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BACKGROUND
[0001] The present invention relates generally to semiconductor device processing techniques and, more particularly, to a method and structure for forming silicide contacts on embedded silicon germanium (eSiGe) regions of CMOS devices.
[0002] Silicide contacts are of specific importance to integrated circuits, including those having complementary metal oxide semiconductor (CMOS) devices, because of the need to reduce the electrical resistance of the contacts (particularly at the source/drain and gate regions) in order to increase chip performance. Silicides are metal compounds that are thermally stable and provide for low electrical resistivity at the silicon/metal interface. Reducing contact resistance improves device speed, therefore increasing device performance.
[0003] Silicide formation typically requires depositing a metal such as Ni, Co, Pd, Pt, Rh, Ir, Zr, Cr, Hr, Er, Mo or Ti onto the surface of a silicon-containing material or wafer. Following deposition, the structure is then subjected to an annealing step using conventional processes such as, but not limited to, rapid thermal annealing. During thermal annealing, the deposited metal reacts with silicon to form a metal silicide. Portions of the metal not formed atop silicon are not reacted during the anneal, and may thus be thereafter selectively removed with respect to the reacted silicide.
[0004] In CMOS devices, both n-type field effect transistors (NFET) and p-type field effect transistors (PFET) are combined in the same structure. Since it has become increasingly difficult to improve MOSFETs (and therefore CMOS device performance) through continued scaling, methods for improving performance without scaling have become critical. One recently implemented approach for doing this is to increase carrier (electron and/or hole) mobilities by introducing an appropriate strain into the silicon lattice. The application of stresses or strains changes the lattice dimensions of the silicon-containing substrate. By changing the lattice dimensions, the energy gap of the material is changed as well. When a semiconducting material is doped (e.g., n-type) and partially ionized, a very small change in the energy bands can cause a large percentage change in the energy difference between the impurity levels and the band edge. Thus, the change in resistance of the material with stress is large.
[0005] In terms of the direction of the stress versus the polarity of the dopant, NFET devices require a tensile stress on the channel for strain-based carrier mobility (electron) improvement, while PFET need a compressive stress on the channel for strain-based carrier mobility (hole) improvement. In the particular case of PFET devices, the use of embedded SiGe (eSiGe) structures is one manner of facilitating a compressive stress on the channel. In the manufacture of such structures, a cavity is created in the active area of the PFET device following gate stack definition, spacer formation and dopant implantation (the NFET devices simultaneously being protected by a suitable layer, such as a hardmask). The cavity is thereafter filled with epitaxially grown SiGe material, which may be in-situ doped with a material such as boron.
[0006] However, during the formation of an embedded SiGe structure, the SiGe may typically be overgrown in the cavity such that a facet is created at the edge of the active area of the transistor, adjacent a shallow trench isolation (STI) region. With respect to the silicidation process discussed above, such faceting can result in the silicide material protruding deeper into the silicon substrate, such as shown in the SEM image of FIG. 1 , for example. This in turn causes undesirable junction leakage current, and adversely affects device performance. Accordingly, it would be desirable to be able to prevent such adverse effects due to silicidation of strain engineered PFET devices of the eSiGe type.
SUMMARY
[0007] The foregoing discussed drawbacks and deficiencies of the prior art are overcome or alleviated by a method of forming silicide contacts for a complementary metal oxide semiconductor (CMOS) device. In an exemplary embodiment, the method includes selectively forming a protective layer over faceted surfaces of an embedded SiGe (eSiGe) region of a substrate, the eSiGe region comprising a compressive stress inducing layer in a PFET portion of the CMOS device, wherein the faceted surfaces are disposed adjacent shallow trench isolation (STI) regions used to separate NFET regions from PFET regions of the CMOS device; depositing a metal layer to form silicide over the CMOS device; and annealing the CMOS device, wherein the protective layer formed over the faceted surfaces prevents the formation of silicide thereon.
[0008] In another embodiment, a complementary metal oxide semiconductor (CMOS) device includes at least one NFET device and at least one PFET device formed on a semiconductor substrate; a protective layer formed over faceted surfaces of an embedded SiGe (eSiGe) region of the PFET device, the eSiGe region comprising a compressive stress inducing layer, wherein the faceted surfaces are disposed adjacent shallow trench isolation (STI) regions used to separate NFET regions from PFET regions of the CMOS device; and a plurality of silicide contacts for the at least one NFET device and the at least one PFET device, wherein the protective layer formed over the faceted surfaces prevents the formation of silicide thereon.
Technical Effects
[0009] As a result of the summarized invention, a solution is technically achieved in which an embedded SiGe transistor is silicided by selectively forming a protective layer over faceted portions of the eSiGe regions, thereby preventing formation of silicide on the faceted portions and eliminating the protrusion silicide material into the silicon substrate adjacent STI regions, which in turn prevents undesirable junction leakage current.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Referring to the exemplary drawings wherein like elements are numbered alike in the several Figures:
[0011] FIG. 1 is a scanning electron microscope (SEM) image of a silicided CMOS device, particularly illustrating an eSiGe region used for compressive tension in the PFET device;
[0012] FIGS. 2( a ) through 2 ( e ) illustrate a sequence of process flow diagrams of a method for forming silicide contacts on eSiGe regions of CMOS devices, in accordance with an exemplary embodiment of the invention;
[0013] FIGS. 3( a ) through 3 ( c ) illustrate an alternative process for forming the protective oxide on the faceted surfaces of the eSiGe regions, in accordance with another exemplary embodiment of the invention; and
[0014] FIG. 4 is an SEM image of a silicided eSiGe region using the exemplary method embodiments disclosed herein.
DETAILED DESCRIPTION
[0015] Disclosed herein is a method and structure for forming silicide contacts on eSiGe regions of CMOS devices. Briefly stated, a protective layer (e.g., oxide) is selectively formed on faceted regions of the eSiGe adjacent the STI regions prior to deposition of a metal layer for silicide formation. Therefore, during the anneal step, the metal does not react to form silicide over the faceted regions, thereby preventing silicide from penetrating deeper into the silicon substrate and adversely affecting junction leakage current.
[0016] FIGS. 2( a ) through 2 ( e ) illustrate a sequence of process flow diagrams of a method for forming silicide contacts on eSiGe regions of CMOS devices, in accordance with an exemplary embodiment of the invention. At the outset, FIG. 2( a ) depicts a CMOS device 200 at in point in processing following the definition of NFET and PFET device regions (labeled “NFET” and “PFET” in the Figures) in a substrate 202 of silicon containing material. A plurality of STI regions 204 (e.g., oxide filled trenches) are formed for separating the PFET region from the NFET region. It will be noted that although FIG. 2( a ) depicts a single PFET device and a single NFET device in the PFET and NFET regions, multiple such devices can exist in actuality.
[0017] The NFET and PFET devices may be initially formed through existing processing steps that are capable of fabricating MOSFET devices. In particular, each device includes a gate conductor 206 (e.g., polysilicon) formed on a gate insulating layer 208 (e.g., oxide). At least one set of sidewall spacers 210 , 212 may be located adjacent the gate region (i.e., gate conductor 206 and gate insulating layer 208 ). NFET source/drain regions 214 , including extension regions 216 , are defined within the NFET portion of the substrate 202 and define an NFET device channel. The NFET source/drain regions 214 and extension regions 216 are doped with a suitable n-type dopant material (e.g., As, Sb, P, N). Similarly, PFET source/drain regions 218 , including extension regions 220 , are defined within the PFET portion of the substrate 202 and define a PFET device channel. The PFET source/drain regions 218 and extension regions 220 are doped with a suitable p-type dopant material (e.g., In, Ga, Al, B).
[0018] In accordance with certain strain engineering techniques described above, the device 200 of FIG. 2( a ) is further processed so as to create embedded SiGe (eSiGe) regions 222 within recessed portions of the PFET source/drain and extension regions 218 ,- 220 . As also indicated above, the compressive strain producing SiGe material 222 is nominally grown in a manner so as to overfill the top of the substrate 202 and adjacent STI regions 204 . In so doing, a faceted surface 224 is formed at the edge of the active area adjacent the STI regions 204 . Whereas the planar portions of the top surfaces of the SiGe material are within the ( 100 ) crystallographic plane, the faceted surface 224 is within the ( 111 ) crystallographic plane of the material. In addition to overfilling the top of the substrate, the process of filling eSiGe to the top of the substrate can also result in faceted surfaces of eSiGe.
[0019] At the point of processing shown in FIG. 2( a ), a cap nitride layer 226 atop the gate conductors 206 would ordinarily be removed to facilitate conventional silicide processing of the CMOS devices. However, in the present embodiments, the cap nitride layer 226 (used for a prior reactive ion etch step) is temporarily left in place, as will be appreciated hereinafter.
[0020] Referring now to FIG. 2( b ), the CMOS device is now subjected to a selective oxidation process (e.g., by thermal anneal) that forms an oxide layer 228 on the exposed silicon surfaces of the device. This includes NFET source/drain regions 214 and eSiGe regions 222 of the PFET device. Notably, the nitride cap layer 226 prevents the oxide formation on the polysilicon gate conductors 206 of both the NFET and PFET devices.
[0021] Because the NFET source/drain regions 214 are substantially planar, the oxide layer 228 thereon is of substantially uniform thickness. In contrast, the portions of the oxide layer 228 over the eSiGe regions 222 are formed anisotropically with respect to the faceted surfaces. As specifically shown in the insert view of FIG. 2( c ), it will be seen that the oxidation rate on the faceted surfaces of the eSiGe material in the ( 111 ) crystallographic plane is greater than the oxidation rate on the horizontal, planar surfaces in the ( 100 ) crystallographic plane. Consequently, the thickness “a” of the oxide formed over the planar portion of the eSiGe material is less than the thickness “b” of the oxide formed over the faceted portion of the eSiGe material.
[0022] As then shown in FIG. 2( d ), the oxide layer 228 over the horizontal planar surfaces is removed, so as to remain only upon the faceted surfaces of the eSiGe material 222 . This may be done, for example, through either an isotropic etch or an anisotropic etch (preferred), wherein a target thickness removal is between dimensions “a” and “b” depicted in FIG. 2( c ). As a practical matter, some STI material will also be removed during this process. Thereafter, the cap nitride layer atop gate conductors 206 may be removed, as also reflected in FIG. 2( d ). Thereby, the CMOS device is now prepared for silicidation, with the faceted surfaces of eSiGe regions 222 being protected by oxide layer 228 to prevent silicidation thereof. Finally, FIG. 2( e ) illustrates the formation of silicide contacts 230 over the planar surfaces of the gate conductors 206 , NFET source/drain regions 214 and PFET eSiGe regions 222 (by suitable metal layer deposition and thermal anneal as described previously).
[0023] It will be appreciated that the selective oxide formation at different growth rates on faceted ( 111 ) plane surfaces of SiGe represents one exemplary manner of preventing silicide growth thereon. For example, FIGS. 3( a ) through 3 ( c ) illustrate an alternative process for forming a protective oxide on the faceted surfaces of the eSiGe regions, in accordance with another exemplary embodiment of the invention. As shown in FIG. 3( a ), a conformal oxide layer 328 is blanket deposited over the entire surface of the device, including the gate conductors 206 , NFET source/drain regions 214 and PFET eSiGe regions 222 .
[0024] Then, in FIG. 3( b ), the conformal oxide layer 328 is directionally (anisotropically) etched so as to be removed from the planar surfaces of the CMOS device. As a result, an amount of the oxide layer 328 is left on the faceted surfaces of the eSiGe regions 222 (as a small amount on the gate sidewall spacers) of both the NFET and PFET devices. Thus protected, the silicidation steps of metal deposition and anneal are implemented so as to form the silicide contacts shown in FIG. 3( c ). As is the case for the embodiment of FIGS. 2( a ) through 2 ( e ), conformal deposition of a protective oxide layer followed by selective removal of the oxide on planar surfaces protects the faceted portions of eSiGe regions at the edge of the active area from silicidation. FIG. 4 is an SEM image illustrating the use of a protective oxide for prevention of silicide formation on faceted surfaces of eSiGe.
[0025] While the invention has been described with reference to a preferred embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A method of forming silicide contacts for a complementary metal oxide semiconductor (CMOS) device includes selectively forming a protective layer over faceted surfaces of an embedded SiGe (eSiGe) region of a substrate, the eSiGe region comprising a compressive stress inducing layer in a PFET portion of the CMOS device, wherein the faceted surfaces are disposed adjacent shallow trench isolation (STI) regions used to separate NFET regions from PFET regions of the CMOS device; depositing a metal layer for silicide formation over the CMOS device; and annealing the CMOS device to form silicide, wherein the protective layer formed over the faceted surfaces prevents the formation of silicide thereon.
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BACKGROUND OF THE INVENTION
The present invention relates generally to a novel plumbing fitting component system adapted to both single handle and dual handle faucets and certain novel plumbing fixture components, and more particularly, to single handle and dual handle faucet fitting constructions with interchangeable components and improved adaptability. The faucets can be installed easily, and maintained generally from above the faucet deck, permit various component parts to be used with either single handle or dual handle faucets, may include an escutcheon in the single handle model that also functions as a cartridge cover, may include an adjustable putty plate, and may include a low-cost valve in the dual handle model which allows for selective on-off control.
Conventional faucet installations are generally time-consuming and difficult to install and maintain because many of the fastening members must be attached and turned from below a sink deck, at times requiring the plumbing contractor installing the fixture to work in extremely cramped quarters. After installation, the same difficult process must be followed to remove and replace the faucet. In the faucet fixture construction of the present invention and the method of installing that fixture, the fixture is inserted into openings in a sink deck and substantially installed from above except for nut-tightening from below the deck. Furthermore, the construction allows for easy maintenance of most serviceable parts from above the sink deck, thus avoiding these difficulties.
Conventional faucet fixtures can be constructed to use separate hot and cold water valves in a dual handle form or can be constructed to use a valve cartridge controller mixing both hot and cold water in a single handle form. Generally these two constructions require entirely separate component parts and little overlap is possible, thus requiring a large cost in manufacturing. In the component system of the present invention, at least the putty plate with breast plate, the waterway spout and aerator and the mounting nuts can each be used with the different escutcheons, metering valves, and waterway paths associated with either a single handle or a dual handle faucet fixture, thus minimizing the costs of manufacturing and the difficulty in assembling the various fixtures.
Conventional single handle faucet fixtures generally include a separate cartridge cover or retaining screw to keep the valve cartridge in place. This can add to the cost of manufacturing as well as create an undesired aesthetic appearance. Furthermore, since a cartridge cover or mounting screw is easily accessible, it allows unwanted tampering with the faucet. In the component system of the present invention, an escutcheon is provided for the single handle model that also functions as a cartridge cover without requiring any separate cover component, and yet conceals the access point to the valve cartridge from casual inspection while still providing easy maintenance.
Conventional faucet fixtures generally include a putty plate forming a seal between the sink deck and the escutcheon base. However, due to manufacturing tolerances and slight differences in the heights of various components, sometimes a gap may remain between the escutcheon and the putty plate, or between the putty plate and the sink deck. Typically, when installing a faucet, therefore, bolts are attached directly to the escutcheon from underneath the sink deck to attach it firmly to the putty plate and sink deck. In addition to requiring an additional difficult installation step and requiring difficult maintenance, the mounting bolts put an undesirable stress on the escutcheon. In the putty plate of the present invention, the periphery of the putty plate includes a flange with a resilient bowed portion and a ridge for mating with the escutcheon base despite differences in the height of the escutcheon over the sink deck, thus providing an effective seal using a simple installation procedure and eliminating any undesirable stress on the escutcheon.
Conventional dual handle faucet fixtures generally require two valves, one each for controlling the hot and cold water. In many cases, it is desired to turn the two valves in opposite directions when opening the flow of water. In other cases, the faucets are turned in the same direction which may be clockwise or counterclockwise, as desired. This change in rotating control direction usually requires a complicated and expensive manufacturing and installation process because valves are typically designed to be turned on in one direction only. In the valve of the present invention, the handle may selectively be turned in either clockwise or counterclockwise directions to open the valve by merely attaching the handle in one of two predefined positions during installation. Furthermore, the valve is inexpensive to manufacture and easier to install than typical valves, and may, for example, have a valve housing formed entirely of plastic. Moreover, the present invention allows the same handle construction and valve construction, and a single waterway to allow operation in opposite directions on the hot and cold water sides. This construction also allows ready changeover between faucet handles and faucet levers.
Accordingly, it is desired to provide a fixture system having components which can be used in both single handle faucets and dual handle faucets, and having improved components which allow for interchangeability and other advantages.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the present invention, a faucet fixture system having components usable in both single handle and dual handle faucets and associated other components, is provided. The system includes a faucet fixture component system wherein the same putty plate with attached breast plate, waterway spout and mounting nuts can be used with the different escutcheons, metering valves, and waterways associated with either the single handle or the dual handle faucet fixtures.
The components of the present invention include a waterway with a manifold and downward extending waterway inlets which are adapted to extend through mounting openings on a sink deck and thereafter be connected to water supplies. The waterway manifold has a spout joint and a connected spout with a nozzle. A putty plate is positioned intermediate the sink deck and the faucet. The waterway also includes at least one valve receiving portion and at least one escutcheon mounting portion near or common to each valve receiving portion. Each valve receiving portion in an assembled fixture is sealingly connected to a metering valve for controlling the flow of water through the waterway and spout.
The components further include an escutcheon with a base portion generally covering the waterway and a spout portion generally covering the waterway spout. The escutcheon includes at least one escutcheon opening generally corresponding to each valve receiving portion when the fixture is assembled for providing access to the corresponding valve. The escutcheon opening may also include a retaining portion which retains the metering valve in fixed position when the fixture is assembled. The escutcheon also includes at least one waterway mounting portion near each escutcheon opening. Each mounting portion is engaged with a corresponding escutcheon mounting portion thus fixing the escutcheon to the waterway.
A putty plate with attached breast plate portion in accordance with the invention includes a substantially flat member that provides mating contact between the base of an escutcheon and a sink deck. The putty plate has apertures corresponding to the mounting openings in the sink deck and fastening members adjacent to the apertures. The waterway has mounting portions which loosely engage with the fastening members to provide relative positioning of the putty plate, the waterway and the mounting openings when the fixture is assembled.
The putty plate also has a ridge and a flange near the outside periphery which engage the escutcheon base to provide relative positioning of the escutcheon, the putty plate and the waterway when the fixture is assembled. The flange includes a resilient bowed portion that can adjust to differences in the distance between the escutcheon base and the sink deck.
The fixture component system is assembled in the manner disclosed. The putty plate is set on the waterway so that the waterway inlets extend through the putty plate apertures. In this position, the waterway nozzle will extend through a nozzle orifice on the breast plate portion of the putty plate. The waterway and the putty plate are fastened to the sink deck. The spout is connected at the spout joint of the manifold. The inlets extending through the putty plate are inserted from on top of the sink deck through the sink deck mounting openings so as to extend below the sink deck so that the waterway mounting portions engage the putty plate fastening members. A metering control valve is secured on the manifold of the waterway. The escutcheon is placed over the waterway and spout, engaging the putty plate, and the escutcheon is fastened to the waterway to generally enclose the waterway and spout within the escutcheon, and putty plate with breast plate. The metering valve is retained in place with a corresponding escutcheon opening retaining portion.
A single handle faucet fixture in accordance with the present invention includes a manifold with a cartridge receiving portion and an escutcheon mounting portion near it. The cartridge receiving portion supports a metering valve cartridge and the escutcheon has a corresponding opening which includes a retention portion which retains the cartridge in place without the need for an additional cap or mounting screw. The escutcheon opening also allows easy access to the metering valve cartridge.
An associated water valve of the present invention for use in a dual handle faucet fixture includes a stationary valve body in fluid communication with, and positioned intermediate an upper waterway and a lower waterway. The body includes a fluid inlet and fluid outlets, and a rotatable drive shaft. The drive shaft has a handle mount, and controls a rotating disk with blocking members and cutouts which control fluid communication with the fluid outlets.
A stationary disk having apertures cooperates with the rotating disk. The rotating disk and stationary disk rotate against each other and allow the cutouts to expose the apertures when the shaft is rotated to a first position to open a fluid flow between the lower waterway and upper waterway, and to allow blocking when the shaft is rotated to a second position to inhibit the water flow. The shaft is rotated between the first and second positions by rotating a handle on the handle mount, thus controlling the water flow through the valve.
The valve body also includes projections which cooperate with stops in the handle to limit rotation and allow for either clockwise or counterclockwise action to turn the faucet on or off.
In such a valve as described, when the handle is rotated clockwise, the shaft is rotated to a first maximum open position when the blocking member is attached to the handle mount in a first position. When the handle is attached to the handle mount in a second orientation, the shaft is rotated to the maximum open position when the blocking member is attached to the handle mount in the second position located at 90° relative to the first position. By mounting the hot water valve at a 90° rotation with respect to the cold water valve, the on-off direction of rotation for both the hot and cold sides can be easily changed by simply reorienting the handle on the handle mount.
Furthermore, the valve housing and drive shaft can be made substantially of plastic and requires no metal parts, yet is resilient and reliable in extended use.
Accordingly, it is an object of the present invention to provide a sink component system wherein certain component parts can be used in faucet fixtures of both single and dual handle construction.
Another object of the present invention is to provide a faucet fixture construction that can easily be installed and generally maintained from above a sink deck.
A further object of the present invention is to provide an escutcheon for a single handle faucet fixture with an integrated cartridge cover thereby avoiding the need for a separate cartridge cover or mounting nut.
Still another object of the present invention is to provide a putty plate between the waterway and the sink deck that attaches to the waterway and engages an escutcheon base for providing relative positioning between the sink deck, waterway and escutcheon.
Still a further object of the present invention is to provide a putty plate having a ridge and a flange wherein the flange has a resilient bow portion for adjusting to differences in the height of the escutcheon base over the sink deck.
A still further object of the present invention is to provide a single handle control waterway as a one piece casting.
Yet still another object of the present invention is to provide a dual handle faucet in which clockwise and counterclockwise handle rotation operation can be achieved with a single valve construction, a single handle construction and a single waterway construction.
Yet another object of the present invention is to provide a low cost valve that can easily be installed to turn on a water flow in a clockwise direction or to selectively turn on a water flow in a counterclockwise direction.
Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the following detailed specification.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the constructions hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a top front left perspective view of a single handle faucet fixture constructed in accordance with the present invention;
FIG. 2 is a top front left exploded view of the single handle faucet fixture depicted in FIG. 1;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 1;
FIG. 5 is a top front left perspective view of a single handle faucet waterway constructed in accordance with the present invention;
FIG. 6 is an enlarged partial sectional view of a portion of the single handle faucet fixture in accordance with the present invention;
FIG. 7 is an enlarged partial sectional view showing a detail of the putty plate and escutcheon orientation in the present invention;
FIG. 8 is an enlarged sectional view of a portion of FIG. 7 showing the escutcheon pressed against the putty plate;
FIG. 9 is an enlarged sectional view taken along line 9--9 of FIG. 7;
FIG. 10 is a top front left perspective view of a dual handle faucet fixture constructed in accordance with the present invention;
FIG. 11 is a top front left exploded view of the dual handle faucet fixture depicted in FIG. 10;
FIG. 12 is an enlarged sectional view taken along line 12--12 of FIG. 10;
FIG. 13 is an enlarged sectional view taken along line 13--13 of FIG. 10;
FIG. 14 is an exploded view of a single control water valve for use in a dual handle faucet constructed in accordance with the present invention;
FIG. 15 is an elevational view of the water valve depicted in FIG. 14;
FIG. 16 is a sectional view taken along line 16--16 of FIG. 15;
FIG. 17 is a sectional view similar to FIG. 16 but showing the valve components in a different orientation;
FIGS. 18 through 27 each show detailed top plan views of the valve of FIG. 14 and a handle showing the relationship of both in different configurations in accordance with the present invention;
FIG. 28 is an exploded view of an alternative embodiment of a single handle faucet fixture in accordance with the present invention; and
FIG. 29 is a sectional view similar to FIG. 4, but showing the assembly according to FIG. 28.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 through 9 of the drawings, a fixture component system of the present invention includes a single handle faucet fixture shown generally at 22 in three dimensional perspective view in accordance with the invention viewed from the top front left position. FIG. 1 shows an assembled faucet fixture 22. Fixture 22 includes an escutcheon 70 in the form of a finished fixture body having an escutcheon base portion 24 and an escutcheon spout portion 26. In the embodiment shown, at the base of escutcheon spout portion 26, where it joins with escutcheon base portion 24, there is an upwardly extending cartridge housing portion 28. Escutcheon base portion 24, escutcheon spout portion 26 and cartridge housing portion 28 together form escutcheon 70 for generally covering the internal plumbing components of the faucet and providing a finished appearance thereto.
Cartridge housing portion 28 is covered by a lever cap 30 which, in the embodiment shown, includes a lever handle 32. Escutcheon 70 is fixed with respect to an internal waterway 36 of faucet fixture 22 as described more fully in detail below.
Interposed between escutcheon 70 and a sink deck 74 (shown in FIG. 3), and in mating relationship to both, there is a putty plate 34 preferably formed from a resilient plastic material, which, along with escutcheon 70 defines a substantially closed chamber generally enclosing the internal plumbing components to be described more fully below. FIG. 2 shows an exploded view of fixture 22 and depicts the relationship between the internal plumbing components, escutcheon 70 and putty plate 34.
FIG. 3 shows waterway 36 fixed to sink deck 74 by mounting nuts 76 which engage an external surface of hot and cold waterway inlets 40a and 40b in a like manner typically used for dual handle fixtures (and described more fully below). In general, it is noted that prior art single handle fixtures typically braze copper tubing waterway inlets to a separate manifold unit, and must often provide separate fixation bolts in the escutcheon to secure the fixture to the sink deck with mounting nuts. Applicant's invention is much easier to fabricate, install and more rugged because only the waterway is a one piece casting and is attached through the deck to the underside of a sink, thus minimizing the stress on the escutcheon which covers the waterway. Furthermore, most faucet maintenance can be accomplished from above the sink deck by simply removing escutcheon 70.
Intermediate waterway 36 and sink deck 74 there is a seal for protecting the inside plumbing of fixture 22 from water which may accumulate on sink deck 74 and to provide a finished appearance thereto. In the present invention, the seal is formed by a putty plate 34. Putty plate 34 includes a putty plate flange 42 extending around its periphery and generally arranged to correspond with the shape of escutcheon base portion 34. Putty plate 34 also includes a putty plate ridge 44 set just inside the periphery of flange 42 and defining putty plate flange 42. Ridge 44 is generally adapted to correspond with the inside bottom walls of escutcheon base portion 24 in a manner such that putty plate 34 is fitted closely to escutcheon 70 when fixture 22 is assembled. Putty plate 34 has two putty plate apertures 78a and 78b adapted to correspond to the position of waterway inlets 40a and 40b and the corresponding mounting openings on sink deck 74.
Putty plate 34 is also loosely supported on waterway inlets 40a and 40b by means of opposing offset fastening members or tabs 46. As best seen in FIG. 9, fastening members 46 loosely engage with waterway mounting portion extensions or wings 48 which are integral with and extend outwardly from waterway inlets 40a and 40b at a location generally just above sink deck 74. Waterway mounting portion extensions 48 engage with fastening members 46 by means of a projection 46a in a manner which generally allows some play in the precise relative positioning of waterway 36 and putty plate 34 before final installation and tightening. Waterway mounting portion extensions 48 are positioned on waterway inlets 40a and 40b at a location which sets the height-wise positioning of waterway 36 with respect to sink deck 74. It should be noted that fastening members 46 and waterway mounting portion extensions 48, while shown as clips and tabs, respectively, are merely one preferred embodiment for positioning waterway 36, putty plate 34 and sink deck 74 with respect to one another, and additional fastening embodiments are easily envisioned by one of ordinary skilled in the art.
Likewise, putty plate ridge 44 and putty plate flange 42 engage with the lower rim of escutcheon base 24 in a manner which allows some play between the relative positioning of escutcheon base 24 and putty plate 34 before final installation and tightening. Waterway inlets 40a and 40b extend through putty plate apertures 78a and 78b which correspond to mounting holes in sink deck 74.
To install fixture 22 on sink deck 74, putty plate 34 is positioned on waterway 36, aligning putty plate apertures 78a and 78b so that waterway inlets 40a and 40b extend therethrough. Waterway 36 with attached putty plate 34 is positioned over the sink deck so that waterway inlets 40a and 40b extend through the mounting holes of sink deck 74. Fastening members 46 of putty plate 34 are engaged with waterway mounting portions 48 so that the combined waterway and putty plate can be installed together. Waterway 36 and putty plate 34 are secured to sink deck 74 by screwing mounting nuts 76 to the threads formed on the outer surface of the downward by extending portions of waterway inlets 40a and 40b under sink deck 74 as best shown in FIG. 3.
Waterway 36 includes an attachable waterway spout 50 having at its end a waterway nozzle 52. Waterway inlets 40a and 40b are connected to a manifold 72 which is integrally formed as part of waterway 36. This unique construction of the present invention allows the same attachable waterway spout construction to be used with both single and dual handle fixtures. Furthermore, the waterway may be unitarily formed from cast brass or other metal.
As shown, putty plate 34 includes a breast plate portion 54 which is adapted to fit in mating relationship to the bottom of the inside walls of escutcheon spout portion 26, thus forming a chamber when assembled. Waterway spout 50 also joins with manifold 72 and extends generally up and away from sink deck 74 in a manner adapted to fit within the chamber formed by breast plate portion 54 and escutcheon spout portion 26 when fixture 22 is assembled. An aerator 38 is attached to waterway nozzle 52 and fixes the nozzle end portion of breast plate portion 54 to waterway nozzle 52.
A single handle control cartridge 58 is positioned on top of manifold 72 which is adapted to allow water from waterway inlets 40a and 40b to be mixed, metered and directed to waterway spout 50 in a known manner for providing a selectable flow amount of hot and/or cold water. The selection of the flow amount and mix of hot and/or cold water is controlled by means of a cartridge controller 60 fixed to cartridge 58. Cartridge controller 60 also acts as a handle mount for handle 32. Cartridge 58 typically is arranged with various chambers selectively placed in fluid communication with waterway inlets 40a and 40b and waterway spout 50. Cartridge 58 may be a conventional ceramic plate single handle fixture cartridge such as is well known in the art.
Cartridge 58 is adapted to fit within cartridge housing portion 28 when escutcheon base portion 24 is engaged with putty plate 34 and escutcheon spout base 26 is engaged with breast plate portion 54. Cartridge 58 rests on manifold 72 and cartridge housing 28 rests on cartridge 58. In order to sealingly fix cartridge 58 to manifold 72 and attach cartridge housing portion 28 to cartridge 58, cartridge housing portion 28 is provided with escutcheon mounting tabs 62 and cartridge 58 is provided with corresponding cartridge mounting portions in the form of through openings 64. In this embodiment, cartridge fasteners 66 are screwed passing through holes in escutcheon mounting tabs 62 and cartridge mounting portions 64. The screws are matingly engaged with threaded manifold openings 80 in the top of manifold 72. It is noted that cartridge fastener 66 may be any suitable means for fixing cartridge housing 28 to cartridge 58, and cartridge 58 may be fixed to manifold 72, by any suitable additional means, or may be fixed by the same means as is used to fix cartridge housing 28 to cartridge 58, as depicted in the embodiment shown.
When assembled, fixture 22 is supported on sink deck 74. However, unlike conventional fixtures, waterway 36 is the only component directly secured to sink deck 74. During assembly or manufacture, cartridge 58 is set on manifold 72, and cartridge fasteners 66 align it in proper position in order to allow the cartridge chambers be in selected fluid communication with waterway inlets 40a and 40b and waterway spout 50, thus allowing regulation of the flow of water.
In the embodiment shown, the fastening of cartridge 58 to manifold 72 is accomplished by the same means used to fasten cartridge housing portion 28 to cartridge 58. Thus, escutcheon 70 is fixed to waterway 36 by fixing cartridge 58 to manifold 72 and escutcheon mounting portions 62 to cartridge 58 through cartridge mount portions 64.
Escutcheon 70 is set over cartridge 58, escutcheon spout portion 26 is set over waterway spout 50, and escutcheon base portion 24 is set generally over waterway inlets 40a and 40b and is matingly engaged with putty plate 34 by means of putty plate ridge 44 and putty plate flange 42. As described more fully below, putty plate flange 42 is pressed towards the bottom of the walls of escutcheon base portion 24, thus forming the matingly engaging relationship thereto and providing the desired seal.
Breast plate portion 54, which is formed as part of putty plate 34 as shown in this embodiment, is in a matingly engaging relationship with the bottom of the inside walls of escutcheon spout 26 and may be held in place by, for example, being interposed between aerator 38 and waterway nozzle 52 when aerator 38 is attached to waterway nozzle 52. An opening 54a in breast plate portion 54 allows a portion of nozzle 52 to extend therethrough.
Lever cap 30 is adapted to fit over cartridge housing portion 28 to allow smooth relative movement between lever cap 30 and cartridge housing portion 28. Lever cap 30 is secured to cartridge controller 60 by means of a lever handle fastener 68, which in the embodiment shown, is a set screw. Lever cap 30 is secured to cartridge control 60 in such a manner that by controlling lever handle 32, lever cap 30 can be rotated or slid over cartridge housing 28 thereby rotating or sliding cartridge controller 60 and opening or shutting one or more of the cartridge chambers, thereby mixing water from either or both waterway inlets 40a and 40b and allowing water to flow through waterway spout 50 and waterway nozzle 52.
When installing fixture 22, mounting nuts 76 are not tightened all the way against sink deck 64 at first thus allowing some play in the relative positions of putty plate 34 and waterway 36. Once all of the components of fixture 22 are properly aligned, mounting nuts 76 can be tightened to sink deck 74, thus fixing in place putty plate 34 and waterway 36.
Manifold 72 includes manifold spout opening 82 and manifold inlet openings 84a and 84b. Manifold inlet openings 84a and 84b correspond with waterway inlets 40a and 40b and provide fluid communication between waterway 36 and chambers in cartridge 58. Manifold 72 also has a spout joint 86 integrally fixed on the underside of manifold 72 and connecting with manifold spout opening 82 to provide fluid communication with chambers in cartridge 58. Waterway spout 50 is attached to waterway 36 by spout joint 86 and is in fluid communication with manifold spout opening 82.
In the embodiment shown, waterway spout 50 has a threaded joint end which matingly engages with threads on the interior wall of spout joint 86. Manifold openings 80 are also threaded in this embodiment and are adapted to matingly engage with cartridge screws 66 for affixing escutcheon 70 to cartridge 58, and cartridge 58 to manifold 72.
As described above, escutcheon mounting portions 62 of escutcheon 70 rests upon and is fixed to cartridge 58 which rests upon and is fixed to manifold 72 of waterway 36 which is fixed to sink deck 74. Due to manufacturing tolerances in producing each of these components of fixture 22, the height of escutcheon 70 will vary with relation to sink deck 74. It is desirable that escutcheon base 24 mate in a sealing relationship to putty plate 34 and that putty plate 34 mate in a sealing relationship to sink deck 74. Thus, it is desirable that the height of escutcheon base portion 24 over sink deck 74 be slightly less than the thickness of putty plate 34 above sink deck 74. When assembled, escutcheon base portion 24 presses against putty plate flange 42.
Putty plate flange 42 includes a bowed or recessed portion 88 in the form of a channel as best seen in FIGS. 7 and 8 to provide a resilient mating seal between putty plate 34 and escutcheon 70. In this manner, escutcheon base portion 24 presses against bowed portion 88 which causes it to flex slightly to accommodate any irregularities in escutcheon base portion 24 or the sink deck. Thus, if the tolerances are met, when escutcheon mounting portions 62 mate with cartridge 58 then the bottom edge of escutcheon base portion 24 should be closer to sink deck 74 than the thickness of putty plate 34. In order to accommodate this spacing, bowed portion 88 flexes downwardly to accommodate escutcheon base portion 24 and provide the desired sealingly mated relationship.
The single handle faucet component construction described above provides a one piece cast waterway construction heretofore not found in single handle faucets. The escutcheon body is coupled only to the waterway, not to the deck itself. The escutcheon body acts as the cartridge cover itself. As described below, the same putty plate with breast plate, mounting nuts, waterway spout and aerator may be used in the alternative embodiment of the single handle faucet as well as in the dual handle embodiment.
FIGS. 28 and 29 depict an alternate embodiment of a single handle faucet shown generally at 322 constructed in accordance with an alternative embodiment of the present invention. Faucet 322 includes an escutcheon 370 having a base portion 324 and a spout portion 326. A waterway 336 includes waterway inlets 340a and 340b and mounting portion extensions 48. The same putty plate 34 described above may be used in conjunction with faucet 322. In this regard, it is noted that internal ribs 327 on opposite sides of the internal surface of spout portion 326 help prevent breast plate portion 54 of putty plate 34 from being pushed inwardly.
In the embodiment of FIGS. 28 and 29, valve cartridge 35 is separately secured to manifold 372 with several through screws. Escutcheon 370 is separately coupled to the waterway using screws 400 which extend through holes 402 in manifold 372 and are threaded into bosses 404 formed on the underside of escutcheon 370. Due to the low profile of cartridge housing portion 328, a separate snap on cap 410 is provided to cover the upper portion of the valve cartridge.
Reference is now made to FIGS. 10 through 13 which depict an embodiment of a dual handle faucet fixture generally shown at 122 constructed in accordance with the dual handle embodiment of the present invention. Fixture 122 includes an escutcheon body 70 having an escutcheon base portion 124 and an escutcheon spout portion 126. Escutcheon base portion 124 and escutcheon spout portion 126 together form escutcheon 170 for covering the internal plumbing components of the faucet and providing a finished appearance thereto. Escutcheon 170 is fixed with respect to an internal waterway 136 as described more fully below. Putty plate 34 is disposed between escutcheon 170 and sink deck 74 and in mating relationship to both. Putty plate 34, which is of the same construction as used in the single handle faucet construction discussed above, together with escutcheon 170, defines a generally closed chamber enclosing the internal plumbing components.
Waterway 136 is fixed to sink deck 74 by threaded mounting nuts 76 which engage with the external threaded surfaces of waterway inlets 140a and 140b. A seal is formed intermediate waterway 136 and sink deck 74 for protecting the inside plumbing of fixture 122 from water which may accumulate on sink deck 74, and to provide a finished appearance thereto. In the present invention, this seal is formed by putty plate 34 which is the same putty plate 34 used in the single handle faucet construction described above.
Putty plate 34 is also affixed to waterway inlets 140a and 140b by means of putty plate fastening members 46. Fastening members 46 engage with waterway mounting portions 148 which are integral with and extend from waterway inlets 140a and 140b at a location generally just above sink deck 74 as in the single handle faucet construction.
Assembly of fixture 122 onto sink deck 74 is the same as described above with respect to the single handle faucet assembly.
Waterway 136 includes waterway spout 50 having the same construction as in the single handle faucet embodiment. Waterway spout 50 is a separate component and joins with waterway 136 through a spout joint 186. Spout joint 186 threadingly engages waterway spout 50 in the same manner as discussed above. In this manner, the same spout component may be used for both single handle and dual handle faucet fixtures because the individual respective waterways 36 and 136 each include a respective spout joint 86 and 186 which positions waterway spout 50 with respect to escutcheon spout portions 26 and 126 and over the bowl of a sink. Spout joint 186 is connected to and is in fluid communication with waterway inlets 140a and 140b.
In the dual handle faucet depicted in FIGS. 10-13, water valves 202 are used to separately control the flow of hot and cold water. Valve 202 is a low cost, sanitary valve constructed and adapted to fit in respective valve receiving portions 204 of waterway 136. Valve 202 is interposed within waterway 136, and when in a first, open position, maintains fluid communication between waterway inlets 140a and 140b and waterway spout 50.
Valve 202 is retained in place by a valve nut 205. Valve nut 205 is fixed to a corresponding portion of valve receiving portion 204 by, for example, being threadingly engaged thereto. Interposed between valve receiving portion 204 and valve nut 205 is a valve gasket 207. The combination of valve gasket 207 and valve nut 205 not only retains valve 202 within valve receiving portion 204, but also acts to secure escutcheon 170 to waterway 136.
Valve receiving portion 204 has a design which permits the flow of fluid through the bottom from waterway inlets 140a and 140b, to a side water outlet which permits the flow of fluid to waterway spout 50. Valve 202 includes a valve housing 228 adapted to fit within valve receiving portion 204. Valve housing 228 is sealingly engaged to valve receiving portion 204 with a valve housing gasket 230, set in a corresponding groove 228a in valve housing 228. Valve housing 228 includes recessed opposing outlet portions 236 which are open to the side and are in fluid communication with waterway spout 50. Valve housing 228 also includes opposing projections 229 which fit in corresponding slots 204a in valve receiving portion 204 to prevent rotation of the valve housing and to properly orient and position the valve housing.
As shown in detail in FIGS. 14-17, valve housing 228 also includes a shaft bearing portion 234 on the upper portion thereof which holds and aligns a drive shaft 224 along the central axis of valve housing 228. Drive shaft 224 includes a shaft gasket 226 which fluidly seals drive shaft 224 against valve housing 228 while permitting drive shaft 224 to rotate about its central axis within bearing portion 234. The bottom of drive shaft 224 includes T-shaped projections 242 each having a leg 242a which fits in a corresponding slot 220a in a bone-shaped rotating disk 220.
Rotating disk 220 is preferably a ceramic plate although other materials may be used. Rotating disk 220 includes opposing cutout regions 222 and opposing solid regions 223. Rotating disk 220 is pressed against a stationary disk 216, which is also preferably made of ceramic material. Stationary disk 216 includes opposing specially shaped apertures 218 which correspond with cutout regions 222 in rotating disk 220 when drive shaft 224 is in a first, open position, and which are blocked by solid regions 223 in rotating disk 220 when drive shaft 224 is in a second, closed position.
Stationary disk 216 is prevented from rotating within valve housing 228 by opposing retaining pins 230 set in corresponding slots 228b on the inner surface of the wall of valve housing 228. Stationary disk 216 is held in place in valve housing 228 when valve 202 is assembled by a retaining assembly 208 including an outer ring 214 which closely with interference fits in a bottom portion of valve housing 228 and surrounds a rubber expansion gasket 210. Rubber expansion gasket 210 is set in outer ring 214 and held in place by the outer ring. An inner ring 212 having projections 212a on the outside thereof helps stabilize the gasket. Retaining assembly 208 includes an inlet opening 206 in fluid communication with waterway inlets 140a and 140b on one side and apertures 218 on the other side. Rubber expansion gasket 210 extends slightly below the lower edge 228c of valve housing 228 and fluidly seals valve 202 in valve receiving portion 204 against the bottom 204a thereof.
In the embodiment shown, valve 202 also includes two stops 232a and 232b on the top surface of housing 228 to be described below with reference additionally to FIGS. 18-27. FIG. 15 depicts valve 202 in an assembled condition. FIG. 16 shows a cross-section of assembled valve 202 when drive shaft 224 is in the second, closed position. FIG. 17 shows the valve in the first, open position. As can be seen, when drive shaft 224 is in the second, closed position, the solid regions 223 of rotating disk 220 sealingly cover and block apertures 218, thus preventing flow of water within valve 202 and waterway 136. However, when drive shaft 224 is rotated to the first, open position of FIG. 17, cutout regions 222 correspond with lower apertures 218 and permit water to flow from inlet portion 206 through the two disks 216 and 220 and to outlet portion 236, and to waterway spout 50, thus allowing fluid to flow through waterway 136.
The above-mentioned first open and second closed positions may be defined by stop members 232a and 232b on valve housing 228. Drive shaft 224 may also include two flat portions 240a and 240b on a handle mount portion 238. Flat portions 240a and 240b define about a 90° angle with respect to one another relative to the rotational axis, and mate and engage with a corresponding handle flat portion 248 of a handle 244. Handle 244 includes blocking members 246a and 246b which abut stops 232 and limit the extent of maximum rotation in either the clockwise or counterclockwise direction.
