly is suppressed by executing a timeshared drive as described below. In the even segments, the eight nozzles of the segments 0 , 32 , 64 , 96 , 128 , . . . , 224 are arranged as a first block, and the eight nozzles of the segments 10 , 42 , 74 , . . . , 234 are arranged as a second block. Whereas, in the odd segments, the eight nozzles of the segments 17 , 49 , 81 , 113 , . . . , 241 are arranged as a first block, and the eight nozzles of the segments 27 , 59 , 91 , . . . , 251 are arranged as a second block. In this construction, respective eight nozzles of the odd and even side segments are arranged as one block unit, and the odd side segments and the even side segments are divided into 16 blocks, respectively. Since the arrangements of a third block to a sixteenth block are similar to those described later, the description of them is omitted here.
[0013] When the image data of the segments 0 to 31 shown in FIG. 8 is turned ON and flows, drive pulses are applied to the heating elements of the segments 0 to 31 in a sequence of the block numbers 1 to 16 . At that time, the drive pulses are applied to the respective blocks at intervals of 5.9 μs and drive every 16 nozzles on one side. In the even segments, a segment having a larger distance (hereinafter, referred to as (C-H distance) between an heating element and an ink supply port (a position 5 branched from an ink supply path) is driven earlier. Whereas, in the odd segments, a segment having a shorter C-H distance is driven earlier.
[0014] When the drive pulses are applied to the heating elements, ink droplets are ejected from ejecting ports. While consumed ink is refilled from the ink supply ports through the ink supply path 1 , a time at which the ink is refilled to a segment having a longer C-H distance is delayed as compared with a time at which it is refilled to a segment having a shorter C-H distance by the difference of the distance thereof. Thus, a problem is arisen in that the throughput of a printer cannot be increased because a response cycle must be set in accordance with a long C-H distance to obtain good print quality.
[0015] In contrast, while a fixed C-H distance can be set to all the nozzles when the ink supply ports are disposed zigzag, a problem is arisen in this case in that a refill time is delayed because the width of the supply ports of the portions thereof disposed zigzag is narrowed.
SUMMARY OF THE INVENTION
[0016] Accordingly, it is an object of the present invention to provide an inkjet recording head and an inkjet recording apparatus capable of maximizing a refill cycle while keeping the linearity of an image even if timeshared drive is executed and capable of improving the throughput of a printer.
[0017] Another object of the present invention is to provide an inkjet recording head and an inkjet recording apparatus for ejecting ink droplets in an off-set state without changing a length of ink flow paths to keep the linearity of an image.
[0018] A still another object of the present invention is to provide an inkjet recording head having a plurality of ink ejecting ports and a plurality of energy generating elements respectively positioned in confrontation with the ink ejecting ports for generating energy utilized to eject ink from the ink ejecting ports, the plurality of ink ejecting ports and the plurality of energy generating elements being divided into a plurality of blocks, and the ejecting ports and the energy generating elements being timeshared driven in a sequence of the blocks in a common driving period, wherein the plurality of energy generating elements are disposed in an approximate straight line, and the respective ink ejecting ports are off-set with respect to the energy generating elements in a projecting relationship in correspondence to the sequence of the timeshared drive and to provide an inkjet recording apparatus having the inkjet recording head.
[0019] A further object of the present invention is to provide an inkjet recording head having a plurality of ink ejecting ports and a plurality of energy generating elements respectively positioned in confrontation with the ink ejecting ports for generating energy utilized to eject ink from the ink ejecting ports, the plurality of ink ejecting ports and the plurality of energy generating elements being divided into a plurality of blocks, and the ejecting ports and the energy generating elements being timeshared driven in a sequence of the blocks in a common driving period, wherein the plurality of ink ejecting ports are disposed in an approximate straight line, and the respective energy generating elements are off-set with respect to the ink ejecting ports in a projecting relationship in correspondence to the sequence of the timeshared drive and to provide an inkjet recording apparatus having the inkjet recording head.
[0020] According to the present invention, since any ones of the energy generating elements and the ink ejecting ports are disposed in the approximate straight line and the positions of the energy generating elements are relatively off-set with respect to the positions of the ink ejecting ports, the linearity of an image can be maintained even if the timeshared drive is executed. Further, when the intervals between the energy generating elements and the positions where ink flow paths are branched from ink supply ports is made as short as possible within a range of allowance required in manufacture as to all the nozzles, a refill cycle can be maximized, whereby a throughput of a printer can be improved.
[0021] Further objects, features and advantages of the present invention will become apparent from the following description of the preferred embodiments with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a schematic view showing a nozzle structure of an inkjet recording head as a first embodiment of the present invention;
[0023] [0023]FIG. 2A is a sectional view of a nozzle the center of an ejecting port of which is off-set near to a branch position side with respect to a heater, and FIG. 2B is a sectional view of a nozzle the center of an ejecting port of which is off-set far from a branch position side with respect to a heater;
[0024] [0024]FIG. 3 is a graph showing a relationship between an amount of off-set of an ejecting port and an off-set amount of an ink droplet arriving position;
[0025] [0025]FIG. 4 is an enlarged schematic view showing traces of ink droplets recorded by the structure of the nozzles of the first embodiment;
[0026] [0026]FIG. 5 is a schematic view showing a nozzle structure of an inkjet recording head as a second embodiment of the present invention;
[0027] [0027]FIG. 6 is a schematic view showing a nozzle structure as a first example of a bubble jet recording head according to background art;
[0028] [0028]FIG. 7 is an enlarged schematic view showing traces of ink droplets recorded by the structure of the nozzles of the first example according to the background art;
[0029] [0029]FIG. 8 is a schematic view showing a nozzle structure as a second example of the bubble jet recording head according to the background art;
[0030] [0030]FIG. 9 is a perspective view, partly in cross section, showing a main portion of an inkjet head according to the embodiments of the present invention;
[0031] [0031]FIG. 10 is a perspective view showing an overall outline of the inkjet head according to the embodiments of the present invention;
[0032] [0032]FIG. 11 is a perspective view showing an overall outline of an inkjet recording apparatus according to the embodiments of the present invention; and
[0033] [0033]FIG. 12 is a perspective view showing a main portion of the inkjet recording apparatus according to the embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Embodiments of the present invention will be described with reference to the drawings. In the present invention, an expression that “A is off-set with respect to B in a projecting relationship” means that “a center line of A is off-set with respect to a center line of B”. Further, when a term “approximate” is used in the present invention, while a term modified by the term “approximate” is outside of the range of the term itself, the difference of the modified term is very small or the modified term is within a range of error.
[0035] (First Embodiment)
[0036] A first embodiment shows a case in which ejecting ports are off-set with respect to heaters disposed in a straight line.
[0037] [0037]FIG. 1 is a schematic view showing a nozzle structure of an inkjet recording head as the first embodiment of the present invention. The inkjet recording head of the embodiment is of a so-called side shooter type (refer to FIG. 2). Note that FIG. 1 shows only 32 nozzles for the convenience of description as apparent from the following description. Further, both ejecting ports 3 and hearers 2 are shown by solid lines in order to indicate a positional relationship therebetween.
[0038] As shown in FIG. 1, the hearers 2 are disposed in a straight line. The reference number 4 is a dot-dash-line showing a center of the heater 2 . The heaters are disposed in two rows (even and odd rows) while keeping the same distances from the ends of ink flow paths (not shown) branched from an ink supply path 1 to respective nozzles (positions 5 branched from the ink supply path 1 ) to the hearers 2 . Each heater is formed in a square shape having the same size of 36 μm, and each ejecting port is formed in a square shape of 26 μm. A nozzle density is set to 600 dpi, and an interval between segments 0 and 1 is set to 42.3 μm.