As a result of dual stops 232a and 232b, dual blocking members 246a and 246b, and dual flat portions 240a and 240b, handle 244 can be mounted in one of two orientations (with handle flat portion 248 matingly engaged with either one of flat portion 240a and 240b) which thus allows rotation in either a clockwise or a counterclockwise direction to turn drive shaft 224 from the second closed position to the first open position. Moreover, as depicted in FIG. 11, the hot water valve housing 228d is oriented at a 90° displacement with respect to the cold water valve housing 228e. This placement orients the openings in the stationary disk on the hot side at a 90° displacement with respect to the openings on the stationary disk or cold side. This helps to assure proper handle placement and rotation during installation. Therefore, depending on the requirements of the sink installation, the very same valve and handle combination may be easily assembled and used to allow a clockwise (looking from down on top) rotation to open water flow, see FIGS. 19, 20 and 27, or to allow a counterclockwise (again looking down from on top) rotation, see FIGS. 22, 24 and 25, to open the water flow. This feature can be particularly useful where faucet handle 244 includes a long lever 254 which would collide with the faucet spout if it were rotated towards the spout.
FIGS. 18 and 21 show cold water valve housing 228e (from FIG. 11) oriented with projections 232a and 232b in the horizontal direction. This also causes apertures 218 in stationary disk 216 to be oriented in the horizontal direction. When the components are oriented as depicted in FIGS. 18 and 21, the valve is closed since solid regions 223 of rotating disk 220 block apertures 218 in stationary disk 216. When handle 244 is positioned on drive shaft 224 with the flat 244a of handle 244 against flat portion 240a of drive shaft 224, as shown in FIG. 19, blocking members 246a and 246b in handle 244 will press against stop members 232a and 232b when handle 244 is rotated in a clockwise direction of arrow A as shown in FIG. 19 to close the valve. When handle 244 is rotated in the counterclockwise direction when the stop and blocking members are oriented as depicted in FIG. 19, the valve will be opened and water will flow.
On the other hand, when handle 244 is positioned on drive shaft 224 with the flat 244a of handle 244 against flat portion 240b of drive shaft 224 as depicted in FIG. 22, blocking members 246a and 246b in handle 244 will press against stop members 232a and 232b when handle 244 is rotated in a counterclockwise direction of arrow B to close the valve. Rotation of handle 244 in the clockwise direction when oriented as shown in FIG. 22, will cause the valve to open.
FIG. 20 depicts a handle 244 having a lever extension 254. When such a handle is used on the cold side, it is desirable to prevent clockwise rotation from the closed valve position shown in FIG. 20 so that lever extension 254 does not contact the faucet spout. Since the valve is based in the orientation of FIG. 20, only rotation in a counterclockwise direction will be allowed to open the valve.
FIGS. 23 and 26 show hot water valve housing 228d (from FIG. 11) oriented with projections 232a and 232b in the vertical direction. This also causes apertures 218 in stationary disk 216 to be oriented in the vertical direction. When the components are oriented as depicted in FIGS. 23 and 26, the valve is closed. When handle 244 is positioned on drive shaft 224 with the flat 244a of handle 244 against flat portion 240b of drive shaft 224, as shown in FIG. 24, blocking members 246a and 246b in handle 244 will press against stop members 232b and 232a when handle 244 is rotated in a counterclockwise direction of arrow C as shown in FIG. 24 to close the valve. When handle 244 is rotated in the clockwise direction when the stop and blocking members are oriented as depicted in FIG. 24, the valve will be opened and water will flow.
On the other hand, when handle 244 is positioned on drive shaft 224 with the flat 244a of handle 244 against flat portion 240a of drive shaft 224 as depicted in FIG. 27, blocking members 246a and 246b in handle 244 will press against stop members 232a and 232b when handle 244 is rotated in a clockwise direction of arrow D to close the valve. Rotation of handle 244 in the counterclockwise direction when oriented as shown in FIG. 27, will cause the valve to open.
FIG. 25 depicts a handle 244 having a lever extension 254. When such a handle is used on the hot side, it is desirable to prevent counterclockwise rotation from the closed valve position shown in FIG. 25 so that lever extension 254 does not contact the faucet spout. Since the valve is based in the orientation of FIG. 20, only rotation in a clockwise direction will be allowed to open the valve.
As noted, this construction is particularly beneficial for faucet handles having long levers attached, such as lavatory fixtures adapted for use by the handicapped. In this case, when it is desired that both hot and cold valves are in an off position when the levers are perpendicular to the faucet spout, with the hot water lever pointing to the left and the cold water lever pointing to the right, the change can be made by merely reorienting the respective handles on the respective drive shafts as described above. The hot water valve on the left hand side will then be turned on by rotating the lever in a counterclockwise direction and the cold water faucet on the right hand side will be turned on by rotating the faucet lever clockwise.
This unique valve construction and assembly which provides that the hot and cold water valves can be oriented so that one valve includes apertures essentially parallel to the spout and the other valve includes apertures essentially perpendicular to the spout allows for a single valve construction for both hot and cold sides, a single handle construction and a single valve body (including the waterway and valve receiving portion) to accomplish both clockwise and counterclockwise opening of the valve. Thus, the same system allows ready changeover from knob handles to lever handles and vice versa, without the need to remove or replace the valves.
The present invention provides a unique system for single and dual handle faucet with interchangeable components which have heretofore been unavailable. The system also provides several improved components, and reduces both manufacturing costs, and manufacturing and installation time.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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A faucet fitting system having interchangeable components useable in both single handle and dual handle faucet fixtures. The component system is designed to allow the same putty plate with breast plate, waterway spout, aerator and mounting nuts to be used with the various escutcheons, metering valves and waterways associated with the single handle and dual handle faucet fixtures. Specially constructed water valves, putty plates and escutcheon constructions useable in conjunction with the system are also disclosed.
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This is a divisional of application Ser. No. 08/401,650 filed on Mar. 10, 1995, which is a continuation of application Ser. No. 07/954,838 filed on Sep. 30, 1992, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the field of digital color printing and, more particularly, to improving print quality by controlling migration or "bleeding" between incompatible liquid printing solutions in a printed product. The invention also is directed to alleviating physical color gamut discontinuities in printing systems, e.g. CMYK systems, that have a redundant color of ink.
Ink jet print cartridges include a plurality of orifices or nozzles, often arranged in vertical columns, for ejecting drops of ink onto the paper. For color ink jet printing, the print cartridge typically includes nozzles for ejecting cyan, magenta and yellow colored inks, called the primary printing colors, or simply "primaries." Some systems additionally include nozzles for ejecting black ink.
Printing occurs as the print cartridge traverses across the width of the paper (a "pass"). As it does so, discrete drops of ink ejected from the nozzles strike the paper or other substrate and then dry to form dots that, when viewed together, create the permanently printed image. Desired image colors are created by combining drops of ink of the primary colors where necessary. The individual dots, typically located on 1/300 inch centers, are not readily discernable to the unaided human eye so that arrays of dots can be printed to form what appear to be solid fields of a desired color.
An important consideration in printing strategies in an ink jet printing system is the intended printing medium. For example, overhead transparencies (OHT) have less affinity for absorbing ink than does a typical paper. As a result, drops of ink deposited on an OHT tend to bead rather than diffuse, as compared to drops deposited on paper. Additionally, the drops of ink deposited on OHT take longer to dry.
U.S. Pat. No. 4,748,453 (Lin et al.) discloses a method of depositing spots of liquid ink upon selected pixel centers on overhead transparencies so as to prevent the flow of liquid ink from one spot to an overlapping adjacent spot. According to that method, a line of information is printed in at least two passes so as to deposit spots of liquid ink on selected pixel centers in a checkerboard pattern, wherein only diagonally adjacent pixel areas are deposited in the same pass. On the second pass, the complementary checkerboard pattern is deposited, thereby completing deposit of ink on all of the pixels in a desired area.
Printing on paper, however, presents a different problem. Paper has an affinity for the liquid ink so that substantial absorption and diffusion of each drop of ink generally occurs. On the one hand, diffusion from one drop of ink to a drop that occupies an adjacent pixel area is helpful in achieving color mixing and obtaining a solid appearance. Along a boundary between two adjacent fields of different colors, however, such diffusion results in color bleeding across the boundary, making the boundary appear fuzzy. This is an undesirable result.
U.S. Pat. No. 5,012,257 (Lowe, et al.) discloses a two-by-two pixel ("superpixel") printing strategy to reduce bleed across color boundaries while providing good color saturation. That solution, however, effectively reduces the printer resolution, as each pixel of data is printed as a corresponding two-by-two superpixel, thereby actually printing four pixel locations. Color saturation is discussed in J. Foley, et al., COMPUTER GRAPHICS PRINCIPLES AND PRACTICE (2d.ed. Addison-Wesley, 1990) at 592.
Ink absorption can be controlled to some extent by the ink chemistry. When printing black, for example text in a letter, limiting absorption is desirable in order to provide a solid black appearance, and sharp, well-defined edges of characters. For that reason, black ink is designed to be absorbed less readily than color inks. Unfortunately, this has the effect of exacerbating bleeding where black ink touches or comes very close to color inks. Black ink is therefore said to be incompatible with color inks. Other inks may be incompatible as well. FIG. 2 illustrates the bleeding problem between a black field and an adjacent yellow field.
The incompatibility problem does not appear where composite black is used instead of true black ink, as composite black is made up of color inks. It is preferable, however, to print with a true black ink wherever possible, rather than composite black, for the following reasons:
1. True black looks better than composite black. Because of practical limitations in ink chemistry, composite black often has a colored tint to it. It might appear, for example, as greenish-black, or bluish-black. Also, the print quality of composite black is more variable over paper type, temperature, humidity and other factors than true black ink.
2. In a typical computer system, print data is sent from the host computer to the printer to control the printing of each of the four colors, CMYK, where K represents black (to avoid confusion with the color blue). If an area on a page is printed with composite black, information must be sent to the printer for the CMY inks. If the same area is printed with a black pen (true black), only data for the K ink must be sent. So use of the black pen represents a potential three-to-one reduction in data transmission between the host and the printer.
3. When printing composite black, the color pen must make three passes over the same region, the first pass putting down cyan ink, the second magenta and lastly yellow. If the same region is printed with the black pen, the black pen needs to make only one pass over the region to put down black ink. This represents a significant improvement in printing speed.
What is needed, therefore, is a liquid ink printing system that allows mixing true black and color inks within a printed page and provides for high resolution printing while controlling ink migration or "bleeding". In general, ink migration (bleed) occurs due to differences in chemical and/or physical properties of inks that must touch (or come very close to) each other on a printed page. In some cases, a substantial difference in surface tension appears to be the culprit, but other factors may contribute.
One way to avoid ink migration is to maintain at least a specified minimum separation between incompatible inks, e.g. black and color inks, on a printed page so that the inks cannot interact with one another. Methods of color separation are described in commonly-owned patent application Ser. No. 07/784,498. According to the invention of that application, black data which would be printed too close to color is instead printed as composite black (i.e. using color inks). This approach is not ideal, however, for some applications because black data "propagates" over the page as composite black, forcing use of composite black even in some areas seemingly remote from color (non-black) data. A need remains, therefore, to allow liquid ink color printing, including use of true black ink and color inks, or other combinations of otherwise incompatible inks, without unsightly bleeding between the inks.
Another problem in the prior art of digital color printing is the discontinuities that typically appear in a printing device's physical (true) color gamut. These discontinuities appear in systems having at least one redundant color, i.e. systems that have more than one physical way to produce the same logical color. By "physical color" we mean the color actually produced on a printed page, as might be observed by counting drops of C, M and Y inks. This is distinguished from a "logical color" which is image data, for example CMY data, comprising 8-bit digital values for each primary color for each pixel.
SUMMARY OF THE INVENTION
One aspect of the present invention is a method of reducing or eliminating a discontinuity in the physical color gamut of printing systems that have a redundant color ink, such as a CMYK system, in which black is redundant. A discontinuity occurs when dithering produces a pure area of the redundant ink. According to the invention, the logical color of each pixel of image data is slightly adjusted before dithering, by adding a carefully selected quantity of a selected adjustment color.
The adjustment color preferably comprises at least two primary colors, preferably cyan and magenta (blue). Adding blue to the image data results in replacing some of the black dots with blue dots in the printer data. Adding blue is conveniently effected in a CMY system by reducing the yellow value. Shades of gray exhibit discontinuities in the physical color gamut as distinguished from the logical color gamut (specified by the digital image data) for reasons explained below. Such discontinuities are avoided by adjusting the image data slightly so as to avoid neutral gray. The result is to provide a substantially continuous spectrum of physical colors in a printed product, with improved saturation.
An appropriate amount of adjustment is greater for pixels having substantial black content, as the redundant (black) ink appears more frequently in the printed image. Conversely, for pixels with high color saturation, i.e. low black content, less adjustment is needed as dots of the redundant color will appear relatively infrequently. The amount of adjustment depends upon each pixel's color saturation value.
Specifically, the selected amounts of adjustment for each pixel of image data increase as the corresponding color saturation values decrease, so that a predetermined maximum adjustment is made to neutral pixels, i.e. shades of gray, while substantially no adjustment is made to pixels having 100% color saturation. The maximum adjustment amount generally will be within a range of less than approximately 25 percent. This has been found adequate to achieve the desired results, without noticeably shifting color hues in the printed product.
Another aspect of the invention includes a method of controlling bleeding between incompatible inks in a liquid ink printing system such as an ink jet printer. According to the invention, digital color image data ("logical data") is modified, prior to dithering, so as to add a small amount of a selected primary color to the data. Preferably, in a four-color (CMYK) printing system, this adjustment comprises reducing the yellow value in each pixel of the image data so that after dithering, proportionately fewer dots of yellow ink are printed in a given area than would be printed otherwise. Where the logical data specifies pure black, the method has the effect of replacing some black dots with blue dots on the printed page. The presence of occasional blue dots within an otherwise black field is hardly noticeable, yet reduces bleed along the field edges.
An appropriate amount of adjustment is greater for pixels having substantial black content. Conversely, for pixels with high color saturation, i.e. low black content, less adjustment is needed. Indeed, corrupting a pixel substantially saturated with a first color by increasing the amount of a second primary color could adversely impact the appearance of the printed product. The amount of adjustment for controlling bleed thus also varies with each pixel's color saturation value.
Specifically, a predetermined maximum amount of adjustment is made to neutral pixels, i.e. shades of gray, while substantially no adjustment is made to pixels having 100% color saturation. The maximum adjustment necessary to control bleed without noticeably impacting color hue must be optimized for the specific dithering algorithm, target printer, ink chemistry, intended paper (or other printing media), etc. Preferably the maximum adjustment is within a range of less than approximately 25 percent. In one example of a commercial embodiment of the invention, we have selected a maximum adjustment of 7.5%. This value was found adequate to achieve the desired results, without noticeably shifting color hues in the printed product.
Thus it may be appreciated that the methods disclosed herein may be used to both control bleed and alleviate the physical color gamut discontinuity problem. Both problems are addressed by a single adjustment to the image data as disclosed.
The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment which proceeds with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prior art color print sample illustrating a discontinuity in the physical color gamut where the logical data passes through a neutral gray color.
FIG. 2 is a prior art color print sample illustrating bleeding between black and yellow color areas.
FIG. 3 is a color print sample prepared using an embodiment of the invention to illustrate the substantially continuous physical color gamut.
FIG. 4 is a color print sample prepared using an embodiment of the invention to illustrate the effect of the invention in controlling bleed across a color field boundary.
FIG. 5 is a three-color space conceptual illustration of color image data adjustment according to the present invention.
FIG. 6A illustrates dots produced by a known four-color ink jet printing system using true black ink in lieu of composite black to form a neutral gray area.
FIG. 6 illustrates the neutral gray area of FIG. 6A rendered after adjustment according to the invention.
FIG. 7 is a conceptual illustration of a discontinuity in the physical color gamut where logical image data passes through a neutral gray color.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Nomenclature
Color image data comprises a value for each primary color for each pixel of an image. An eight-bit value, for example, provides a range of 0 to 255 "counts" or digital units for each primary. Each pixel of image data thus includes a total of 24 bits in a three-color system. Gray is indicated by equal values for all three primaries. In monochrome systems, eight bits provides a 0-255 count gray scale. Certainly other resolutions, both higher and lower, are used. In any event, we refer to this type of full-resolution data as "image data".
A "logical color" is a color specified by a pixel of image data. In a theoretical perfect printing system, the color of a physical pixel on the printed page exactly matches the logical color of the corresponding pixel of image data.
Digital halftoning is used to effect the perception of millions of colors, even though the print cartridge actually provides only three colors of ink: cyan, magenta and yellow. Put another way, digital halftoning, also referred to as spacial dithering, is the method of rendering the illusion of continuous-tone pictures on displays that are capable of producing only binary picture elements (pixels). There are various digital halftoning techniques. The halftoning algorithm must be selected and adapted so as to match the specific parameters of any target display device, such as a printer, taking into account its resolution, aspect ratio, etc.
The present invention preferably is implemented in software, e.g. in a printer driver, and operates by adjusting color image data. Thereafter, the adjusted data undergoes a digital halftoning ("dithering") process to reduce it to the resolution of the target device, here an ink jet printer. Many ink jet printers have three color inks available: cyan, magenta and yellow. Hence, the printer can resolve only 3 bits per pixel of printer data, one bit for each primary color. A selected dithering process provides the appropriate printer data as its output. We will use the terms "3-bit data" or "printer data" herein to mean resulting data after dithering. Printer data generally is transmitted to the ink jet printer, where it may undergo additional processing before actual printing.
Some liquid ink printing systems also provide a separate ink for printing a particular logical color, while the same logical color may also be produced with a composite of some or all of the other inks available in the system. For example, in a four-color system having cyan, magenta, yellow and true black (CMYK) inks, there are two ways to produce the logical color black. Logical black may be produced by using the true black ink alone, or by a combination of cyan, magenta and yellow. We therefore call true black a "redundant color".
The "physical color gamut" of a printing system is the corresponding set of physical colors actually produced on a printed product in response to the full gamut of logical colors, i.e. all possible image data values.
Printing Neutral Colors
Black, white and shades of gray are neutral. "Neutral" means the image data values for each primary color are equal. If all three primary values are zero, no ink is printed; the pixel is white. If all three primaries are at maximum value (e.g. 255 units in a 24-bit system), black is specified, and all three primaries are ON in the corresponding printer (3-bit) data. In a three-color system (e.g CMY), all three primaries are printed for the pixel to create composite black. In a four-color system, e.g. CMYK, true black is substituted for the black pixel and the other three primaries turned off.
"Grayness" is an indicator of how close the primary values are to each other, in other words an indication of the range or spread of the primary values. Where the primary values are exactly equal, the color is pure gray or 100% gray. A pure primary color is 0% gray. All colors other than pure primaries (or a composite of two pure primaries) thus have some gray content. Color saturation, for present purposes, is considered the complement of grayness. Thus, color saturation equals one minus grayness, as further explained below and illustrated in the tables.
"Darkness" (or blackness) of a pixel is an indication of how close the pixel color is to black. The closer to black, the darker the color. If the color is neutral (100% gray), the common value of the primaries determines the darkness of the pixel. The lower the value, the lighter the appearance of a corresponding area of a printed image. Darkness is commonly expressed as a percentage of the maximum value, in other words as a percentage of black. For example, where 255 is the maximum value, C=Y=M=9 yields 9/255 or approximately 3.5% black. A neutral, 3.5% black area is illustrated in FIG. 6A.
Since all three primary values are the same for gray, and each color plane is dithered separately, the resulting printer data will be the same for each color plane on a dot-for-dot basis. In other words, for the dot locations to be printed, all of them will have C, M and Y on. The percentage of the dot locations printed is the same as the percentage darkness. So continuing the 3.5% black example, nine out of 256 dot locations will be printed with CMY in a three-color system, the remaining locations being left white. However, since true black is preferred over composite black, true black ink will be used to print those same dot locations in a four-color system. No drops of CMY therefore appear in the gray region. The resulting dot pattern is illustrated in FIG. 6A. Note that one drop of ink is printed per pixel for true black, rather than two or three drops per pixel for composite black, so the gray region appears lighter in a printed product than if the same data were printed with composite black. This difference in dot density leads to a discontinuity in the physical color gamut where the logical data passes through neutral values.
FIG. 6B illustrates a gray area printed in response to image data that had been adjusted prior to dithering according to the invention. (The figure also reflects the effects of an error diffusion dithering algorithm.) Compare to FIG. 6A, which is based on the very same 3.5% darkness image data, printed without the adjusting the image data.
Physical Color Gamut Discontinuity
Referring now to FIG. 1, a prior art color print sample 20 is shown to illustrate a discontinuity in the physical color gamut where the logical data passes through a neutral gray color. The image data used to generate the print sample 20 has continuously varying color content (within the limits of resolution of the data), from pure red (both magenta and yellow at maximum values, and cyan off), in corner 30, to pure cyan (both magenta and yellow off), in corner 40. A discontinuity in the physical color gamut appears as the printer data passes through neutral (i.e. where magenta, yellow and cyan values are equal).
The discontinuity appears as a lightened gray band 22, approximately vertical, and about one-eighth inch wide in the drawing. On the other hand, where the primary values are not quite equal, in other words, where even a little color is indicated in the logical data, since each plane is dithered separately, the resulting printer data will direct dot placement that varies in a more or less random fashion. Note the regions 24A, 24B near the neutral region. In these areas, only a very few dots will happen to have all three CMY colors on, and only those few dots therefore, will be printed with true black ink. Most of the gray content will be formed by randomly located dots of the various primary colors, some of those dot locations having two primary colors. The result is, for even a little color, i.e. for a logical color that is nearly but not exactly neutral (gray), significantly more ink is applied to the paper than if the logical color happened to be exactly neutral. So a small change in the logical data that crosses the "neutral line" (in a conceptual three-color space) causes a significant change or discontinuity in the physical color and its appearance on the printed product. The discontinuity could be avoided by always using composite black. This is undesirable, however, since composite black is inferior to true black, as discussed above. What is needed is to produce a continuous physical color gamut over the entire range of logical colors.
FIG. 8 further illustrates the discontinuity problem. It shows a logical color gamut formed by continuously varying values of cyan 80, magenta 82 and yellow 84. Logical color saturation varies as shown in curve 86, having a minimum 90 (zero saturation) where the CMY data is neutral, as indicated by dashed line 88. The physical color gamut exhibits an apparent color saturation as illustrated by curve 92, having a discontinuity 94 about the neutral line.