[0039] Incidentally, as a result of a diligent study, the inventors have found that when an ejecting port 3 , which is in confrontation with a thermal energy generator (heater) 2 disposed in an ink flow path 6 , is located at a position slightly off-set in a direction where the ejecting port 3 is near to or far from the ink supply path 1 (or the branch position 5 ), there is a tendency that a position at which an ink droplet arrives is off-set in a direction where the ejecting port 3 is off-set (refer to FIG. 2).
[0040] [0040]FIG. 2A is a sectional view of a nozzle the center of an ejecting port of which is off-set near to a branch position side with respect to a heater, and FIG. 2B is a sectional view of a nozzle the center of an ejecting port of which is off-set far from a branch position side with respect to a heater.
[0041] It should be noted that while FIG. 2 shows an odd nozzle, it is a matter of course that an even nozzle also tends to eject an ink droplet in an off-set state as shown in FIG. 2 without the need of illustrating it. Further, in FIG. 2, a flow path has a height H set to 17 μm, and an orifice plate has a thickness T set to 9 μm. While the ejecting port is formed in a squire shape in FIG. 2 for the sake of convenience, a similar effect can be obtained even if it is formed in, for example, a rectangular, circular, or star shape.
[0042] [0042]FIG. 3 is a graph showing a relationship between an amount of off-set of an ejecting port and an amount of off-set of arriving position of an ink droplet.
[0043] As shown in FIGS. 2 and 3, when an amount of off-set of the ejecting port 3 with respect to the hearer 2 has a positive value, the ejecting port 3 is off-set in a direction where it is far from the ink supply path 1 , whereas when it has a negative value, the ejecting port 3 is off-set in a direction where it is near to the ink supply path 1 . In the present invention, an ejecting direction of an ink droplet can be controlled by adjusting an amount of off-set of each ejecting port in accordance with a driving sequence thereof in timeshared drive, making use of the above phenomenon.
[0044] Thus, the distances between the centers of the respective hearers 2 of the segments 0 , 2 , 4 , . . . , 30 of an even heater group on a left side shown in FIG. 1 and the centers of the ejecting ports 3 of the respective segments are set as follows.
[0045] That is, the segment 0 is off-set +2.0 μm, the segment 2 is off-set −1.5 μm, the segment 4 is off-set −0.5 μm, the segment 6 is off-set 0 μm, the segment 8 is off-set +1.0 μm, the segment 10 is off-set +2.0 μm, the segment 12 is off-set −2.0 μm, the segment 14 is off-set −1.0 μm, the segment 16 is off-set 0 μm, the segment 18 is off-set +0.5 μm, the segment 20 is off-set +1.5 μm, the segment 22 is off-set −2.0 μm, the segment 24 is off-set −1.0 μm, the segment 26 is off-set −0.5 μm, the segment 28 is off-set +0.5 μm, and the segment 30 is off-set +1.0 μm, in correspondence to the sequence of the timeshared drive.
[0046] In contrast, the distances between the centers of the respective hearers of the segments 1 , 3 , 5 , . . . , 31 of an odd heater group on a right side shown in FIG. 1 and the centers of the ejecting ports of the respective segments are set as follows. That is, the segment 1 is off-set 0 μm, the segment 3 is off-set −0.5 μm, the segment 5 is off-set −1.5 μm, the segment 7 is off-set +2.0 μm, the segment 9 is off-set +1.0 μm, the segment 11 is off-set +0.5 μm, the segment 13 is off-set −0.5 μm, the segment 15 is off-set −1.0 μm, the segment 17 is off-set −0.2 μm, the segment 19 is off-set +1.5 μm, the segment 21 is off-set +0.5 μm, the segment 23 is off-set 0 μm, the segment 25 is off-set −1.0 μm, the segment 27 is off-set −2.0 μm, the segment 29 is off-set +2.0 μm, and the segment 31 is off-set +1.0 μm.
[0047] Operation of the inkjet recording head of the first embodiment will be explained with reference to the drawings.
[0048] First, when pulses are applied to the heaters, ink is supplied from the ink supply path 1 at the center to the nozzles of the segments 0 to 255 through the ink flow paths, and ink droplets are ejected from the ejecting ports 3 . Since a lot of the nozzles, that is, the 256 nozzles are provided, a value of a current that flows instantly is suppressed by executing the timeshared drive as described below.
[0049] In the even segments, the eight nozzles of the segments 0 , 32 , 64 , 96 , 128 , . . . , 224 are arranged as a first block, whereas, in the odd segments, the eight nozzles of the segments 17 , 49 , 81 , 113 , . . . , 241 are arranged as a first block.
[0050] In the even segments, a second block is composed of the segments 10 , 42 , 74 , . . . , 234 , whereas, in the odd segments, a second block is composed of the segments 27 , 59 , 91 , . . . , 251 . Then, every eight nozzles are driven on one side. In the same way, third blocks are composed of the even segments 20 , 52 , . . . , 244 and the odd segments 5 , 37 , 69 , . . . , 229 ; fourth blocks are composed of the even segments 30 , 62 , . . . , 254 and the odd segments 15 , 47 , 79 . . . , 239 ; fifth blocks are composed of the even segments 8 , 40 , . . . , 232 and the odd segments 25 , 57 , 89 , . . . , 249 ; sixth blocks are composed of the even segments 18 , 50 , . . . , 242 and the odd segments 3 , 35 , . . . , 227 ; seventh blocks are composed of the even segments 28 , 60 , . . . , 252 and the odd segments 13 , 45 . . . , 237 ; eighth blocks are composed of the even segments 6 , 38 , . . . , 230 and the odd segments 23 , 55 , . . . , 247 ; ninth blocks are composed of the even segments 16 , 48 , . . . , 240 and the odd segments 1 , 33 , . . . , 225 ; tenth blocks are composed of the even segments 26 , 58 , . . . , 250 and the odd segments 11 , 43 , . . . , 235 ; eleventh blocks are composed of the even segments 4 , 36 , . . . , 228 and the odd segments 21 , 53 , . . . , 245 ; twelfth blocks are composed of the even segments 14 , 46 , . . . , 238 and the odd segments 31 , 63 , . . . , 255 ; thirteenth blocks are composed of the even segments 24 , 56 , . . . , 248 and the odd segments 9 , 41 , . . . , 233 ; fourteenth blocks are composed of the even segments 2 , 36 , . . . , 226 and the odd segments 19 , 51 , . . . , 243 ; fifteenth blocks are composed of the even segments 12 , 46 , . . . , 236 and the odd segments 29 , 61 , . . . , 253 ; and sixteenth blocks are composed of the even segments 22 , 56 , . . . , 246 and the odd segments 7 , 39 , . . . , 247 .
[0051] When the image data of the segments 0 to 31 shown in FIG. 1 is turned ON and flows, drive pulses are applied to the heating elements of the segments 0 to 31 in a sequence of the block numbers 1 to 16 . At that time, the drive pulses are applied to the respective blocks at intervals of 5.9 μs.
[0052] The ejecting ports of the segments in the blocks which are timeshared driven first, second, and third to seventhly, for example, the ejecting ports of the above-mentioned even segments 0 , 10 , 20 , 30 , 8 , 18 , and 28 are off-set in the (+) direction where the ejecting ports are apart from the ink supply path 1 . Accordingly, the ejecting ports eject ink droplets 7 in a direction similar to that shown in FIG. 2A. Likewise, the ejecting ports of the odd segments 17 , 27 , 5 , 15 , 25 , 3 , and 13 are off-set in the (−) direction where they are near to the ink supply path 1 . Thus, the ejecting ports eject ink droplets 7 in a direction similar to that shown in FIG. 2B. In this case, it can be said that the first to seventh even segments execute “going-away” ejection, and the first to seventh odd segments execute “coming-near” ejection.