Adjusting Image Data
According to the present invention, the image data is modified to avoid the discontinuity by adjusting each pixel so as to avoid neutral data. This may be done by logically adding a carefully selected amount of a predetermined color, called the "adjustment color," to each pixel of image data. This is done in the preferred CMYK system by reducing the complementary color. If we consider each pixel of image data as a point in three-color space, this adjustment may be described as adding an adjustment vector to the image data point, thereby forming a new, adjusted data point. The direction of the adjustment vector is a color, i.e. the adjustment color. The magnitude of the adjustment vector, i.e the amount of adjustment, depends upon the color saturation of the pixel of interest, as described below.
The exact "adjustment color" must be selected for optimum performance in a target system. It depends upon various factors including the inks, dithering algorithm, paper selection, and subjective judgment about the resulting printed product. The adjustment color may be selectable among multiple colors, as well, under user-input or program control for various applications. For example, different adjustment colors may improve results for different papers.
In general, the adjustment color should be close to the redundant color. For example, in a CMYK system, the adjustment color should be dark so that it is less noticeable when substituted for the redundant color, true black. The adjustment color may be any logical color. The color adjustment has the effect of reducing the frequency of redundant color dots, and hence improves ink coverage in the printed image. This benefit may be maximized in some systems by adding an adjustment color that consists of two or even three primaries (composite black in a CMYK system).
We have found that depleting one primary color (yellow), in other words selecting a secondary color as the adjustment color (blue), provides a good, practical tradeoff for a CMYK system. In appropriate amounts, this depletion avoids the discontinuity around neutral colors and controls bleed, while maintaining high quality black printing. Selecting a secondary color as the adjustment color had the advantage of simplicity in implementation. Blue is the adjustment color of choice, as it is a dark primary color. In a CMY system, as noted, blue is added to an image data pixel by reducing the yellow value.
The appropriate amount of correction depends upon the color saturation of the pixel. If the pixel has substantial color saturation, little or no correction is necessary, as the discontinuity effect will not occur, or will not be apparent in the printed product to the unaided eye. Conversely, where there is little or no color saturation, i.e. the pixel is gray or nearly gray, more correction is necessary to avoid the discontinuity effect.
Measuring Color Saturation
Color saturation of a pixel of image data may be determined as a ratio of the "range" of the pixel to the highest color value indicated (among the three primaries). The range is defined as the difference between the highest value and the lowest value indicated among the three primaries. Several examples to illustrate the concept are shown in the following table:
TABLE I______________________________________Color Saturation ExamplesC M Y(RANGE/MAX) MAX MIN RANGE COLOR SAT.______________________________________0 0 240 240 0 240 1.00 (yellow)128 128 128 128 128 0 0.00 (med. gray)20 10 10 20 10 10 0.5020 10 5 20 5 15 0.755 5 4 5 4 1 0.209 9 9 9 9 0 0.00 (light gray)220 230 250 250 220 30 0.1210 20 250 250 10 240 0.960 128 100 128 0 128 1.00 (red)______________________________________
According to the invention, the yellow value is reduced to increase the blue content (i.e. cyan plus magenta) of the pixel. The correction must be subtle, so that colors are not unduly distorted. The correction generally should not exceed 25 percent. For most systems, five to ten percent works well. The actual value must be optimized for the target application, inks, paper, etc. The maximum correction is used when the color is neutral, i.e. color saturation is zero.
As color saturation increases, less correction is needed. Assume for illustration purposes that the maximum correction is selected to be 7.5 percent. This is the value we have selected for commercial use. So a corrected yellow value equals the original yellow value times a correction factor between 92.5% (maximum depletion) and 100% (no depletion). The actual correction factor applicable to a specific pixel depends upon the color saturation value. Thus, in algebraic terms, new yellow=old yellow×correction factor 92.5% to 100%!:
correction factor=MCF+ color saturation×(1-MCF)!,
where MCF is the maximum correction factor, i.e. 92.5% in the example. This formula, applied to the sample data shown in Table 1 above, yields the corrections shown in Table 2, below. (Figures are approximate)
TABLE 2______________________________________Color Adjustment Examples Correction New YC M Y COLOR SAT Factor (rounded)______________________________________ 0 0 240 1.00 1.00 240128 128 128 0. 0.925 118 20 10 10 0.50 0.96 10 20 10 5 0.75 0.98 5 5 5 4 0.20 0.94 4 9 9 9 (gray) 0.00 0.925 8220 230 250 0.12 0.934 234 10 20 250 0.96 0.997 249 0 128 100 1.00 1.00 240______________________________________
It may be observed from the examples that the maximum correction factor, 92.5%, is applied where the color saturation is zero. The resulting reduction in yellow value forces some cyan and magenta dots to be printed even where the original image data indicated black. This reduces use of true black in the printer data, as described above, especially near neutral colors, and thus alleviates the physical color gamut discontinuity.
The image data adjustment concept is illustrated in the diagram of FIG. 5. Referring now to FIG. 5, orthogonal C, M and Y axes (cyan, magenta and yellow) are shown for representing color image data points. Vector 74 defines a black or gray line. All points along this line are neutral colors, as all three primary values are equal. At the tip of vector 74 is a first pixel, at location CMY=(255, 255, 255) (black). According to the invention, the black pixel is adjusted by reducing the yellow value, as indicated by vector 78 in the CY plane in the figure. Vector 76 points to the resulting adjusted pixel at location CMY=(255, 255, 236). This is the special case (black) in which the maximum correction is made.
Another example is shown by image data pixel 77 in FIG. 5. The image data pixel lies at CMY=(200, 50, 70). Correction is determined as follows. Saturation=150/200=0.75. New yellow value=old yellow× 92.5%+(0.75×7.5%)!. The resulting new yellow value is 69, a slight correction. In practice, integer arithmetic is preferred for speed, and rounding is applied.
An example of the effect of the described adjustments is shown in FIG. 3. Referring now to FIG. 3, a print sample 70 was generated with continuously varying image data, as described with respect to FIG. 1. Here, prior to dithering, the image data was adjusted as described above, by depleting the yellow value, by a maximum of 7.5% at the neutral point 72. The magnitude of the correction was linearly reduced as the image data color saturation increased, to zero correction at the 100% color saturation endpoints 30,40. It may be observed that no discontinuity in the physical color gamut is visible.
Controlling Bleed
The foregoing adjustments to the image data also have the advantage of reducing bleed between incompatible inks. In the preferred embodiment, since a little blue is added to the image data, logical black image data pixels are shifted slightly toward blue. In our improved CMYK system, as noted, the yellow value is reduced for this purpose. The effect on the printed page is to introduce a relatively small number of blue dots within an otherwise black area. Since the correction is small, true black ink drops still predominate to provide a solid black appearance.
The blue content, however (appearing as occasional cyan and/or magenta drops) helps to reduce bleed along the area boundary where the black field touches or comes close to a color field. It seems that the superior absorption of the color ink helps to retain the black dye within the black area, in other words reducing migration of the black dye toward the color field boundary. FIG. 4 is a color print sample comprising a yellow field 50 surrounding and touching a black field 64. Bleeding along the boundary 64 is reduced, as compared to the prior art print sample of FIG. 2.
Since essentially the same adjustment is made to address the color gamut discontinuity, a single adjustment to the image data may suffice to achieve these dual advantages. Where improved ink chemistry controls the bleed problem, a different correction color may be selected for addressing the discontinuity problem, as noted above.
Having illustrated and described the principles of our invention in a preferred embodiment thereof, it should be readily apparent to those skilled in the art that the invention can be modified in arrangement and detail without departing from such principles. We claim all modifications coming within the spirit and scope of the accompanying claims.
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A method for alleviating a problem in color graphics printing that incompatible inks, such as true black and color inks, tend to bleed across color field boundaries includes depletion of yellow in the image data so that more blue content is present in the image data. For each pixel, the amount of correction is inversely related to the color saturation and a corresponding correction factor related to the amount of correction is selected to be less than or equal to a preselected maximum correction factor. The presence of blue ink dots within a substantially black field, resulting from the depletion of yellow, reduces bleed along the field edges.
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FIELD OF THE INVENTION
The present invention generally relates to apparatus and methods for extruding thermoplastic filaments and, more particularly, apparatus for spunbonding multi-component or single component filaments.
BACKGROUND OF THE INVENTION
Melt spinning techniques, such as spunbonding or meltblowing techniques, for extruding fine diameter filaments find many different applications in various industries including, for example, in nonwoven material manufacturing. This technology generally involves extruding a thermoplastic material from multiple rows of discharge outlets extending along the lower surface of an elongate spinneret. Spunbonded and/or meltblown materials are used in such products as diapers, surgical gowns, carpet backings, filters and many other consumer and industrial products. The machines for meltspinning such materials can be very large and include numerous filament discharge outlets.
For certain applications, it is desirable to utilize two or more types of thermoplastic liquid materials to form individual cross-sectional portions of each filament. Often, these multi-component filaments comprise two components and, therefore, are referred to as bicomponent filaments. For example, when manufacturing nonwoven materials for use in the garment industry, it may be desirable to produce bicomponent filaments having a sheath-core construction. The outer sheath may be formed from a softer material which is comfortable to the skin of an individual and the inner core may be formed from a stronger, but perhaps less comfortable material having greater tensile strength to provide durability to the garment. Another important consideration involves cost of the material. For example, a core of inexpensive material may be combined with a sheath of more expensive material. For example, the core may be formed from polypropylene or nylon and the sheath may be formed from a polyester or co-polyester. Many other multi-component fiber configurations exist, including side-by-side, tipped, and microdenier configurations, each having its own special applications. Various material properties can be controlled using one or more of the component liquids. These include, as examples, thermal, chemical, electrical, optical, fragrance, and anti-microbial properties. Likewise, many types of die tips exist for combining the multiple liquid components just prior to discharge or extrusion to produce filaments of the desired cross-sectional configuration.
One problem associated with multi-component extrusion apparatus involves the cost and complexity of the manifolds used to transmit liquid(s) to the spinneret or extrusion die. Typical manifolds are machined with many different passages to ensure that the proper flow of each component liquid reaches the die under the proper pressure and temperature conditions. These manifolds are therefore relatively complex and expensive components of the melt spinning apparatus.
For these reasons, it would be desirable to provide a an extruding apparatus having a manifold system which may be easily manufactured while still achieving the goal of effectively transmitting the heated liquid or liquids to the die tip.
SUMMARY OF THE INVENTION
The invention generally provides a lamellar die apparatus for extruding a heated liquid into filaments preferably by spunbonding techniques. The apparatus is constructed with a plurality of plates each having opposite side faces. At least two of the side faces confront each other and have a liquid passage positioned therebetween for transferring the heated liquid. At least two of the side faces confront each other and have a heating element passage therebetween. A heating element is positioned within the heating element passage for heating the liquid in the liquid passage. An extrusion die is coupled with the plurality of plates and communicates with the liquid passage for discharging the heated liquid as multiple filaments.
The liquid passage is preferably formed by respective first and second recesses on adjacent plates that abut one another. Likewise, the heating element passage is formed by respective third and fourth recesses on adjacent plates that abut one another. Recesses from different ones of these pairs of recesses may, for example, be located on opposite sides of the same plate. In the preferred embodiment, multiple heating element passages are positioned between two of the plates and multiple heating elements are respectively contained in the heating element passages.
The liquid passage includes an inlet portion and an outlet portion with the outlet portion being wider than the inlet portion. The outlet portion of the liquid passage forms an elongate liquid outlet slot. The extrusion die includes an elongate liquid inlet slot aligned in communication with the elongate liquid outlet slot to facilitate liquid flow to the extrusion outlets.
The invention further contemplates methods of extruding liquid filaments, such as single or multiple component thermoplastic polymeric filaments, in general accordance with the use of the apparatus described above.
Various advantages, objectives, and features of the invention will become more readily apparent to those of ordinary skill in the art upon review of the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a multi-component spunbonding apparatus constructed in accordance with a preferred embodiment of the invention.
FIG. 2 is a cross sectional view taken along line 2 — 2 of FIG. 3 .
FIG. 3 is a fragmented top view of the assembled apparatus of FIG. 1 taken generally along line 3 — 3 of FIG. 2 .
FIG. 4 is a cross sectional view similar to FIG. 2 , but illustrating an alternative embodiment of the apparatus and taken along line 4 — 4 of FIG. 5 .
FIG. 5 is a cross sectional view taken along line 5 — 5 of FIG. 4 .
FIG. 6 is a cross sectional view similar to FIG. 2 , but illustrating another alternative embodiment of the apparatus.
FIG. 7 is a cross sectional view similar to FIG. 4 , but illustrating another alternative embodiment of the apparatus.
DETAILED DESCRIPTION
FIGS. 1–3 illustrate a die apparatus 10 constructed in accordance with a first embodiment. Apparatus 10 is comprised of a manifold structure 12 coupled for fluid communication with an extrusion die 14 . Manifold structure 12 is a lamellar construction or plate assembly comprised of multiple plates 16 a–c , 18 a–c and 20 . These plates are securely fastened together in side-by-side relation using appropriate fasteners 22 (only one shown in FIGS. 2 and 3 ) extending through holes 24 in each of the plates. As best shown in FIG. 2 , respective outside pairs of plates 16 a , 16 b and 18 a , 18 b form optional air manifold sections and include respective quench air input ports 26 , 28 . Positive pressure quench air assists in quickly cooling the discharged filaments. Optionally, vacuum may be drawn through ports 26 , 28 for purposes of removing monomer gases at the filament discharge area. In each case, it will be understood that the appropriate openings (not shown) will be provided in or adjacent die 14 to allow the discharge of quench air or intake of monomer gases. Plates 16 a , 16 b and 18 a , 18 b respectively abut each other and contain air passages 27 , 29 therebetween. Air passages 27 , 29 are respectively formed by pairs of recesses 30 , 32 and 34 , 36 that align with each other in abutting faces of the plates 16 a , 16 b and 18 a , 18 b.
As shown best in FIG. 1 , these recesses 30 , 32 and 34 , 36 take the form of so-called coat hangar recesses which become wider in dimension from the inlet portion 40 located proximate input ports 26 , 28 to an outlet portion 42 located proximate respective distribution passages 44 . Distribution passages 44 extend respectively through plates 16 b and 18 b and lead to extrusion die 14 . Plates 16 c and 18 c respectively abut central plate 20 as shown.
Respective liquid passages 54 , 56 are formed between plates 16 c , 20 and 18 c , 20 and, again, are formed by respective pairs of coat hangar recesses 58 , 60 and 62 , 64 that align with each other in abutting surfaces of these plates 16 c , 20 and 18 c , 20 . As shown in FIG. 1A , these recesses 58 , 60 and 62 , 64 are also formed with a coat hangar configuration between inlet portions adjacent respective liquid input ports 66 , 68 and outlet portions which form elongate liquid outlet slots 70 , 72 for abutting the top surface of the extrusion die 14 and aligning with coextensive liquid inlet slots 73 , 75 . In this embodiment, the two liquid input ports 66 , 68 and coat hangar passages 54 , 56 are provided for producing bicomponent filaments from extrusion die 14 . Extrusion die 14 may be any suitable extrusion die having, for example, a laminated plate construction with appropriate porting and passages to combine and extrude filaments from the outlet orifices extending along the underside of the extrusion die 14 and to attenuate or otherwise affect those filaments with process air. Representative dies are, for example, disclosed in U.S. Pat. Nos. 5,562,930; 5,551,588; and 5,344,297, however, such dies would require modification with suitable passages to transfer and discharge quench air received from distribution passages 44 .
Also in accordance with the invention, heating elements 74 , 76 are respectively contained in passages 80 , 82 between plates 16 b , 16 c and 18 b , 18 c . Each passage is again preferably formed by respective pairs of aligned and abutting recesses 84 , 86 and 88 , 90 in plates 16 b , 16 c and 18 b , 18 c . These heating elements 74 , 76 , which are preferably electrically operated heating elements, may be advantageously situated between the respective air and liquid passages 27 , 54 and 29 , 56 so as to heat both the liquid and the air traveling to extrusion die 14 . Sufficient heat may also be supplied to heat the extrusion die 14 itself to the appropriate operating temperature.
FIGS. 4 and 5 illustrate another apparatus 10 ′ constructed in accordance with the invention. In this embodiment, apparatus 10 ′ again comprises a multiple plate assembly or manifold structure 12 ′ coupled with an extrusion die 14 ′. Manifold structure 12 ′ and die 14 ′ are similar to the first embodiment except that a five plate construction is used instead of a seven plate construction thereby eliminating the quench air. In this embodiment, plates 16 a , 18 a have been eliminated from the outside of the manifold structure 12 ′ to eliminate the quenching air to the extrusion die 14 ′. This quenching air can instead be discharged at the filaments by other means such as conventional components located below die 14 ′. Other elements indicated with like reference numerals to the first embodiment but have prime mark (′) designations are only slightly modified as shown. Elements having like numerals to the first embodiment are identical elements. In both cases, no further description is necessary to an understanding of the invention.
FIG. 6 illustrates another alternative die apparatus 200 having a laminated plate construction. This apparatus 200 is similar to that described above with respect to the first embodiment ( FIGS. 1–3 ), but is configured to discharge single component filaments or monofilaments rather than a bicomponent filament. Thus, the central plate 20 used in the first embodiment has been eliminated thereby resulting in a six plate construction rather than a seven plate construction for manifold structure 202 . As with the previous embodiments, an extrusion die 204 is coupled to manifold structure 202 for discharging one or more filaments and, optionally, discharging quenching air. A single liquid input port 206 and coat hanger passage 208 receive the liquid, such as a thermoplastic polymer. Coat hanger passage 208 is formed by aligned recesses 210 , 212 in abutting faces of plates 16 c ′ and 18 c ′. Plates 16 c ′ and 18 c ′ are designated with prime marks (′) to denote that they are slightly modified, as illustrated, from plates 16 c , 18 c . All other aspects of apparatus 200 are as described above with respect to the first embodiment and, therefore, identical reference numerals have been used and no further description is necessary.
FIG. 7 illustrates another alternative apparatus 220 similar to that described above with respect to FIGS. 4 and 5 but, like the embodiment of FIG. 6 , apparatus 220 is configured to discharge single component filaments or monofilaments rather than bicomponent filaments. Again, the central plate 20 of the embodiment illustrated in FIGS. 4 and 5 has been eliminated and a four plate manifold structure 222 results. Manifold structure 222 is configured to deliver a single type of liquid, such as a thermoplastic polymer, to an extrusion die 224 . A single liquid input port 206 and a coat hanger passage 208 is formed between abutting plates 16 c ′, 18 c ′ to communicate with an appropriate elongate inlet slot (not shown) in the top of the extrusion die 224 . Plates 16 c ′ and 18 c ′ are identical to those shown in FIG. 6 . All other aspects of the embodiment shown in FIG. 7 are described with respect to the first two embodiments described above and, therefore, identical reference numerals have been used and no further description is necessary.
While the present invention has been illustrated by a description of various preferred embodiments and while these embodiments has been described in some detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The various features of the invention may be used alone or in numerous combinations depending on the needs and preferences of the user. This has been a description of the present invention, along with the preferred methods of practicing the present invention as currently known.
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A lamellar die apparatus for extruding a heated liquid into single or multiple component filaments. The apparatus includes a plurality of plates each having opposite side faces. At least two of the side faces confront each other and have a liquid passage positioned therebetween for transferring the heated liquid. At least two of the side faces confront each other and have a heating element passage therebetween. A heating element is positioned within the heating element passage for heating at least two of the plates. An extrusion die is coupled with the plurality of plates and communicates with the liquid passage for discharging the heated liquid as multiple filaments.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor device in which a field effect semiconductor element is formed in a resin mold package and a method of making the same.
2. Description of the Background Art
FIG. 6(a) is a perspective view schematically showing the appearance of a conventional resin mold field effect semiconductor device SD p (simply referred to as a "semiconductor device" hereinafter). FIG. 6(b) is a perspective view schematically showing the internal structure of the semiconductor device SD p of FIG. 6(a).
The semiconductor device SD p includes a semiconductor element 10, in which a power MOS field effect transistor (hereinafter referred to as a "power MOSFET") whose major face is the (111) plane of silicon single crystal is formed. The semiconductor element 10 (a power MOSFET chip) is fixed to the surface of a metal plate 3 made of Cu and the like with a brazing filler metal 2.
An extraction electrode layer not shown is provided on the top face of the semiconductor element 10, and is connected to external terminals 5 through inner lead wires 4 joined therewith by wire bonding. There is formed a passivation film 6 such as varnish on the surface of the semiconductor element 10. After the structure shown in FIG. 6(b) is formed, the semiconductor element 10 and the metal plate 3 are sealed in a resin 70 such as an epoxy resin by means of a transfer molding technology. Finally formed is the semiconductor device SD p in the shape shown in FIG. 6(a).
In the conventional semiconductor device SD p , the resin 70 having a linear expansion coefficient approximate to that of the semiconductor element 10 is selectively used. For instance, such a resin is obtained by adding appropriate filler material to the epoxy resin and the like. The purpose of this addition is to relax the thermal stress generated in the interface between the resin 70 and the semiconductor element 1 resulting from change in an environmental temperature in using the semiconductor device SD p or from temperature rise by the exothermic reaction of the semiconductor element 10 itself. This enables the prevention of the generation of cracks and chip fractures in the semiconductor element 10.
For a large current flow in the semiconductor device SD p of the present invention in which the semiconductor element 10 is used as the power MOSFET, it is preferable that a drain-source ON resistance R on (simply referred to as an "ON resistance" hereinafter) is as small as possible. However, the ON resistance R on is relatively large (about 1 106 at 25° C.) in the conventional structure mentioned above.
Thus the achievement of a semiconductor device has been desired, in which the ON resistance R on is smaller than the conventional one while relaxing the thermal stress applied to the semiconductor element 10 to prevent the chip cracks.
SUMMARY OF THE INVENTION
According to the present invention, a resin mold field effect semiconductor device comprises a field effect semiconductor element having (100) plane of silicon single crystal as a major face, a metal plate to which the semiconductor element is fixed, and a resin for covering the semiconductor element and the metal plate, the linear expansion coefficient of the resin being larger than that of the metal plate.