[0053] Here, an ejection mode in which the ejecting ports of the even segments or the odd segments eject ink dropletso that the ink droplets go away from the ink supply path 1 is defined as the “going way” ejection, whereas an ejection mode in which they eject ink dropletso that the ink droplets come near to the ink supply path 1 is defined as the “coming-near” ejection. According to this definition, FIG. 2A shows the “going-away” ejection, and FIG. 2B shows the “coming-near” ejection. As to a relationship between an amount of off-set of ejecting port and an amount of off-set of arriving position, a larger amount of off-set of ejecting port causes an ejecting direction to be off-set in a larger amount.
[0054] The ejecting directions of the segments which are timeshared driven eighthly and ninthly (for example, the even segments 6 and 16 and the odd segments 23 and 1 which were described above) are not changed because these segments are not off-set.
[0055] As to the segments in the blocks which are timeshared driven tenthly to sixteenthly (for example, the even segments 26 , 4 , 14 , 24 , 2 , 12 , and 22 and the odd segments 11 , 21 , 31 , 9 , 13 , 29 , and 7 which were described above), the even segments execute the “coming-near” ejection similarly to that shown in FIG. 2B, whereas the odd segments execute the “going-away” ejection similarly to that shown in FIG. 2A, inversely.
[0056] As described above, when the timeshared drive is carried out, the arriving positions of ink droplets, which are otherwise off-set as shown in FIG. 7, can be maintained linearly as shown in FIG. 4, whereby an excellent image can be obtained.
[0057] (Second Embodiment)
[0058] In a second embodiment, heaters are off-set with respect to ejecting ports disposed in a straight line as shown in FIG. 5, contrary to the first embodiment. The reference number 4 a is a dot-dash-line showing a center of the ejecting port 3 .
[0059] Also in the second embodiment, the distances between the centers of the respective hearers of the segments 0 , 2 , 4 , . . . , 30 of an even heater group on a left side and the centers of the ejecting ports of the respective segments are set as described below. That is, the segment 0 is off-set +2 μm, the segment 2 is off-set −1.5 μm, the segment 4 is off-set −0.5 μm, the segment 6 is off-set 0 μm, the segment 8 is off-set +1 μm, the segment 10 is off-set +2.0 μm, the segment 12 is off-set −2.0 μm, the segment 14 is off-set −1.0 μm, the segment 16 is off-set 0 μm, the segment 18 is off-set +0.5 μm, the segment 20 is off-set +1.5 μm, the segment 22 is off-set −2.0 μm, the segment 24 is off-set −1.0 μm, the segment 26 is off-set −0.5 μm, the segment 28 is off-set +0.5 μm, and the segment 30 is off-set +1.0 μm in correspondence to the sequence of timeshared drive. In contrast, the distances between the centers of the respective hearers of the segments 1 , 3 , 5 , . . . , 31 of an odd heater group on a right side and the centers of the ejecting ports of the respective segments are set as follows. That is, the segment 1 is off-set 0 μm, the segment 3 is off-set −0.5 μm, the segment 5 is off-set −1.5 μm, the segment 7 is off-set +2.0 μm, the segment 9 is off-set +1.0 μm, the segment 11 is off-set +0.5 μm, the segment 13 is off-set −0.5 μm, the segment 15 is off-set −1.0 μm, the segment 17 is off-set −0.2 μm, the segment 19 is off-set +1.5 μm, the segment 21 is off-set +0.5 μm, the segment 23 is off-set 0 μm, the segment 25 is off-set −1.0 μm, the segment 27 is off-set −2.0 μm, the segment 29 is off-set +2.0 μm, and the segment 31 is off-set +1.0 μm in correspondence to the sequence of timeshared drive.
[0060] In the second embodiment, the “going-away” ejection is executed by the segments which are timeshared driven at a first half timing or first to seventhly, that is, the even segments 0 , 10 , 20 , 30 , 8 , 18 , and 28 and by the segments which are timeshared driven at a second half timing or tenthly to sixteenthly, that is, the odd segments 11 , 21 , 31 , 9 , 19 , 29 , and 7 , similarly to the first embodiment. Whereas, the “coming-near” ejection is executed by the segments which are timeshared driven at the second half timing or tenthly to sixteenthly, that is, the even segments 26 , 4 , 14 , 24 , 2 , 12 , and 22 and by the segments which are timeshared driven at the first half timing or first to seventhly, that is, the odd segments 17 , 27 , 5 , 15 , 25 , 3 , and 13 . Since the heaters are not off-set with respect the centers of the ejecting ports of the even segments 6 and 16 and the odd segments 1 and 11 which are disposed at the middle portion of the segments and timeshared driven eighthly and ninthly, these segments eject ink droplets and form an image having linearlity as shown in FIG. 4.
[0061] It should be noted that while a difference of a C-H distance is 4 μm, nozzles having a short C-H distance and nozzles having a long C-H distance have almost no refill difference.
[0062] While a case in which the nozzles of the recording head are disposed in the two rows is described in the above embodiments, persons skilled in the art will understand that the number of the rows is not limited to two and that the present invention can be executed even if the number of the rows is more than two or the nozzles are disposed in only one row.
[0063] [0063]FIG. 10 shows an overall outside view of an inkjet head 11 in the embodiments of the present invention, and FIG. 9 shows a head chip 12 as a main portion of the inkjet head 11 in a broken state. The head chip 12 is made using, for example, a Si wafer of 0.51 mm thick, and six slender ink supply ports 15 , which are disposed in parallel with each other, are formed in correspondence to six color inks used in the inkjet head 11 .
[0064] Ink chambers 13 are disposed at predetermined intervals in two rows along the lengthwise direction of the ink supply ports 15 so as to hold the ink supply ports 15 therebetween. Each ink chamber 13 has an electrothermal conversion element 14 and an ejecting port 16 which are disposed therein, the ejecting port 16 being positioned in confrontation with the electrothermal conversion element 14 so as to eject ink as a droplet.
[0065] In the embodiments, the ejecting ports 16 , which are in parallel with each other in the two rows with the ink supply ports 15 held therebetween, are disposed in a so-called zigzag state by being off-set a half pitch one another so that the ink chambers 13 corresponding to the ejecting ports 16 of the respective rows are disposed at intervals of 600 dpi pitch. Thus, the ejecting ports 16 are apparently disposed at a high density of 1200 dpi along the lengthwise direction of the ink supply ports 15 in correspondence to the inks of the respective colors. Further, the electrothermal conversion elements 14 and electrode wirings 17 formed of Al or the like for supplying power to the electrothermal conversion elements 14 are formed on the surface of a Si wafer by a film firming technology, and the other end of each electrode wiring 17 is arranged as a bump 18 which is formed of Au and projects from the surface of a heating substrate 12 .
[0066] The electrothermal conversion elements 14 in the embodiments are a part of a heating resistor layer 19 , which is not covered with the electrode wirings 17 formed of Al or the like and is formed of, for example, TaN, TaSiN, TaAl or the like, and have a sheet resistance value of 53Ω. These electrothermal conversion elements 14 and electrode wirings 17 are covered with a protective layer 20 composed of SIN of 4000 Å thick, and a cavitation resistance layer 21 of 2300 Å thick composed of Ta is formed on the surface of the protective layer 20 on the electrothermal conversion elements 14 .
[0067] The above-mentioned ink supply ports 15 are formed by anisotropic etching making use of the crystal direction of a Si wafer used as the heating substrate 12 . That is, when the surface of the Si wafer is <100> and the Si wafer has a crystal direction <111> in the thickness direction thereof, the heating substrate 12 is etched in a desired depth by providing selectivity with it in an etching direction using an alkaline anisotropic etching solution such as KOH, tetramethylammonium hydroxide (TMAH), or hydrazine.
[0068] Further, the ink chambers 13 and the ejecting ports 16 are formed by photolithography. Then, ink droplets of, for example, 4 pico-litters are ejected from the ejecting ports 16 by energizing the electrothermal conversion elements 14 .
[0069] [0069]FIGS. 11 and 12 show a schematic construction of a printer employing an inkjet recording system.