The present invention is also intended for a method of making a resin mold field effect semiconductor device. The method comprises the steps of fixing to a metal plate a field effect semiconductor element having (100) plane of silicon single crystal as a major face, covering the semiconductor element and the metal plate with a fluid resin at a relatively high first temperature, the linear expansion coefficient of the resin being 1.2 times larger than that of the metal plate, and cooling the resin with the semiconductor element and the metal plate to a relatively low second temperature to harden the resin.
The linear expansion coefficient of the resin of the present invention is larger than that of the metal plate. After the molding by means of the transfer molding technology, the resin shrinks more than the metal plate, so that relatively large compressive stress is applied to the semiconductor element. The compressive stress enables the ON resistance of the semiconductor element to decrease.
Since the (100) plane of the silicon single crystal is used as the major face, the proof stress against the compressive stress is large, so that chip cracks are prevented.
The method of the present invention provides the above-mentioned semiconductor device. The desirable linear expansion coefficient of the resin is specified in relation to the linear expansion coefficient of the metal plate.
According to the present invention, the silicon single crystal whose major face is the (100) plane is used as the field effect semiconductor element. The relation between the linear expansion coefficients of the metal plate and sealing resin is specified such that the compressive stress is applied to the semiconductor device. This enables the ON resistance of the field effect semiconductor element to decrease. Therefore, the exothermic reaction of the semiconductor device itself is restrained. A large current flow is permitted in the semiconductor device.
The above-mentioned semiconductor device can be made by the method of the present invention.
An object of the present invention is to provide a semiconductor device capable of reducing the occurrences of chip cracks in a semiconductor element, decreasing an ON resistance to restrain an exothermic reaction and flowing a large current, and a method of making the same.
These and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(a) and 1(b) schematically illustrate the appearance and inner structure of a semiconductor device according to a preferred embodiment of the present invention, respectively;
FIG. 2 is a flow chart of the major steps of making the semiconductor device of FIGS. 1(a) and 1(b);
FIG. 3 is a cross-sectional view of the semiconductor device in a transfer molding process;
FIG. 4 is a cross-sectional view of the semiconductor device at room temperature;
FIG. 5 is a graph showing experimental results for the temperature dependence of an ON resistance R on of the semiconductor device; and
FIGS. 6(a) and 6(b) schematically illustrate the appearance and inner structure of a conventional resin mold field effect semiconductor device, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1(a) is a perspective view schematically showing the appearance of a semiconductor device SD according to a preferred embodiment of the present invention, and FIG. 1(b) is a perspective view schematically showing the inner structure of the semiconductor device SD of FIG. 1(a). FIG. 2 is a flow chart of the major steps of making the semiconductor device SD. Hereinafter discussed is the structure of the semiconductor device SD in accordance with the steps.
The semiconductor device SD includes a semiconductor element 1. A vertical power MOSFET whose major face is the <100> azimuth plane, i.e., the (100) plane of silicon single crystal is formed in the semiconductor element 1. The initial step of making the semiconductor element 1 is to prepare a silicon wafer having the (100) plane as a major face. The vertical power MOSFET is formed through the step of doping the silicon wafer and otherwise steps.
Next, the semiconductor element 1 is fixed to the surface of a metal plate 3 made of Cu and the like with a brazing filler metal 2 such that the (100) plane of the silicon single crystal constituting the semiconductor element 1 is approximately parallel to the top face of the metal plate 3. In general, the metal plate 3 in various shapes is employable. A metal plate the end of which is partially used as an external terminal may be employed. The brazing filler metal 2 may be solders, conductive adhesives and the like.
An extraction electrode layer (not shown) provided on the top face of the semiconductor element 1 is connected to external terminals 5 through inner lead wires 4 joined therewith by wire bonding. Unlike the semiconductor element 10 shown in FIGS. 6(a) and 6(b), a passivation film such as varnish is not formed on the surface of the semiconductor element 1 of the preferred embodiment.
The structure thus obtained is introduced into a transfer molding device, in which a fluid resin is provided around the semiconductor element 1 and metal plate 3 at a first temperature selected in the range of 160° to 180° C. The property required for the resin will be described later.
After the semiconductor device SD is cooled to a temperature below the hardening temperature (glass-transition temperature) of the resin, the semiconductor device SD is taken out of a sealing metal mold (not shown). The resin with the semiconductor element 1 and metal plate 3 is further cooled to room temperature (a second temperature, e.g., 25° C.). The semiconductor device SD is thus accomplished. A resin 7 thus molded is illustrated in FIG. 1(a).
The property required for the resin 7 is that its linear expansion coefficient α re is larger than the linear expansion coefficient α m of the metal plate 3. It is preferable that the linear expansion coefficient of the resin is 1.2 times larger than the linear expansion coefficient α m of the metal plate 3. For example, a resin commercially obtainable from SUMITOMO BAKELITE CO., LTD., Japan, under the trade mark of "EME5000" is employable as the resin 7. In practice,
the linear expansion coefficient α Si of silicon is about 2.9×10 -6 /° C.,
the linear expansion coefficient α m of the metal plate 3 (Cu) is about 17.2×10 -6 /° C.,
the linear expansion coefficient α re of the resin 7 (EME5000) is about 26.7×10 -6 /° C., and
the linear expansion coefficient α* re of the prior art resin 70 is about 20.2×10 -6 /° C.
Therefore, the following formula holds:
α.sub.re >1.2α.sub.m >α*.sub.re >α.sub.Si(1).
Hereinafter described is the property of the semiconductor device SD made by the aforesaid process. FIG. 3 is a cross-sectional view schematically showing respective components of the semiconductor device SD where the resin 7 is fluid at the first temperature in the transfer molding device, and corresponds to the cross section taken along the line D--D of FIGS. 1(a) and 1(b). Both the resin 7 and the metal plate 3 are thermally expanded substantially at thermal equilibrium.
FIG. 4 schematically illustrates the respective components of the semiconductor device SD which has been sealed in the resin and has been cooled to room temperature. Since the resin 7 tends to shrink more than the metal plate 3 because of the difference in linear expansion coefficients, the semiconductor element 1, the brazing filler metal 2, the metal plate 3 and the resin 7 are strained into downwardly convex form. Compressive stress T is applied to the semiconductor element 1, so that the strain is generated within the semiconductor element 1. This results in the change of the electrical resistivity of the semiconductor element 1 by piezoresistance effect.
In the semiconductor device SD of the preferred embodiment, the silicon single crystal having the main face of the (100) plane (hereinafter referred to as "(100) Si single crystal) is used as the base material of the semiconductor element 1. A drain-source ON resistance R on can be decreased, compared with the semiconductor device which uses the silicon single crystal having the main face of the (111) plane (hereinafter referred to as "(111) Si single crystal), as described later. In addition, since the (100) Si single crystal has a large proof stress against the compressive stress T, less chip cracks occur when the compressive stress T is applied to the semiconductor element 1.
FIG. 5 is a graph showing the experimental results for the temperature dependence of the ON resistance R on of the semiconductor device where the base material of the semiconductor element 1 is the (111) Si single crystal and the (100) Si single crystal. In FIG. 5, the curve a shows the result of the (111) Si single crystal (where the open circles indicate experimental values). The curve b shows the result of the (100) Si single crystal (where the crosses indicate experimental values). The abscissa of the graph is an ambient temperature Ta of the semiconductor device. The ambient temperature Ta of 150° C. corresponds to the first temperature in the transfer molding process. The ordinate of the graph is the ON resistance R on .
As is apparent from FIG. 5, the ON resistance R on decreases as the ambient temperature Ta decreases. Within the range of objective temperatures, the ON resistance where the (100) Si single crystal is used is smaller than that where the (111) Si single crystal is used. At 25° C., for example, the former is about 0.88Ω while the latter is about 1Ω. The use of the (100) Si single crystal decreases the ON resistance by about 12% compared with the (111) Si single crystal.
Now compared is the change rate of the ON resistance R on relative to the change in ambient temperature Ta (the ratio of the ON resistance R on when Ta=150° C. to the ON resistance when Ta=25° C.). The change rate of the ON resistance R on where the (111) Si single crystal is used is about 2.2, while that of the ON resistance R on where the (100) Si single crystal is used is about 2.4. It is found that the latter is larger than the former. Therefore, when the base material of the semiconductor element 1 is the (100) Si single crystal, the piezoresistance effect is larger and is utilized more effectively.
As described hereinabove, to decrease the ON resistance R on of the semiconductor element 1 by the piezoresistance effect, it is effective to selectively use the resin having the linear expansion coefficient larger than that of the metal plate as the sealing resin 7 and the (100) Si single crystal as the base material of the semiconductor element 1. It has been also confirmed by experiments that only the removal of the passivation film 6 such as varnish of the prior art can decrease the ON resistance R on . The combination of the removal with the structure of the present invention will enables the ON resistance R on to decrease furthermore.
In general, the linear expansion coefficient of the resin often changes before and after the hardening (glass transition). The "linear expansion coefficient" of the resin in the present invention in such a case is defined as the average value of the respective linear expansion coefficients before and after the hardening in the range of the changing temperatures.
While the invention has been shown and described in detail, the foregoing description is in all aspects illustrative and not restrictive. It is therefore understood that numerous modifications and variations can be devised without departing from the scope of the invention.
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A semiconductor element includes a vertical power MOSFET whose base material is silicon crystal having (100) plane as a major face. The semiconductor element is brazed to the surface of a metal plate with a brazing filler metal. By means of a transfer molding technology, the semiconductor element, the metal plate, inner lead wires and parts of external terminals are sealed in a resin having a linear expansion coefficient 1.2 times larger than that of the metal plate.
The ON resistance of the field effect transistor can be decreased by 10% or more, and the exothermic reaction of a semiconductor device itself is restrained.
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CROSS-REFERENCE
[0001] This is a continuation of patent application Ser. No. 10/426,215 filed Apr. 30, 2003, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to a battery charger having a plurality of series connected charging sections for charging a plurality of rechargeable batteries.
[0003] Series charging is typically used for simultaneously charging a plurality of rechargeable batteries of small voltage, for example batteries of AA or AAA size, typically of 1.2 to 2 volts terminal voltage. This is because it allows for fast charging and requires a power supply of lesser current rating than would be required for a charger that is arranged to charge the batteries in parallel. However series charging presents problems in that if a battery is removed from the charging circuit, the series circuit will be broken and charging will cease, or if a battery is fully charged before others in the series, it may be damaged or destroyed by continued passage of the charging current through it. Thus battery chargers for series charging of a plurality of batteries need to provide for individual batteries in the series circuit to be by-passed by the charging current.
[0004] Hong Kong Short-Term Patent No. 1045076, entitled “An Intelligent Serial Battery Charger and Charging Block”, discloses a serial battery charger including a number of serially connected battery charging sections in which each battery charging section is characterised by a first and a second parallelly connected branch. The first branch includes terminals for connecting to the battery to be charged and a current blocking device, and the second branch includes a by-passing switch which shunts across the terminals of the first branch when activated. The blocking device in the first branch prevents adverse reverse current flow from the battery to the charger when there is no power supply and also functions as a current block to prevent adverse flow of current from the battery into the shunting by-passing switch when the power supply to the charging section is in operation. In this disclosure the current blocking device (claimed as “a one-way electronic device”) is a diode and more specifically, in practical embodiments of the development, a Schoitky-barrier diode, and the by-passing switch is a FET, more specifically a MOSFET. This patent specifically states that a MOSFET is not suitable for the current blocking “one-way electronic device”. Thus the charging circuit of this Hong Kong patent is limited to the combined use of a diode as the “one-way electronic device” for current blocking in its first (charging) parallel branch of the circuit and a MOSFET (an “electronically controllable by-passing switch”) in the second (by-passing) parallel connected branch. Limitations of this disclosed charging circuit are that when charging a battery, the diode consumes a relatively large amount of the available power thereby slowing the charging rate compared to what might otherwise be possible. Furthermore, the diode, being a one-way device, does not readily provide for a circuit configuration allowing for a discharge current to flow from a battery, as in for example a charger providing for negative pulse charging of a battery.
[0005] An object of the present invention is to provide a battery charger having a plurality of series connected charging sections for charging a plurality of rechargeable batteries which is improved compared to the above identified Hong Kong patent. There are two main improvements which may be separately realised in different embodiments of the invention. The first is that components may be used in the charging sections of the battery charger circuit that consume less power than a diode. The second is that such components also facilitate the provision of an embodiment that provides for negative pulse charging.
SUMMARY OF THE INVENTION
[0006] The present invention provides a battery charger having a plurality of series connected charging sections for charging a plurality of rechargeable batteries, wherein each charging section comprises a charging path for a charging current to flow through a battery connected into the charging path, and
[0007] a by-pass path for the charging current to by-pass the charging path when a battery connected therein is fully charged. The charging path and the by-pass path each include in series therewith an electrically operable switching device, which is preferably a solid state device, for example each device may be a FET or preferably a MOSFET. The charger furthermore includes control circuitry for operating the two electrically operable switching devices of each charging section. The switching devices of each charging section are operated such that when one is conductive the other is non-conductive. Generally the switching device in the charging path of a charging section will be conductive whilst the switching device in the by-pass path of that charging section is non-conductive for passage of the charging current through a battery in the charging path and not through the by-pass path, and to prevent any discharge current from the battery from passing through the by-pass path upon cessation of the charging current. For by-passing a battery that is fully charged in a charging section, the switching device in the charging path of that charging section will be non-conductive whilst the switching device in the by-pass path of that charging section will be conductive for the charging current to by-pass the charging path and thus the battery.
[0008] Preferably the control circuitry includes a micro-processor for providing control signals for effecting operation of the switching devices of each charging section to render them either conductive or non-conductive. More preferably, with solid state switching devices, a single control signal is provided for each charging section, and this signal is effective to cause one of the switching devices of that charging section to switch on such that it is conductive and the other switching device to switch off such that it is non-conductive.
[0009] Preferably the charger further comprises a discharge circuit which can be opened or closed via the control circuitry, whereby when the switching device in the charging path of a charging section is conductive and the switching device in the by-pass path of that charging section is non-conductive, cessation of the charging current together with closure of the discharge circuit provides for a discharge current to flow from the battery through the switching device of that charging section and through the discharge circuit. For preceding charging sections in the series connected charging sections, the discharge current may flow through the switching device in the by-pass path of such preceding sections.
[0010] Generally the charger will include a constant current source which is switchable on and off via the control circuitry. Preferably the charger is operable for the constant current source to supply the charging current to a charging section in pulses having a long duty cycle and for the battery in that charging section to discharge between the charging pulses, the discharge periods having a short duration, thereby providing negative pulse charging of the battery.
[0011] The invention according to a preferred embodiment thereof provides for a two-way electrically controllable solid state switching device, most readily realised in a MOSFET, to be used instead of a one-way diode, that is a non-electronically controllable switching device as in the above mentioned Hong Kong patent. Contrary to the findings in that Hong Kong patent, it has been discovered that a MOSFET can be used to provide a blocking function in the charging path without burning out, as will be described in detail hereinbelow.
[0012] For a better understanding of the invention and to show how it may be carried into effect, preferred embodiments thereof will now be described, by way of non-limiting example only, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 is an idealised current waveform illustrating negative pulse charging.
[0014] FIG. 2 is a battery charger circuit according to a preferred embodiment of the invention that employs N-channel MOSFETs as switching devices.
[0015] FIG. 3 is another embodiment of the invention which employs P-channel MOSFETs as switching devices; and
[0016] FIG. 4 is a further embodiment of the invention which employs relay-switches as switching devices.
DESCRIPTION OF PREFERRED EMBODIMENT
[0017] Negative pulse charging of a rechargeable battery facilitates fast and efficient charging of the battery. It involves a cyclic charging regime wherein a charging current I c (see FIG. 1 ) is supplied to the battery for a specified time period ‘a’, following which the battery is allowed to discharge for a specified time period ‘b’, and this cycle is repeated until the battery is fully charged. Generally the discharge time period is short compared to the charging time period, for example, for a total one hour charging period, a cycle can consist of one second of charging followed by 0.1 second of discharging.
[0018] With reference to FIG. 2 , a battery charger circuit according to an embodiment of the invention comprises a DC power source 10 , a constant current source 12 , a Microprocessor Control Unit 14 and other control circuitry including transistors 16 a, 16 b . . . 16 n and 18 a, 18 b . . . 18 n, and a plurality of charging sections generally referenced 20 a, 20 b . . . 20 n (where ‘a’ signifies a first described integer and ‘n’ signifies a number nth such integer). The charging sections 20 a to 20 n are connected in series, as described in more detail below. The constant current source 12 is connected to the positive of the main power source 10 and supplies charging current to the first of the series connected charging sections 20 a along a line 22 under control of the Microprocessor Control Unit 14 via a signal on a control line 26 . The negative of the power source 10 (and the current return paths) are illustrated as grounded, see reference 24 .
[0019] Each charging section 20 a, 20 b . . . 20 n comprises a charging path 28 (the first of which is connected to line 22 ), that includes contacts 30 and 32 for contacting the terminals of a battery 34 (respectively 34 a, 34 b . . . 34 n ) connectable into each charging section 20 a, 20 b, . . . 20 n, and a bypass path 36 (the first of which is also connected to line 22 ). The charging path 28 of each charging section 20 a, 20 b . . . 20 n includes in series therewith an electrically operable solid state switching device, namely an N-channel MOSFET, respectively 38 a, 38 b . . . 38 n, connected such that charging current from line 22 flows through the N-channel MOSFETs respectively 38 a, 38 b . . . 38 n in the source terminal to drain terminal direction (that is, in the forward direction of its internal diode) and through a battery, respectively 34 a, 34 b . . . 34 n via respective pairs of contacts 30 and 32 . Thus the source terminal S of the first MOSFET 38 a is connected to line 22 and its drain terminal D is connected to contact 30 for contacting the positive terminal of the battery 34 a. The source terminal S of the next MOSFET 38 b is connected to the contact 32 for contacting the negative terminal of the battery 34 a and its drain terminal D is connected to the contact 30 for contacting the positive terminal of the next battery 34 b, and so on.
[0020] The by-pass path 36 of each charging section 20 a, 20 b . . . 20 n also includes, in series therewith, an electrically operable solid state switching device, namely an N-channel MOSFET respectively 40 a, 40 b . . . 40 n, connected such that a charging current from line 22 when bypassing a charging path 28 flows through the respective N-channel MOSFETs 40 a, 40 b . . . 40 n in the drain terminal D to source terminal S direction (that is, in the reverse direction of its internal diode). The charging path 28 and by-pass path 36 of each charging section 20 a, 20 b, 20 n, are connected in parallel by a line 41 connected between the negative battery contact 32 and source terminal S of the by-pass path MOSFET 40 of that charging section 20 . Thus the charging sections 20 a, 20 b . . . 20 n are series connected and each charging section comprises parallely connected charging and by-pass paths 28 and 36 .
[0021] Control circuitry comprising the Microprocessor Control Unit 14 and, for each charging section 20 a, 20 b . . . 20 n, a pair of switching transistors respectively 16 a and 18 a, 16 b and 18 b, . . . 16 n and 18 n, operates the N-channel MOSFETs 38 and 40 of each charging section by providing signals to influence the voltage levels at their gate terminals to either switch a MOSFET on, that is render it conductive, or switch the MOSFET off, that is render it non-conductive. The Microprocessor Control Unit 14 has a number of control line outputs 42 a, 42 b . . . 42 n, one for each respective charging section 20 a, 20 b, . . . 20 n. Each control line output 42 is connected to the base of the first switching transistor 16 for a charging section 20 . The collector of the transistor 16 is connected to the gate terminal of the MOSFET 40 of the by-pass path 36 of that charging section 20 , that is, at a circuit point referenced 44 , (respectively 44 a, 44 b . . . 44 n for the charging sections 20 a, 20 b . . . 20 n ) and the emitter of the transistor is grounded at 24 . The collector circuit point 44 of the transistor 16 is also connected to the base of the switching transistor 18 via a line 46 . The collector of the switching transistor 18 is connected to the gate terminal of the MOSFET 38 of the charging path 28 of that charging section 20 , that is, at a circuit point referenced 48 (respectively 48 a, 48 b . . . 48 n ) and the emitter of the transistor 18 is grounded at 24 . The gate terminals of the MOSFETs 38 and 40 are also connected to a circuit control or reference voltage Vcc via lines referenced 50 and 52 . As is known, appropriate resistors are included in the base circuits of the transistors 16 and 18 and gate circuits of the MOSFETs 38 and 40 .
[0022] The charger circuit also includes a discharge circuit which is a continuation of line 22 to a switch 54 which is closable and openable under a control signal from Microprocessor Control Unit 14 supplied via a line 56 to, respectively, connect and disconnect a resistive load 58 into and out of the discharge circuit. The discharge circuit is completed by connection of the other side of the resistive load 58 to ground at 24 .
[0023] Before describing the operation of the overall charging circuit, it will be convenient to describe the operation of a switching transistor pair 16 - 18 for switching the N-channel MOSFETs 40 and 38 on and off. With reference to the first charging section 20 a, a high signal on control line 42 a will switch on transistor 16 a which will cause a low voltage at circuit point 44 a and thereby switch off the MOSFET 40 a because the voltage at its gate terminal is low. Thus MOSFET 40 a is rendered non-conductive. Simultaneously the low voltage at circuit point 44 a will switch off the transistor 18 a thereby causing a high voltage at circuit point 48 a which will switch on the MOSFET 38 a because the voltage at its gate terminal is high. Thus the MOSFET 38 a will be rendered conductive. Conversely, a low voltage signal on control line 42 a will switch off the transistor 16 a, thereby causing a high voltage at circuit point 44 a and switching on the MOSFET 40 a, and simultaneously switching on the transistor 18 a, which will cause a low voltage at circuit point 48 a and thus switching off of the MOSFET 38 a. When the MOSFET 38 a is on, charging current from line 22 will flow in path 28 (note that switch 54 of the discharge circuit will be open) through the MOSFET 38 a and battery 34 a to charge the battery, whilst MOSFET 40 a which is off and thus non-conductive, will prevent the charging current from by-passing the charging path 28 . When the battery 34 a is fully charged, MOSFET 38 a is switched off and MOSFET 40 a is switched on such that the charging current then flows through by-pass path 36 and through either the following MOSFET 40 b or MOSFET 38 b depending on which one is conductive and which is non-conductive.
[0024] Operation of the charging circuit when charging all batteries 34 a, 34 b . . . 34 n will now be described. During a charging period ‘a’ (see FIG. 1 ) a high signal on control line 26 of Microprocessor Control Unit 14 switches on the constant current source 12 such that a charging current Ic can flow in line 22 . The Microprocessor Control Unit 14 also outputs a high signal on lines 42 a, 42 b . . . 42 n, which (as described hereinabove) switches by-pass path MOSFETs 40 a, 40 b . . . 40 n off and charging path MOSFETs 38 a, 38 b . . . 38 n on. The Microprocessor Control Unit 14 also outputs a low signal on line 56 which opens the switch 54 such that no current can flow through the discharge circuit. Thus the charging current Ic flows from constant current source 11 through line 22 and through the charging paths 28 of each charging section, that is, through MOSFET 38 a, battery 34 a, MOSFET 38 b, battery 34 b . . . MOSFET 38 n, battery 34 n, thereby charging the batteries. During a discharging period ‘b’ (see FIG. 1 ), Microprocessor Control Unit 14 outputs a low signal on control line 26 which switches off the constant current source such that no charging current Ic can flow. High signals are maintained on control lines 42 a, 42 b . . . 42 n such that the by-pass path MOSFETs 40 a, 40 b . . . 40 n remain off and the charging path MOSFETs 38 a, 38 b . . . 38 n remain on. The Microprocessor Control Unit 14 also outputs a high signal on control line 56 which closes switch 54 to complete the discharge circuit. Because the charging path MOSFETs 38 a, 38 b . . . 38 n remain on, there is a low impedance path across each from the drain to the source terminals whereby a discharge current can flow from the positive terminal contacts 30 of the batteries 34 a - 34 n through charging paths 28 including MOSFETs 38 n . . . 38 b, 38 a (that is, in reverse direction to the charging current flow) to line 22 through switch 54 and load 58 .
[0025] If one of the batteries 34 a, 34 b . . . 34 n becomes fully charged before the others, the charging circuit operates to by-pass that battery and continue charging the others. The fully charged status of a battery may be detected by appropriate circuitry (not shown) for detecting when a battery reaches a predetermined temperature, as is known. Assuming battery 34 b is detected as fully charged, during a charging period ‘a’, the Microprocessor Control Unit 14 outputs a low signal on control line 42 b which (as described hereinabove) switches by-pass path MOSFET 40 b on and charging path MOSFET 38 b off. This causes the charging current Ic to flow from battery 34 a, through paralleling connection 41 , through MOSFET 40 b (from its drain to its source terminals' direction), through the next paralleling connection 41 to the charging path 28 of the next charging section 20 n, that is through MOSFET 38 n and battery 34 n. Thus the by-pass path 36 of charging section 20 b acts to by-pass or shunt the charging current Ic due to the low impedance in by-pass path 36 provided by the MOSFET 40 b and the high impedance blocking provided in charging path 28 by MOSFET 38 b. During a discharge period ‘b’, constant current source 12 is turned off and switch 54 closed by Microprocessor Control Unit 14 as before, however the discharge path now comprises battery 34 n, MOSFET 38 n, connection 41 , MOSFET 40 b (in the source to drain direction) connection 41 , battery 34 a, MOSFET 38 a, line 22 , switch 54 and load 58 . It will be evident from the above explanation how the charging circuit operates if any other battery or more than one of the batteries become fully charged whilst others are still being charged until they all become fully charged, at which stage a cut-out (not shown) can operate to maintain the constant current source 12 off.
[0026] The N-channel MOSFETs 38 a, 38 b . . . 38 n of the charging paths 28 are connected such that the charging current passes through them when they are switched on in the direction of their source terminal to drain terminal. It has been found that the MOSFETs 38 a, 38 b . . . 38 n when so connected do not burn out. For example, if the MOSFET 38 a is connected with its drain to line 22 and its source to contact 30 (i.e. the other way around), then when the by-pass MOSFET 40 a is on, the MOSFET 38 a will be off but its internal diode will also be in a forward biased condition such that a current path can be established from the positive terminal of battery 34 a through the internal diode of the MOSFET 38 a and the switched-on MOSFET 40 a to the negative terminal of battery 34 a. Since MOSFET 40 a has a low impedance when switched on, and the nominal voltage of battery 34 a upon fully charged is around 1.2 V, but the nominal voltage drop of a forward biased diode is only about 0.7 V, a large current will be generated through the said current path. Such a current will cause the N-channel MOSFET 38 a if connected the other way around to that illustrated in FIG. 2 to burn out. The configuration of the two N-channel MOSFETS 38 and 40 of each charging section 20 a, 20 b . . . 20 n prevents such burn outs.
[0027] An embodiment of the invention according to FIGS. 1 and 2 offers greater efficiency when charging compared to the prior art circuit of the Hong Kong Patent. For example, for a one hour charger with a charging current of 2 Amps, when using a MOSFET with internal resistance RDS-ON of 0.015 ohms in the charging path as in FIG. 2 , the power loss on one MOSFET device as given by its forward impedance times the current squared is: 0.015 ohms×2 Amps×2 Amps=0.06 watts. In contrast the power loss on one device when that device is a Schottky barrier diode as in the Hong Kong Patent, the power loss as given by the voltage drop across that device times the current is 0.5v.×2 Amp=1.0 watts. Thus there is only a 6% power loss per device in the charging path in the circuit of FIG. 2 compared to the one-way diode device in the charging paths of the circuit of the Hong Kong Patent.
[0028] A further advantage is that the circuit of FIG. 2 offers the possibility of providing for negative pulse charging because of the possible two-way current flow through the MOSFETs, with the addition of minimal further components. That is, fundamentally only two extra components namely switch 54 and load 58 need be provided.
[0029] If a negative pulse charging regime is not required, the discharge circuit 22 - 54 - 58 may be omitted. Thus the provision of a discharge circuit is an optional feature of the invention.
[0030] N-channel MOSFETs instead of P-channel MOSFETs are preferably used because they are generally less expensive. However P-channel MOSFETS may be used if desired. FIG. 3 illustrates a circuit in which P-channel MOSFETS have been used to provide the electrically operable switching devices in the charging and bypass paths. The FIG. 3 circuit is generally equivalent to that of FIG. 2 and thus the same reference numerals are used to indicate corresponding components. Persons skilled in the art will, in light of the description provided above of the functioning of the FIG. 2 circuit, readily understand the functioning of the FIG. 3 circuit and thus further description thereof is unnecessary. As in the FIG. 2 circuit, charging current in the charging paths 28 flows through the P-channel MOSFETs 38 in a direction that corresponds to the forward direction of their internal diodes, and the charging current when flowing in the bypass paths 36 flows through the P-channel MOSFETs 40 in a direction that corresponds to the reverse direction of their internal diodes (as is known, the current does not actually flow through the internal diode of a MOSFET).
[0031] Also, electrically operable switching devices other than the MOSFETs 38 and 40 may be provided. For example, non-solid state switching devices such as relay switches may be used. Persons skilled in the art will readily be able to provide appropriate control circuitry to operate the coils of the relays. For example, FIG. 4 illustrates a circuit which is generally equivalent to the FIG. 2 and 3 circuits, but in which the MOSFETS are replaced by relay switches. Reference numerals the same as used in FIG. 2 have again been used for corresponding componentry to illustrate the equivalency of the circuits. Thus in the FIG. 4 circuit, relay switches 38 a, 38 b . . . 38 n and 40 a, 40 b . . . 40 n are used. Each such relay switch comprises (as referenced for relay switch 38 a ) an operating coil 60 bridged by a diode 62 and connected to the switching transistors 16 and 18 for operation thereby. As is known, when current flows through a coil 60 it causes the relay contacts 64 to close.
[0032] The invention described herein is susceptible to variations, modifications and/or additions other than those specifically described and it is to be understood that the invention includes all such variations, modifications and/or additions which fall within the scope of the following claims.
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A battery charger having a plurality of series connected sections for serially charging a plurality of rechargeable batteries, for example rechargeable batteries of AA or AAA size. Each charging section includes a charging path for a battery and a parallel bypass path for bypassing a battery when it is fully charged. The charging path and the bypass path of each charging section each include an electrically operable switching device, which devices are preferably MOSFETs. Control circuitry is included to ensure one switching device is off when the other is on. MOSFET switching devices are connected into the circuit in directions to ensure they are not burnt out by the charging currents. A discharge circuit may be included for the batteries to discharge briefly between pulses of charging current thereby providing for “negative pulse charging” of the batteries. The charger provides for improved efficiency of charging in that very little power is consumed by the switching devices in the charging paths.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates in general to delta-sigma modulators and, in particular, to noise shaping circuits and methods with feedback steering overload compensation and systems using the same.
2. Background of Invention
Delta-sigma modulators are particularly useful in digital to analog converters (DACs) and analog to digital converters (ADCs). Using oversampling, a delta-sigma modulator spreads the quantization noise power across the oversampling frequency band, which is typically much greater than the input signal bandwidth. Additionally, the delta-sigma modulator performs noise shaping by acting as a highpass filter to the quantization noise; most of the quantization noise power is thereby shifted out of the signal band.
The typical delta-sigma modulator in an ADC includes an input summer which sums the analog input signal with negative feedback, an analog linear (loop) filter, a quantizer, and a feedback loop with a digital to analog converter (feedback DAC) coupling the quantizer output and the inverting input of the input summer. A delta-sigma DAC is similar, with a digital input summer, a digital linear filter, a digital feedback loop, a quantizer, and an output DAC at the modulator output: In a first order modulator, the linear filter comprises a single integrator stage; the filter in higher order modulators normally includes a cascade of a corresponding number of integrator stages. Higher-order modulators have improved quantization noise transfer characteristics over modulators of lower order, but stability becomes a more critical design factor as the order increases. For a given topology, the quantizer is either a one-bit or a multiple-bit quantizer.
One cause of instability in digital delta-sigma modulators is input overload. For example, input overload occurs when the gain of the input data is greater than one, when a digitized squarewave with significant Gibbs overshoot is received at the modulator input, or when a bad stream of data is fed from a preceding interpolator. Single-bit delta-sigma modulators are notoriously susceptible to input overload. Multiple-bit delta-sigma modulators are less susceptible to input overload, although overload will still often occur when the input stream approaches its maximum positive and negative levels.
Current techniques for handling overload in delta-sigma modulators are relatively complex and require detection of overload conditions and subsequent resetting or limiting of the modulator circuitry to avoid saturation and instability. However, modulator overload remains an important problem that must be addressed, especially in higher order modulators that provide higher quality noise shaping. Modulator overload is particularly troublesome in audio applications, in which an unstable modulator causes extremes in the output signal that damage the following processing stages and/or result in an unpleasant audible output to the listener.
SUMMARY OF INVENTION
According to the inventive concepts, methods and circuits are disclosed which provide noise shaper immunity to input overload. One representative embodiment of these concepts is a noise shaper including a first filter for noise shaping an input signal under normal operating conditions and a second filter that is stable under overload conditions. A quantizer responds to the sum of the outputs of the first and second filters. Signal steering circuitry steers feedback from the output of the quantizer to inputs of the first and second filters to maintain stability of the first filter under the overload conditions.
Circuits and methods embodying the inventive concepts directly address the problem of noise shaper input overload. When an overload condition occurs, the overload loop receives and bears the increased energy load while the energy being passed by the primary (high quality) noise shaping loop is sustained at a level to maintain primary loop stability. When the overload condition ceases, the primary loop resumes passing the majority of the energy and continues to provide the high quality noise shaping operation . The present invention does not require additional circuitry to either detect overload conditions or reset the noise shaper circuitry to avoid saturating the noise shaper output. Additionally, brief deviations of the input stream outside of the normal maximum limits of the noise shaper input do not substantially disrupt noise shaper operation. These circuits and methods are particularly useful in audio applications in which noise shaper overload causes damage in the following processing stages, such as the audio amplifiers and speakers, and even produce an audible output injurious to the hearing of the listener.
BRIEF DESCRIPTION OF DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagram of a representative audio system application of a digital to analog converter (DAC) according to the principles of the present invention;
FIG. 2 is a high-level block diagram of an exemplary delta-sigma digital to analog converter (DAC) generally embodying the principles of the present invention and suitable for use in such applications as the DAC shown in the system of FIG. 1;
FIG. 3 is an operational block diagram depicting one particular exemplary delta-sigma DAC with feedback steering overload control embodying the principles illustrated by the general example of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
The principles of the present invention and their advantages are best understood by referring to the illustrated embodiment depicted in FIGS. 1-3 of the drawings, in which like numbers designate like parts.
FIG. 1 is a diagram of a typical audio system application of a digital to analog converter (DAC) subsystem 100 according to the principles of the present invention. In this example, DAC subsystem 100 forms part of an audio component 101 , such as a compact disk (CD) player, digital audio tape (DAT) player or digital video disk (DVD) unit. A digital media drive 102 recovers the digital data, such as 1-bit audio data in the Sony/Philips 1-bit format or multiple-bit PCM in multiple-bit audio applications, from the given digital data storage media, and passes the data along with clocks and control signals to DAC subsystem 100 . The resulting analog (audio) data is further processed in analog/audio processing block 103 prior to amplification in amplifier block 104 . Audio amplifier block 104 then drives a set of conventional speakers 105 a and 105 b , a headset, or similar device.
Digital audio data is received as serial words through the SDATA path timed by the sampling clock (SCLK). The left and right channel data are alternately processed in response to the left-right clock signal (LRCK). The LRCK signal is normally at the same rate as the data input rate (i.e., the sampling rate). The master clock signal (MCLK) synchronizes the overall timing of audio component 101 and has an oversampling frequency of a given multiple of the audio sampling rate. Control signals DF 1 and DF 0 allow for the selection of the input format, such as a right or left justified format, a 20-bit or 24-bit word width format, etc. . When 1-bit data is being input, the SDATA port receives left channel data and the DF 1 port right channel data.
As discussed above, higher order delta-sigma modulators (e.g. third order or higher) typically provide better noise shaping over lower order delta-sigma modulators (e.g. first or second order). However, as the order of the modulator increases, modulator stability becomes a more critical design factor. One particular cause of instability is input overload, in which deviation of the input signal beyond the maximum positive or negative modulator input limits causes one or more of the modulator filter stages to saturate and the entire loop to oscillate.
In typical digital delta-sigma modulators, when the input stream exceeds a given maximum positive or negative value, the quantizer output is driven to its corresponding maximum or minimum value, at which point the throughput data steam is clipped (limited). In turn, the clipped output of the quantizer limits the amount of negative feedback available to the modulator input summer and loop filter. With insufficient feedback, the integrators of the loop filter saturate to their maximum or minimum values, and the modulator becomes unstable. In turn, when the integrator stages saturate, the following circuits, such as the DAC in a delta-sigma digital to analog converter, are overdriven. The result of overdriving is extreme transitions in the analog output signal, which in audio systems may damage the audio speakers and/or cause discomfort or injury to the listener.
One common technique for addressing overload in digital delta-sigma modulators is to reset the integrator stages of the loop filter to zero when overload is detected. Integrator overload detection and reset, however, is relatively difficult to implement. For example, the modulator has to be designed to be immune from disruptions due to occasional brief deviations of the input signal beyond its maximum values and at the same time still detect true overload conditions at the modulator input and reset accordingly.
FIG. 2 is a high-level block diagram of an exemplary delta-sigma digital to analog converter (DAC) 200 with feedback steering overload control embodying the principles of the present invention. DAC 200 is suitable for use in such applications as DAC subsystem 100 of FIG. 1 . DAC 200 includes two delta-sigma loops 201 and 202 and a shared quantizer 203 . Generally, primary delta-sigma loop 201 is a higher order filter that provides the desired noise shaping operation during normal (low level) operation. Delta-sigma loop 202 generally is a lower order “overload” data path that is unconditionally stable under overload conditions. Steering circuitry 204 , which is discussed further below, controls the negative feedback from quantizer 203 to the inputs of delta-sigma loops 201 and 202 . By steering the feedback to the inputs of loops 201 and 202 , the amount of energy passed through the corresponding loop 201 / 202 is controlled.
In the illustrated embodiment of DAC 200 , primary loop 201 is a sixth (6 th ) order loop and includes an input summer 205 , which sums the digital input signal with negative feedback from steering circuitry 204 , and also a sixth (6 th ) order primary loop filter 206 . Primary loop filter 206 preferably has a conventional topology, such as a feedforward or feedback topology. A general discussion of the design and construction of various delta-sigma loop filter topologies are found in various publications such as Norsworthy et al., Delta - Sigma Data Converters, Theory, Design and Simulation , IEEE Press, 1996.
Exemplary overload delta-sigma modulator loop 202 is a second (2 nd ) order loop and includes an input summer 207 summing a fixed input value (in this case zero) with feedback from steering circuitry 204 , and also a second (2 nd ) order loop filter 208 . Second (2 nd ) order delta-sigma loops are relatively immune to overload and generally straightforward to implement. In other words, second order loop filter designs are able to operate at or up to one hundred percent (%100) of their input range and still remain stable. Additionally, the stability of second order filters in general is provable. Hence, in the illustrated embodiment of DAC 200 , a second (2 nd ) order loop 202 is selected for overload loop 202 . In general, the state variables of the second order stage are clipped or limited to insure that finite word length registers are able to be used.
The outputs of primary loop 201 and overload loop 202 are summed into shared quantizer 203 by summer 209 . In the illustrated embodiment, quantizer 203 is a nine (9)-level quantizer with limiting or truncating capabilities. In illustrated quantizer 203 , the maximum positive truncated (quantized) digital output value is plus four (+4) and the maximum negative output value is minus four (−4). Steering circuitry 204 controls two feedback streams: one stream from the output of shared quantizer 203 to input summer 205 of primary loop 201 and another stream to input summer 207 of overload loop 202 . The output stream from quantizer 203 , which is equal to the sum of the energy of the two feedback streams, drives a conventional switched-capacitor or current steering DAC 211 through dynamic element matching (DEM) circuitry 210 . DAC 211 typically has eight (8) elements, which are nominally equivalent to each other, and DEM 210 guarantees equal usage of the elements to remove noise due to mismatch.
In normal operation, quantizer 203 provides an output without clipping and therefore steering circuitry 204 directs the majority of the feedback from quantizer 203 to primary loop 201 . Consequently, input summer 205 at the input to 6 th order loop filter 206 receives sufficient negative feedback to maintain primary loop 201 in the stableoperating regime. In this case, depicted nine-level limiting quantizer 203 outputs digital values in the range of negative four (−4) to positive four (+4). If the modulator input into primary loop 201 remains sufficiently small, feedback values in the range of minus four (−4) to plus four (+4) will provide sufficient feedback to maintain stability of the primary loop 201 .
As the input to modulator loop 201 increases and overload approaches, steering circuitry 204 steers sufficient negative feedback to the input of primary loop 201 to maintain stability. At the same time, a compensating level of feedback is sent to the negative input of summer 207 of low-order, unconditionally stable overload loop 202 . For example, if the limiting quantizer 203 clips its output at a value of +4, but the input requires feedback with a value of +5 to maintain stability, steering circuitry 204 feeds back a stream with a value of +5 to the input of primary loop 201 and a compensating stream with a value of −1 to the input of overload loop 202 . The total value out of feedback steering circuitry 204 thus remains equal to the value out of quantizer 203 . In order to minimize signal degradation under overload conditions, the operation of steering circuitry 204 guarantees that the two outputs from steering circuitry 204 sum to the output of quantizer 203 . Also, under low signal conditions, a minimal or no amount of the signal is returned to the input of low order modulator loop 202 .
In other words, the increased feedback into summer 205 of primary loop 201 sums with the increased (overload) digital input signal of DAC 200 and maintains the stages of primary 6 th order loop filter 206 out of saturation. The compensating feedback into overload loop 202 increases the energy through loop 202 .
Consequently, primary loop 201 is prevented from overloading and remains stable. Overload loop 202 passes the majority of the overload energy but remains stable due to its lower order. When the overload condition ceases, the majority of the feedback energy is redirected to primary loop 202 which returns to generating a high quality output signal. Second (2 nd ) order loop 202 is simple to construct and implement, since it does not have any input signals and only has quantized feedback signals. Therefore, the wordlength of the registers may be made to be very short.
A number of ways exist for implementing feedback steering overload compensation, such as shown in DAC 200 of FIG. 2 . FIG. 3 is an operational block diagram depicting one particular exemplary delta-sigma DAC 300 with feedback steering overload control. Delta-sigma DAC 300 includes a high-order (6 th order) primary loop filter 301 and a low-order (unconditionally stable) (2 nd order) overload loop filter 302 . For illustrative purposes, primary loop filter 301 is a sixth (6 th ) order filter, and low order filter 302 is a second (2 nd ) order filter. Again, a second (2 nd ) order topology is selected for low order filter 302 since second (2 nd ) order loop filters are provably stable under overload conditions. In this example, low order filter 302 is the overload filter.
Primary 6 th order loop filter 301 provides the high quality filtering of the input signal under normal (low level) operating conditions. The signal output of primary loop filter 301 is quantized by a non-limiting quantizer 303 , which in turn feeds one input to summer 304 . Summer 304 is placed after quantizer 303 , as the output of a simple second order loop filter is also an integer since the input is always driven with an integer and hence does not participate in the truncation. The output of non-limiting quantizer 303 also provides negative feedback to input summer 305 to close the primary deltasigma modulator loop, which also includes a delay (Z −1 ) block 306 for signal timing.
A second input to summer 304 is fed by overload filter 302 . The input to overload filter 302 is a fixed value, such as a logical zero (0) in this example. The negative feedback to summer 307 from the output of overload filter 302 , which is delayed by delay (Z − 1) element 308 , is discussed further below.
The sum of the outputs from respective primary and overload filters 301 and 302 generated by summer 304 is passed through a limiter 309 which performs a clipping (truncation) operation. The resulting output signal from limiter 309 drives DEM circuitry 310 and DAC 311 at the output of DAC 300 .