[0070] In FIG. 11, a main body M 1000 acting as an outside shell of the printer according to the embodiments includes a lower case M 1001 , an upper case M 1002 , an access cover M 1003 , an exterior member of a discharge tray M 1004 , and a chassis M 3019 accommodated in the exterior member (refer to FIG. 12).
[0071] The above chassis M 3019 is composed of a plurality of metal sheets having a predetermined rigidity, acts as a framework of the printer, and holds respective recording operation mechanisms which will be described later.
[0072] Further, the lower case M 1001 forms an approximately lower half portion of the main body M 1000 , and the upper case M 1002 forms an approximately upper half portion thereof, both the cases are combined with each other so as to form a hollow structural member having an accommodating space therein in which the respective mechanisms to be described later are accommodated, and openings are formed on the upper surface and the front surface of the hollow structural member.
[0073] Further, the discharge tray M 1004 is turnably supported by the lower case M 1001 at an end thereof, and the opening formed on the front surface of the lower case M 1001 can be opened and closed by turning the discharge tray M 1004 . As a result, when the printer executes recording operation, the opening is formed by turning the discharge tray M 1004 forward so that recording sheets P can be discharged from the opening and successively placed on the discharge tray M 1004 . Further, two auxiliary trays M 1004 a and M 1004 b are accommodated in the discharge tray M 1004 , and a sheet support area can be increased or reduced in three steps by drawing out the respective trays forward as necessary.
[0074] The access cover M 1003 is turnably supported by the upper case M 1002 at an end thereof so as to open and close the opening formed on the upper surface. When the access cover M 1003 is opened, a recording head cartridge, ink tanks and the like accommodated in the main body can be replaced. It should be noted that while not shown particularly here, when the access cover M 1003 is opened and closed, a projection formed on the back surface thereof turns a cover opening/closing lever, and an open/close state of the access cover can be detected by detecting a turning position of the lever by a microswitch or the like.
[0075] Further, a power key E 1008 and a resume key E 0019 are disposed on the upper rear surface of the upper case M 1002 so as to be depressed as well as an LED E 0020 is disposed thereon. When the power key E 1008 is depressed, the LED E 0020 lights, indicating that recording is possible to an operator. The LED E 0020 has various display functions which are executed in such a manner that it blinks differently, changes colors or sounds a buzzer. Note that when a trouble is overcome, recording can be resumed by depressing the resume key E 0019 .
[0076] Next, the recording operation mechanisms of the embodiments, which are accommodated in and held by the main body M 1000 of the printer, will be explained. The recording operation mechanisms of the embodiments includes an automatic sheet feeder M 3022 for automatically feeding recording sheets P into the main body of the printer, a sheet transportation unit M 3029 for guiding the recording sheets P fed from the automatic sheet feeder one by one to a desired recording position as well as guiding the recording sheets P from the recording position to a sheet discharge unit M 3030 , a recording unit for recording desired data on the recording sheets P transported to the sheet transportation unit M 3029 , and a restoration unit M 5000 for restoring the recording unit and the like. The recording unit is mainly composed of a carriage M 4001 movably supported by a carriage shaft M 4021 and a recording head cartridge detachably mounted on the carriage M 4001 .
[0077] While the present invention has been described with reference to what are presently considered to be the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
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In an inkjet recording head having a plurality of ink ejecting ports and a plurality of energy generating elements respectively positioned in confrontation with the ink ejecting ports for generating energy utilized to eject ink from the ink ejecting ports, the plurality of ink ejecting ports and the plurality of energy generating elements being divided into a plurality of blocks, and the ejecting ports and the energy generating elements being timeshapred driven in a sequence of the blocks in a common driving period, the plurality of energy generating elements are disposed in an approximate sraight line, and the respective ink ejecting ports are off-set with respect to the energy generating elements in a projecting relationship in correspondence to the sequence of the timeshapred drive. With this construction, the inkjet recording head can maximize a refill cycle while keeping the linearity of an image even if timeshared drive is executed, whereby the throughput of a printer using the inkjet recording head can be improved.
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