The feedback to input summer 307 is generated by summer 312 . The inverting (negative (−))_ input FB 1 to summer 312 is driven by the output of non-limiting quantizer 303 . The non-inverting (positive (+)) input of summer 312 is driven by the output of limiter 309 .
As long as the output from non-limiting quantizer 303 remains below the maximum (positive to negative) output from limiter 309 , the overload feedback FB 2 from summer 312 remains at zero (0). The majority of the energy is therefore passed through high-quality, 6 th order loop filter 301 . On the other hand, as the output from quantizer 303 exceeds the positive or negative maximum output values from limiter 309 , the overload feedback FB 2 from summer 312 increases accordingly. The full feedback FB 1 from non-limiting quantizer 303 to the input of sixth (6 th ) order loop filter 301 maintains 6 th order loop filter 301 stable by insuring that the stages of loop filter 301 do not saturate. The overload feedback FB 2 to the input of second (2 nd ) order filter 302 ensures that more energy passes through loop filter 302 , which remains stable under overload conditions. The total feedback into summers 305 and 307 equals the output from limiter 309 .
Other steering mechanisms may also be used in alternate embodiments of the present invention, such as a system that uses the overload filter path only when overload is severely affecting the operation of the main loop filter, but allows short, transient overloads to be clipped in the quantizer. Additionally, the feedback steering may be based upon the level of the input signal.
The principles of the present invention were described above with respect to exemplary digital delta-sigma modulators in exemplary DACs 200 and 300 . Feedback steering overload control according to these principles, however, are also applicable to analog delta-sigma modulators and related applications such as analog to digital converters.
Although the invention has been described with reference to a specific embodiments, these descriptions are not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
It is therefore, contemplated that the claims will cover any such modifications or embodiments that fall within the true scope of the invention.
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A noise shaper includes a first feedback loop for noise shaping a first feedback signal under normal operating conditions and having a first filter with a first signal transfer function and a second feedback loop that is stable under overload conditions and has a second filter having a second signal transfer function differing from the first signal transfer function. The noise shaper also includes an output circuit block including a quantizer and steering circuitry. The quantizer includes an input simultaneously responsive to outputs of the first and second filters. The steering circuitry steers a feedback from an output of the quantizer to input of the first and second feedback loops. The steering circuitry steers feedback from output of the quantizer to inputs of the first and second feedback loops, the steering circuitry including a first output for providing the first feedback signal to the first feedback loop and a second output for providing a second feedback signal to the second feedback loop.
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BACKGROUND INFORMATION
1. Field of the Invention:
This invention relates to wire fencing and in particular it relates to a mechanism for securing a flexible gate in a closed position.
2. Background Information:
Fences constructed from wire are placed under tension to maintain the wires in position. This applies to fences constructed of stranded wire, such as barbed wire, woven wire and combinations of woven wire and stranded wire. Without tension, the fence would not effectively provide a barrier to prevent intrusion or escapement. Fences are often used to confine animals, such as livestock within a confined area.
Gates provide doorways through the fences. The gates are generally constructed of the same material as the fence. That is a barbed wire fence will have a barbed wire gate and a woven wire fence will have a woven wire gate. This provides for unity of construction and provides the same barrier as the fence. The gates will vary in width depending on the need. A simple walk gate may be on the order of three feet and a gate spanning a roadway may exceed twenty feet. The gate has an end post and depending on the length of the span may have multiple support posts placed at intervals along the span. The gate posts are not secured to the ground and rely on the wire tension to maintain them in a vertical position.
It has always been a problem to tension the gate. A gate requires the same tension as the fence to provide the same protective barrier. Users also desire the same tension for aesthetic appeal.
A post is provided in the fence at each end of the opening that the gate is to span. Typically, one end of the gate is fixedly fastened to one gate post, which we will refer to as a hinge post, and is removably fastened to the other gate post, which we will refer to as a latch post, by various fastening methods. Typical removable fastening methods include a loop placed near the lower end of the latch post with another loop placed on the latch post at an elevation to engage the end post of the gate.
The gate is closed by inserting the bottom of the end post into the lower loop. The end post is generally tilted with reference to the latch post to relieve the tension and permit easy insertion of the lower end of the end post into the lower loop. The top of the end post is then forced toward the latch post and the upper loop is placed over the end post of the gate. For a gate of any span, this requires a great deal of force to place the wire gate under tension.
Gates are also utilized to span openings other than that of fences. For example, a rancher may utilize a gate to span a doorway of a pole barn during the warm months of the year.
BRIEF SUMMARY OF THE INVENTION
The present invention is a closing mechanism for selectively tightening and loosening a flexible gate of a fence or other structure as generally described above. The gate, in order to provide the same barrier as the fence proper must be closed in a similar tensioned condition as the fence. The closing mechanism has a mechanical advantage to provide the force necessary to tighten or tension the gate. An operating lever is pivotally mounted to a latch post of the fence. A bail for receiving an upper end of an end post of the gate is in turn pivotally mounted to the lever at a distance from the pivotal axis of the lever. As the lever is pivoted, the bail is either moved toward or away from the latch post depending on the direction of pivot of the lever. A gate end post received in the bail is thus moved either toward or away from the latch post. Movement toward the latch post causes a tightening of the gate and movement away from the latch post loosens the gate. The mechanical advantage is provided by the difference in the length of the lever arm pivoting the lever versus the length of the lever arm moving the bail.
The throw of the mechanism is adjustable, that is the distance the bail is moved as the lever is pivoted may be adjusted to suit the need.
A locking mechanism is provided for security.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a fence and a gate with a gate closer of the present invention;
FIG. 2 is a view of the gate closer of the present invention installed on a latch post of a fence;
FIG. 3 is a top view of the gate closer of FIG. 2; and
FIG. 4 is another view of the gate closer of the present invention shown in the open and closed positions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Wire gates, to be effectively closed and to provide the same barrier as the wire fence must be tensioned. Closing the gate under tension requires a large force. The present invention provides a closer for a gate that provides a user the mechanical advantage to effectively close the gate under tension.
Refer now to FIG. 1 of the drawings which illustrates a fence 10 having a flexible gate 12. The gate 12 is openable to provide an opening through the fence 10 and is closeable to provide a barrier for a span that reaches from a hinge post 16 to a latch post 18. The fence 10 and gate 12 illustrated in FIG. 1 are of the multiple strand type having wires 14, but the fence may be of any of the common wire constructions such as barbed, woven, combination of barbed and woven, square mesh, chicken wire and other types or combinations as required by a user. The gate 12 is usually of the same construction as the fence 10 but it may be of other combinations also. The gate 12, regardless of the type provides an opening for passage through the fence, i.e. between posts 16, 18. The gate 12 is of course openable to provide passage and closeable to provide the same barrier as the fence 10. In order to provide the same barrier as the fence 10, it is preferable to close the gate 12 of the fence in the same tensioned manner as the fence 10. The present invention is a closer to accomplish this task.
The wires 14 of the gate 12 are affixed to the hinge post 16 (i.e., one end of the opening that the gate spans) as by stapling or other types of fastening in a conventional manner. The wires 14 are of a length to extend from the hinge post 16 to the gate end post 20 and are attached to the gate end post 20 as by stapling. As shown in FIG. vertical riser posts 22 are positioned at intervals along the length of the gate -2 in a spaced relation and are affixed to the wires 14 as by stapling. The gate 12 in FIG. 1 is shown in the closed position.
Refer now to FIG. 2 of the drawings which illustrates the closer mechanism 30, which is preferably fabricated from mild steel. The closer mechanism 30 has an "L" shaped anchor strap 32 having multiple spaced bores 34 provided in one leg of the "L" as shown. As shown, two anchor straps 32 are affixed to a latch post 18 (i.e., one end of the opening that the gate spans), one on either side of the post. The opposed straps 32 are placed in alignment and attached by fasteners 36, such as a lag screws inserted through the bores 34 and threadably installed in the latch post 18. The multiple bores 34 are provided to accommodate different sizes of posts and also to allow discriminate positioning of the anchor strap 32 in reference to the post 18. A stud 38 is provided on the other leg of the "L" on each of the anchor straps 32. The studs 38 are affixed to the anchor strap 32 as by welding and as shown are normal to the surface of the anchor strap 32 and have a cross bore 39 (not shown) for receiving a cotter pin in a conventional manner. The anchor straps 32 are preferably installed to the latch post 18 with the studs 38 in axial alignment.
A lever 40, preferably in the shape of a "U", has multiple spaced bores 42 in each of its legs 46, 48 with one bore near the end of leg 46 and a corresponding bore near the end of leg 48. The bores 42 near the ends of legs 46, 48 of the lever 40 are aligned with and fitted to the studs 38 of the anchor straps 32. The lever 40 is pivotally mounted to the anchor straps 32 with leg 46 being pivotally mounted to one anchor strap 32 and leg 48 being pivotally mounted to the other anchor strap 32. The lever 40 is secured to the studs 38 of the anchor straps 32 by a washer 44 and cotter pin 45 fitted in the cross bore 39 in the stud 38 in a conventional manner.
A bail 50, preferably "U" shaped similar to lever 40, having studs 52 fitted adjacent its ends 54 and 56 is pivotally attached to the lever 40. The studs 52 are affixed to the bail 50 as by welding and as shown are normal to the surface of the bail 50 and have a cross bore 39 for receiving a cotter pin in a conventional manner. The bail 50 has an offset bend 55 near end 54 and an offset bend 57 near end 56. The stud 52 adjacent end 54 of the bail 50 is aligned with and installed in a bore 42 in the leg 46 of the lever 40 and the stud 52 adjacent end 56 is aligned with and installed in a corresponding bore 42 in the leg 48. The bail 50 is thus pivotally attached to the lever 40 by the studs 52 fitting in the aligned bores 42 of the legs 46, 48 of the lever 40. The studs 52 are secured in the bores 42 as by washers 44 and cotter pins 45 fitted in the cross bores 39 in a conventional manner.
The lever 40 is thus pivotally mounted to the anchors 32 and the bail 50 is pivotally mounted to the lever 40. The lever 40 and the bail 50 may be pivoted independent of each other.
Note that although studs have been described and illustrated for pivotally mounting the lever 40 to the anchor straps 32 and the bail 50 to the lever 40, other conventional fastening members may be utilized as for example bolts and nuts.
The axis of the aligned studs 38 is the pivotal axis of the lever 40 and the axis of the aligned studs 52 is the pivotal axis of the bail 50.
Refer now also to FIGS. 3 and 4 of the drawings. FIG. 4 shows the anchor straps 32 secured to the top of a latch post 18, the anchor straps 32 being mounted to the latch post at height corresponding to the height of the gate 12 so that a top portion (end) of the gate end post 20 may be received in the bail 50. A "U" shaped strap 60 is mounted near the ground on the latch post 18 by fasteners 62, such as lag bolts. The strap 60 is for receiving the lower portion (end) of the gate end post 20.
As seen in FIG. 3 the closer mechanism is shown in the "open" position with the upper portion of the end gate post 20 received in the bail 50 and the lower portion of the end gate post 20 received in the "U" shaped strap 60. For clarity of the drawing, the end gate post is shown in phantom lines.
FIG. 4 illustrates the closer mechanism 30 in both the open and closed positions, with the mechanism 30 shown in solid lines in the open position and shown in dashed lines in the closed position. As best seen in FIG. 4 the lever 40 is pivotable relative to the anchor straps 32 as indicated by the bi-directional arrow 64. The bail 50 is pivotable relative to the lever 40 as indicated by the bi-directional arrow 66. The arc length of the directional arrows 64, 66 are not indicative of the degree of pivot but only indicate the direction of the pivotal motion capability.
FIG. 4 also shows the blocks affixed to the lever 40 and anchor strap 32. Block 74 is fixedly attached to the lever 40 and the block 76 is fixedly attached to the anchor 32 as by welding. The blocks 74, 76 are positioned adjacent each other when the mechanism 30 is in the closed position. Each block 74, 76 has an elongate slot 78 and as shown the slot 78 in block 74 is positioned transverse to the slot 78 in block 76. The slots 78 in blocks 74, 76 will cooperatively receive a locking mechanism, such as a padlock (not shown) to secure the locking mechanism in the closed position. The transverse positioning of the slots 78 permits insertion of a lock mechanism even during misalignment.
The mechanism 30 provides a user with a mechanical advantage to close the gate tightly in a tensioned condition. As seen in FIG. 4, the distance from the handle end 72 to the axis of pivot of the lever 40 (i.e. the studs 38) is greater than the distance from the pivotal mounting of the bail 50 to the axis of pivot of the lever (i.e. the studs 52).
OPERATION
With reference to FIG. 4., the closer 30 is operable by pivoting the lever 40 on the studs 38 of the anchors 32.
To close, i.e. tighten, the gate 12, the lever 40 is first pivoted to the right (as viewed in FIG. 4) to thus move the mechanism 30 to the open position. The lower end of the gate end post 20 is placed in the "U" shaped strap 60 and the bail 50 is positioned over the upper end of the gate end post 20. This is the condition as shown by the solid lines in FIG. 4. The lever 40 is then pivoted to the left (as viewed in the figure). which forces the upper end of the gate end post received in the bail 50 to be moved toward the latch post 18. As the gate end post is moved toward the latch post 18, the wires 14 of the gate are tensioned. The distance moved is indicated by the distance arrow 68, which represents the throw of the mechanism 30. (The throw of the mechanism 30 may be changed by changing the pivotal mounting position of the bail 50 with reference to the lever 40).
As seen in FIG. 4, the pivot axis of the bail 50 goes over center as the lever 40 is pivoted to the closed position. As viewed in the figure, any force that urges the post 20 received in the bail 50 away from the post 18 will force the lever 40 to pivot downward. As shown the pivotal axis of the bail 50 is below the pivotal axis of the lever 40 when in the closed position. Thus a force, such as caused by the tensioned gate is directed in a line from the bail connections to the engagement of the bail loop with the gate end post and is below the pivotal axis of the lever 40.
To open the gate 12, i.e. loosen, the lever 40 is pivoted to the right (again as viewed in FIG. 4) which moves the bail 50 to the right and allows the upper end of the gate post received in the bail to move away from the latch post 18.
Those skilled in the art will recognize that variations and modifications may be made without departing from the true spirit and scope of the invention. The invention is therefore not limited to the illustrated and described embodiments but is to be determined by the appended claims.
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A closer mechanism for a flexible gate is disclosed. The mechanism is mountable to a member at one end of the gate opening. A bail for receiving the upper end of a gate post is moveable toward and away from the stationary member by the pivoting motion of an operating lever. The mechanism provides a mechanical advantage to provide a force to tension the gate as it is closed. The mechanism has adjustable features for mounting the mechanism and adjusting the distance the bail is moved as the lever is pivoted. A lower loop is provided for receiving the lower end of the gate post.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to gas turbine engines and, more particularly, to oil scavenging systems.
2. Description of the Prior Art
Proper scavenging of used oil in bearing assemblies is essential to prevent overheating and premature wear of gas turbine engine mechanical parts. The used oil is usually circulated to an oil treatment system to remove air and particles therefrom before being returned to the bearing assemblies.
Oil scavenging systems typically rely on a simple pressure imbalance to direct the used oil into collection tubes for transport to a main oil pump of the oil treatment system. More efficient systems have been devised, employing special pumps or spinning vanes to improve the used oil circulation. However, such special pumps and vanes increase the weight of the engine and thus the costs of operation.
Accordingly, there is a need for an efficient scavenge system for a bearing assembly that has a minimal weight.
SUMMARY OF THE INVENTION
It is therefore an aim of the present invention to provide an improved scavenge system for a bearing assembly of a gas turbine engine.
Therefore, in accordance with a general feature of the present invention, there is provided a scavenge system for a bearing assembly, the system comprising a scavenging passage extending axially through a rotating shaft supported by the bearing assembly, and at least one scoop provided on the rotating shaft, said at least one scoop impelling oil internally of said rotating shaft into said scavenging passage as said at least one scoop rotates with said rotating shaft.
In accordance with a further general aspect of the present invention, there is provided a scavenge system for a bearing assembly, the system comprising a scavenging passage extending axially through a rotating shaft supported by the bearing assembly, and means provided on the rotating shaft for drawing oil internally of said rotating shaft into said scavenging passage as said shaft rotates.
In accordance with a further general aspect of the present invention, there is provided a gas turbine engine comprising a compressor section, a combustor and a turbine section in serial flow communication with one another, a main rotating shaft supported by a bearing assembly, and a scavenge system for the bearing assembly, the scavenge system comprising a scavenging passage extending axially through said main rotating shaft, and at least one inlet hole defined in said main rotating shaft and in flow communication with said scavenging passage, said at least one inlet hole extending at an angle to a radius of the main rotating shaft to thereby cause oil about the rotating shaft to be drawn into said scavenging passage in said main shaft via said at least one inlet hole as said main shaft rotates.
Also in accordance with another general aspect of the present invention, there is provided a scavenge system for a bearing assembly supporting a rotating shaft in a gas turbine engine, the system comprising first fluid communication means between a lubricant cavity containing the bearing assembly and an annular inner surface closely surrounding an outer surface of the rotating shaft, second fluid communication means within the rotating shaft communicating with a stationary chamber, and third fluid communication means between the outer surface of the rotating shaft and the second fluid communication means, the third fluid communication means being defined such as to communicate with the first fluid communication means during at least a portion of a rotation of the shaft, and such that the rotation of the shaft causes used lubricant coming from the lubricant cavity to be moved from the first fluid communication means to the third fluid communication means so as to deliver the used lubricant to the stationary chamber through the second fluid communication means.
In accordance with a still further general aspect of the present invention, there is provided a method of evacuating scavenge air and oil from a bearing assembly supporting a main shaft of a gas turbine engine, the method comprising the steps of: a) feeding the scavenge air and oil from the bearing assembly to an interface with said main shaft, b) drawing the scavenge air and oil from said interface into said main shaft, and c) evacuating the oil axially through said main shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment of the invention and in which:
FIG. 1 is a schematic side view of a gas turbine engine, in partial cross-section, to which an embodiment of the present invention is applied;
FIG. 2 is a cross-sectional side view showing bearing assemblies supporting a rotating shaft of the gas turbine engine of FIG. 1 ; and
FIG. 3 is a cross-sectional view of a scavenge system taken along lines B—B of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a gas turbine engine 10 of a type preferably provided for use in subsonic flight, generally comprising in serial flow communication a fan 12 through which ambient air is propelled, a multistage compressor 14 for pressurizing the air, a combustor 16 in which the compressed air is mixed with fuel and ignited for generating an annular stream of hot combustion gases, and a turbine section 18 for extracting energy from the combustion gases. A rotating shaft 20 extends within the engine 10 and transfers energy from the turbine section 18 to the compressor 14 and the fan 12 .
Referring to FIG. 2 , the rotating shaft 20 is supported by a plurality of annular bearing assemblies 22 , as well known in the art. Each annular bearing assembly 22 comprises a series of roller bearings 24 located in a bearing compartment 26 . The bearing compartment 26 is defined such that each bearing assembly 22 is located within an annular oil cavity 28 . The annular oil cavity 28 contains oil providing adequate lubrication to the bearing assembly 22 .
During use, used oil from the oil cavity 28 is circulated to an oil treatment system (not shown) in order to remove unwanted debris and air from the used oil. A scavenge system 40 is used to direct the mixture of air and oil from the oil cavity 28 to the oil treatment system. The scavenge system 40 is illustrated in FIGS. 2–3 and will be described in the following.
In the bearing compartment 26 , a series of axial tubes 50 extend along an axial direction of the rotating shaft 20 , and a series of radial tubes 48 extend along a radial direction relative to the rotating shaft 20 . Each axial tube 50 has one end connected to one end of a corresponding radial tube 48 . The opposed end of each axial tube 50 is in fluid communication with the oil cavity 28 . The opposed end of each radial tube 48 defines an opening 51 in an inner annular surface of the bearing assembly 22 which closely surrounds the rotating shaft 20 . The openings 51 are distributed along a circumference of the inner annular surface.
The combination of each axial tube 50 with the corresponding radial tube 48 forms a conduit going from the oil cavity 28 to an opening 51 at the interface between the bearing compartment 26 and the rotating shaft 20 .
An annular channel 42 is defined within the rotating shaft 20 and is concentric therewith. A plurality of holes 44 are defined around a circumference of an outer surface of the rotating shaft 20 . The holes 44 are in fluid communication with the annular channel 42 . The holes 44 are preferably perpendicular to the annular channel 42 and defined at a large angle with respect to a radius of the rotating shaft 20 . The holes 44 are machined so that the remaining shaft material between adjacent holes forms a curved scoop 46 . The holes 44 are located in the same diametrical plane as the openings 51 , such that each hole 44 can be aligned in turn with each opening 51 and be in fluid communication therewith during the rotation of the shaft 20 .
The scoops 46 preferably have a curved section, and are progressively thinner toward the outer surface of the shaft 20 . As such, they have a profile which is similar to an airfoil. The scoops 46 are curved in the direction of rotation of the shaft 20 as depicted by arrow 47 in FIG. 3 . A space between adjacent scoops 46 , which is curved and thinner toward the center of the shaft 20 , defines the shape of the holes 44 . The shape and angle of the holes 44 and scoops 46 minimizes the effects of the centrifugal forces acting to push the air and oil mixture away from the shaft 20 . Thus, a rotation of the holes 44 and scoops 46 brought by the rotation of the shaft 20 will “pick up” and draw the air and oil mixture coming from the openings 51 to bring it to the annular channel 42 through the holes 44 .
Because the angle of the holes 44 with respect to the radial direction of the shaft 20 is preferably large, the number of holes 44 and scoops 46 is preferably limited to three. As illustrated in FIG. 3 , a preferred embodiment of the scavenge system 40 includes three groups having each three radial tubes 48 and axial tubes 50 defined in proximity to one another such as to have a common opening 51 for each group. The holes 44 , scoops 46 and groups of tubes 48 , 50 , are all equally angularly spaced apart in order to provide a balanced scavenge system 40 .
Thus, the mixture of air and oil can be transported from the oil cavity 28 to the openings 51 at the interface between the bearing compartment 26 and the rotating shaft 20 , then from the openings 51 to the holes 44 . The mixture then travels along the annular channel 42 to an extremity thereof which extends such as to define an annular exit port at the end of the shaft 20 . This exit port provides fluid communication between the annular channel 42 and a stationary chamber 52 located at the downstream end of the shaft 20 , where the mixture is collected. Pipes 54 provide fluid communication between the chamber 52 and an oil treatment system. A sufficient pressure gradient ensures that the air and oil mixture will circulate adequately from the oil cavity 28 to the oil treatment system following arrow 56 . The following treatment of the air and oil mixture and subsequent return of the cleaned oil to the oil cavity 28 is well known in the art and as such will not be discussed herein.
In an alternate embodiment, it is contemplated to replace the chamber 52 located at the end of the shaft 20 by an annular stationary chamber located around the rotating shaft 20 and in fluid communication with the channel 42 through a series of radial holes. In this case, the centrifugal forces acting on the used oil propels it from the channel 42 to the annular chamber, where it can be led to the oil treatment system through appropriate piping.
The scavenge system 40 can also be used with other types of bearing assemblies supporting a rotating shaft, and as such should not be construed as being limited to aircraft engines.
The scavenge system 40 uses a channel 42 which is directly machine within the shaft, and scoops 46 are preferably formed by removing material from the rotating shaft 20 in order to machine the holes 44 . Thus, these components reduce the weight of the rotating shaft rather than increase the overall engine weight, as added components would. The scavenge system 40 therefore has the advantage of representing a minimal weight increase for the engine.
It is understood that the present invention applies to any gas turbine engines, and in fact to any rotating machinery in which oil is scavenged.
The embodiments of the invention described above are intended to be exemplary. Those skilled in the art will therefore appreciate that the forgoing description is illustrative only, and that various alternatives and modifications can be devised without departing from the spirit of the present invention. Accordingly, the present is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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A bearing scavenge system comprises a scavenging passage extending axially through a rotating shaft supported by the bearing assembly. Oil and air are drawn from an oil cavity of the bearing assembly and evacuated through the rotating shaft as the shaft rotates.
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FIELD
[0001] The subject matter herein generally relates to a tri-proof structure, and a mobile phone using the same.
BACKGROUND
[0002] Products which are tri-proof (waterproof, dustproof, and shockproof) are desirable. A conventional tri-proof structure usually include a first casing, a waterproof rubber ring, and a second casing. The first casing is provided with a first soft rubber. The first soft rubber and the first casing are double-color molded. The second casing is provided with a second soft rubber. The second soft rubber and the second casing are also double-color molded. The first soft rubber and the second soft rubber cooperatively form a soft rubber surface, the soft rubber surface provides a buffer and shockproof effect. Simultaneously, the second casing further defines a groove, the waterproof rubber ring is assembled in the groove. The first casing presses on the waterproof rubber ring and is assembled together with the second casing via a fixing member. In the aforementioned structure, the first soft rubber and the first casing are double-color molded, and the second soft rubber and the second casing are double-color molded. A structure of the mold is complex, a cost of the mold manufacture is high, and a precision requirement to the molding machine is high, thus the manufacturing cost of a mobile phone is increased. In addition, because of the sole complete circle structure and a small cross-section area of the waterproof structure, during the process of assembling the waterproof structure to the groove, the operation is inconvenient, and the assembly has an inferior consistency and a structural bias. Thus the waterproof effect is affected. In an aspect of the waterproof and sealing effect, the waterproof effect of the structure mainly depends on a degree of pressure and sealing between the waterproof rubber ring and the first casing and between the waterproof rubber ring and the second casing. Moreover, the waterproof rubber ring has manufacturing tolerances and assembly biases, thus a larger interference value is required to ensure the waterproof effect. A greater locking force is accordingly required between the first casing and the second casing and a larger casing strength is accordingly required. In addition, there exists an assembly line after the assembly of the first casing soft rubber and the second casing soft rubber, which can affect the aesthetic appearance of the product. Simultaneously, the first casing soft rubber and the second casing soft rubber only provide a buffer and shockproof effect, and the waterproof rubber ring only provides a waterproof and dustproof effect, all must be used simultaneously to achieve a tri-proof effect.
SUMMARY OF THE INVENTION
[0003] An object of the present disclosure is to provide a tri-proof structure. The structure with a tri-proof effect reduces a production manufacturing cost of the product, and reduces an assembly difficulty. In the present disclosure, the assembly consistency is better and the tri-proof effects are more reliable.
[0004] Preferably, the present disclosure employs two kinds of tri-proof structures on a single structure. Tri-proof requirements at different structural positions are presented, thus the application of the present disclosure is wider and more flexible.
[0005] Another object of the present disclosure is to provide a mobile phone using the same. The manufacturing cost of the mobile phone is decreased and the assembly efficiency is improved.
[0006] A tri-proof structure includes a first casing, a second casing, and a third casing. The first casing is provided with a protrusion. The third casing is provided with a convex block. The second casing is made of soft material. The second casing defines a first groove corresponding to the protrusion of the first casing and defines a second groove corresponding to the convex block of the third casing. The protrusion and the first groove, and the convex block and the second groove are both interference fittings. The first casing and the third casing are both assembled to the second casing. The second casing further includes a cosmetic surface. The first casing and the third casing each further include an outer surface. The cosmetic surface protrudes out of the outer surfaces of the first casing and the third casing.
[0007] Preferably, the third casing further includes opposite upper and lower ends. The opposite upper and lower ends employs another waterproof structure. The opposite upper and lower ends each define a concavity. The second casing also includes another opposite upper and lower ends. The other opposite upper and lower ends each is a strip structure. Each strip structure is received in one concavity and is an interference fit with the first casing in assembly together with the first casing.
[0008] A mobile phone using the same is provided.
[0009] The groove of the second casing is an interference fit with the protrusion of the first casing and is an interference fit with the convex block of the third casing. Thus the present disclosure can efficiently achieve a waterproof and dustproof effect between the second casing and the first casing and between the second casing and the third casing. The second casing is made of soft material and is protruded out of the outer surface of the first casing and the third casing, thus the second casing provides a buffer and shockproof effect. The present disclosure employs a single structure and simultaneously achieves a tri-proof effect. In addition, the first casing, the second casing, and the third casing are made of one material, which does not need double-color molding and thus saves molding production cost. A common sole color molding machine can satisfy the production requirement, thereby decreasing a production manufacturing cost of the product. In the assembly process, because of the groove defined at the second casing, the third casing and the second casing, and the first casing and the second casing, are assembled in a plug or socket manner. As compared to the related art of providing a complete circle waterproof soft rubber with a small cross-section area, the operation process of the present disclosure is simpler and more reliable. Simultaneously, the second casing is made of soft material, the first casing, the second casing, and the third casing are interference fits and tightly joined after assembling, there is not a gap between the first casing, the second casing, and the third casing. Moreover, the plug or socket assembly employs a certain depth of plugging. Therefore, as compared to the related art of a mere press fit between the first casing and the second casing, the waterproof and dustproof effects of the present disclosure are more reliable.
[0010] Furthermore, because the size of the ends of the casing is small and the present disclosure employs a concave third casing and a strip second casing, the present disclosure achieves a better waterproof effect in a defined space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Implementations of the present technology will now be described, by way of example only, with reference to the attached figures, wherein:
[0012] FIG. 1 illustrates an exploded view of an embodiment of a tri-proof structure.
[0013] FIG. 2 illustrates an assembly view of the structure of FIG. 1 .
[0014] FIG. 3 illustrates a cross-sectional view taken along line A-A of FIG. 2 .
[0015] FIG. 4 illustrates an enlarged view of a portion “R” of FIG. 3 .
[0016] FIG. 5 illustrates an exploded view of portion “R” of FIG. 4 .
[0017] FIG. 6 illustrates a cross-sectional view taken along line B-B of FIG. 2 .
[0018] FIG. 7 illustrates an enlarged view of a portion “S” of FIG. 6 .
[0019] FIG. 8 illustrates an exploded view of portion “S” of FIG. 7 .
[0020] FIG. 9 illustrates a cross-sectional view taken along line C-C of FIG. 2 .
DETAILED DESCRIPTION
[0021] The present disclosure and mobile phone are to be understood in conjunction with the accompanying drawings and specific embodiments herein.
[0022] Referring to FIGS. 1-2 , a tri-proof structure for a mobile phone is shown. The mobile phone includes a first casing 1 , a second casing 2 , and a third casing 3 . The first casing 1 and the third casing 3 are both assembled to the second casing 2 , and are assembled together via a fixing member. The tri-proof structure for the mobile phone includes a tri-proof structure for opposite left and right sides 60 , 61 and a tri-proof structure for opposite upper and lower ends 70 , 71 . The waterproof structures that the opposite left and right sides 60 , 61 and the opposite upper and lower ends 70 , 71 employ are different. Thus a problem that the spaces of the opposite left and right sides 60 , 61 are sufficient but the spaces of the opposite upper and lower sides 70 , 71 are limited are resolved.
[0023] Referring to FIGS. 3-5 , the tri-proof structure for the opposite left and right sides 60 , 61 is shown. The first casing 1 is provided with a protrusion 11 at each of the opposite left and right sides of the first casing. Each protrusion 11 includes a first top surface 11 a. The third casing 3 is provided with a convex block 31 at each of the opposite left and right sides of the third casing 3 . Each convex block 31 includes a second top surface 31 a. The second casing 2 is made of soft material, and defines a first groove 21 corresponding to each protrusion 11 of the first casing 1 and a second groove 22 corresponding to each convex block 31 of the third casing 3 . Each first groove 21 includes a first bottom surface 21 a, and each second groove 22 includes a second bottom surface 22 a. The fit between each first top surface 11 a and the corresponding first bottom surface 21 a and the fit between each second top surface 31 a and the corresponding second bottom surface 22 a are interference fit 50 a and interference fit 50 b correspondingly. The interference fits ensure a waterproof and dustproof effect between the first casing 1 and the second casing 2 , and between the second casing 2 and the third casing 3 . Preferably, each protrusion 11 further includes two opposite first sidewalls 11 b. A gap 100 a is provided between each first sidewall 11 b and a corresponding first groove 21 . Each convex block 31 also includes two opposite second sidewalls 31 b. Similarly, a gap 100 b is also provided between each second sidewall 31 b and a corresponding second groove 22 . Thus, the assembly of the protrusions 11 to the first grooves 21 and the assembly of the convex blocks 31 to the second grooves 22 is convenient and employ a “plug-in” process. Simultaneously, the gaps 100 a and 100 b respectively provide a space for deformation in relation to interference fits 50 a and 50 b. Deformation is more reliable, which improves the waterproof and dustproof effects. Simultaneously, the second casing 2 further includes a cosmetic surface 25 at each of the opposite left and right sides of the second casing 2 . The first casing 1 and the third casing 3 respectively further include an outer surface 12 and an outer surface 32 at each of the opposite left and right sides of the third casing. Each outer surface 12 and a corresponding outer surface 32 are substantially located on a same plane. Each cosmetic surface 25 protrudes out of the plane formed by the corresponding outer surfaces 12 and 32 after assembly, simultaneously a partial structure of the second casing 2 at each cosmetic surface 25 wraps around the corresponding outer surfaces 12 and 32 for a better joint between the first casing 1 and the second casing 2 , and between the second casing 2 and the third casing 3 . The cosmetic surfaces 25 of the second casing 2 are firstly in contact when dropping, thereby resolving the shockproof problem efficiently. Simultaneously, an anti-skid structure is provided on each cosmetic surface 25 and provides a better feel for users.
[0024] Preferably, the position of each protrusion 11 of the first casing 1 and the position of the corresponding convex block 31 of the third casing 3 are opposite to each other. The position of each first groove 21 and the position of the corresponding second groove 22 are opposite to each other rather than in a staggered configuration. A divider is further provided between each first groove 21 and the corresponding second groove 22 . Each protrusion 11 and the corresponding convex block 31 cooperatively push against the divider. Thus, the protrusions 11 and the convex blocks 31 support each other, and the deformation of the divider is more efficient.
[0025] The first casing 1 is further provided with at least four first positioning columns 16 . The second casing 2 is provided with a number of first positioning holes 26 . The number of the first positioning holes 26 is the same as the number of the first positioning columns 16 . The position of each first positioning column 16 is opposite to the position of one corresponding first positioning hole 26 . Moreover, the assembly of the first positioning columns 16 and the first positioning holes 26 provide positioning for the assembly of the first casing 1 and the second casing 2 together. Preferably, the third casing 3 is further provided with at least four in number of the second positioning columns 36 . The second casing 2 is also provided with the same number of second positioning holes 27 . The position of each second positioning column 36 is opposite to the position of one corresponding second positioning hole 27 . Moreover, the assembly of the second positioning columns 36 and the second positioning holes 27 provide positioning for the assembly of the second casing 2 and the third casing 3 together.
[0026] Referring to FIGS. 6-8 , a tri-proof structure for the opposite upper and lower ends 70 , 71 is shown. The third casing 3 further includes opposite upper and lower ends 33 , 34 . The opposite upper and lower ends 33 , 34 each defines a concavity 35 . The second casing 2 also includes other opposite upper and lower ends 23 , 24 . The other opposite upper and lower ends 23 , 24 are each a strip structure. Each strip structure is assembled in a concavity 35 and is interference fitted with the first casing 1 during further assembly. The interference fit ensures effective waterproofing and dustproofing between the opposite upper and lower ends of the first casing 1 and the second casing 2 and between the opposite upper and lower ends of the second casing 2 and the third casing 3 . Moreover, the first casing 1 also includes opposite upper and lower ends structures 13 , 14 . The opposite upper and lower ends structures 13 , 14 are each provided with a protruding strip 15 . Each protruding strip 15 is assembled in a concavity 35 and presses the strip structure 23 or the strip structure 24 to form an interference fit. The assembly of the protruding strips 15 in the concavities 35 sufficiently ensures the pressuring and reliable deformation of the strip structures 23 , 24 , thus the waterproof and dustproof effect is improved. Each protruding strip 15 further includes a top surface 15 a. Each of the strip structures 23 , 24 includes two opposite sidewalls 23 b. The top surface 15 a of each protruding strip 15 and each of the strip structures 23 , 24 constitutes interference fit 50 c. A gap 100 c is provided between each of the two opposite sidewalls 23 b and the concavity 35 . Thus, assembly of each of the strip structures 23 , 24 and the concavity 35 is easy and convenient.
[0027] Referring to FIG. 9 , the third casing 3 is further provided with at least four protruding cylindrical columns 38 . Each cylindrical column 38 defines a bolt hole. Each cylindrical column 38 further includes an annular step 40 . The second casing 2 is provided with the same number of circular rings 28 as there are cylindrical columns 38 . The respective positions of the circular rings 28 corresponds to the positions of the cylindrical columns 38 . Each circular ring 28 is sleeved on an annular step 40 . The first casing 1 is provided with screw holes, in positions corresponding to the positions of the bolt holes. The screw holes are the same in number as the number of the bolt holes. The third casing 3 , the second casing 2 , and the first casing 1 are assembled and held together via bolts.
[0028] In any particular embodiment, the tri-proof structure of the present disclosure mainly employs the second casing made of soft material to simultaneously achieve the tri-proof effect, reducing the production cost of the product. Simultaneously the tri-proof structure of the present disclosure provides sufficient space for the elastic deformation generated by the interference fit, thus the deformation is ensured to be reliable. Convenience in assembly is paramount in the tri-proof structure of the present disclosure, thus the production efficiency is improved. Moreover, the present disclosure further provides a new tri-proof design idea, namely two kinds of tri-proof structures are combined and applied in one tri-proofed product.
[0029] In the present disclosure, the interference fits 50 a, 50 b, and 50 c form the waterproof and dustproof structure. The second casing 2 is made of soft material and is protruded out of the outer surfaces of the first casing 1 and the third casing 3 . The second casing made of soft material is in first contact when the mobile phone is dropped, thus the second casing provides a buffer and shockproof effect. The present disclosure employs a single second casing structure to simultaneously achieve a tri-proof effect. Simultaneously, the first casing 1 , the second casing 2 , and the third casing 3 are each made of a single material, which avoids double-color molding. A common single color molding machine can satisfy the production requirement, thereby decreasing a production manufacturing cost of the product. In the assembly process, because of the gaps 100 a, 100 b, and 100 c, the assembly is convenient and can be completed in a “plug-in” manner. As compared to the related art of providing a complete circle waterproof soft rubber with a small cross-section, the operation process of the present disclosure is simpler and more reliable. In addition, the interference fits 50 a, 50 b, and 50 c operate to a certain plug depth when being plugged together. Therefore, the first casing, the second casing, and the third casing of the present disclosure are interference fits and held together tightly after assembling, and there is no gap. Compared to the related art of a mere press fitting between the first casing and the second casing, the waterproof and dustproof effect of the present disclosure is more reliable. Moreover, the present disclosure further provides a new tri-proofing design idea, namely two kinds of tri-proofing structures are combined and applied in one tri-proofed product. When there is sufficient space, the tri-proof structure for the opposite left and right sides of the present disclosure is employed. When the space is limited, the tri-proof structure for the opposite upper and lower ends of the present disclosure is employed.
[0030] The above is a detailed description with the accompanying drawings of a tri-proof structure and a mobile phone using the tri-proof structure. The ideas of the present disclosure are not limited to the field of mobile phones, for example, any waterproofing requirement between casings can use the ideas of the present disclosure to change and develop. In addition, the combination of two kinds of tri-proof structures in one device of the present disclosure can further be developed to even more types of tri-proof structures.
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A mobile phone proofed against water, dust, and physical shocks (tri-proofed) has a structure comprising a first casing, a second casing, and a third casing. The first casing is provided with protrusions, and the third casing is provided with convex blocks. The second casing is provided with a first groove for a protrusion, and is provided with a second groove for a convex block. The protrusions and the convex blocks are both interference fits in the grooves. Moreover, the second casing also includes cosmetic surfaces. The first casing and the third casing have outer surfaces and each cosmetic surface protrudes out of the outer surfaces. The cosmetic surfaces are in first contact when the mobile phone is dropped. Waterproofing, dustproofing, and shockproofing are simultaneously achieved with the single second casing structure.
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BACKGROUND OF THE INVENTION
This invention relates generally to the field of explosives and more particularly to means, known as detonators, used to set off or detonate explosives. In the use of explosives to shatter or remove large masses, such as boulders, rock formations, etc., it is important that the explosive be in the proper location when it is detonated, and that other objects and people be where they will not be damaged or injured by the force of the explosion. This requires control of the time when the explosion occurs.
While explosives have long been used in various fields, their use is always subject to the dangers of premature explosion with resultant injury and damage. Explosives that produce the greatest force are likely to be explosives that are most easily detonated by heat or shock. To achieve the desired safety it is advisable to use explosives that are not likely to be unintentionally detonated by a rise in temperature or by a moderate shock. While such explosives are known, the characteristics that contribute to their safety also contribute to the difficulty of detonating them at the desired time. Thus, the detonation of such an explosive requires the use of some other explosive trigger means and the trigger means, in turn, must be one that is not subject to premature explosion. Many of these problems can be solved by the use of a less sensitive explosive such as HNS, (hexanitrostilbene) that, in turn, is detonated by means such as an exploding bridge.
It has long been known that the passage of an electric current through a conductor generates a certain amount of heat, the amount of heat varying directly with the resistance of the conductor and with the square of the current. This phenomenon is relied upon in fusible links that are installed in electrical circuits to prevent the flow of more than a predetermined amount of current in such a circuit. When the predetermined flow is exceeded, the heat melts the fusible link so that the circuit is broken. If a sufficient current is passed through the link in a small period of time, the link is not only melted but may be vaporized. If the fusible link is enclosed in a small space the vaporizing of the link can increase the pressure in that space.
For a number of years it has been customary to detonate an explosive by means of a blasting cap having a heat sensitive explosive set off by an electrical resistance heated by the passage of an electric current through the resistance. More recently, explosives have been detonated by means making use of a relatively high resistance bridge extending between conductors and through which a relatively high current is passed so that the bridge portion is not only heated to its melting point but is heated so much that it vaporizes and literally explodes to provide a shock wave to detonate the explosive. While such a system can use an explosive that is much less sensitive to heat and shock, there are still a distressing number of accidents that occur when an explosive is prematurely detonated. While less sensitive explosives have heretofore been available, it has been difficult to cause the detonation of such explosives at a selected time.
Recently, it has been proposed to detonate these more stable explosives by an electrical means of some sort that creates a sudden pressure to shear a film and form a disk or flyer which is then impacted against the explosive material.
In the construction of such a detonator, it is important that the explosive material be properly supported and sealed against the admission of materials such as moisture that would tend to deteriorate it. This is particularly important when the detonator is used in environments, such as deep wells, where the ambient pressures can become very high. It is also important that the physical construction be such that the flyer has sufficient kinetic energy imparted to it to insure the detonation of the explosive.
SUMMARY OF THE INVENTION
A detonator for a primary explosive, the detonator making use of a less sensitive secondary explosive that in turn is detonated by a flyer that is sheared from a sheet or film and propelled through a barrel to impact the secondary explosive. The flyer is sheared from the sheet by the pressure generated when an electrical conductor adjacent the sheet is vaporized by the sudden passage of a high current (as by the discharge of a capacitor) through it. The explosive is sealed against moisture, and the mechanical configuration of the detonator is such as to take full advantage of the kinetic energy of the flyer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a detonator constructed in accordance with the present invention;
FIG. 2 is a cross sectional view of such a detonator; and
FIG. 3 is a plan view of an exploding bridge used in that detonator.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the drawings, the present invention comprises a detonator indicated generally by the numeral 10 and including an electrical bridge composed of an insulating web on ribbon 12 carrying an electrical conductor such as a foil 14. The ribbon 12 is relatively thin, and the foil 14, likewise thin and of substantially uniform thickness, is cemented or otherwise suitably held to the ribbon. While the foil 14 is generally of uniform width, it has its width reduced to form a necked-down portion 16 that provides a higher electrical resistance to current flowing through the foil.
The necked-down portion 16 is termed a bridge and it and the ribbon 12 carrying it form a bridge assembly 18. A seal member 20 bears against the foil 14, and a support member 22 presses against the seal member and provides means for supporting the detonator assembly 10.
On the side of the bridge assembly 18 away from the foil 14 is a barrel sleeve 24 aligned with the necked-down portion 16 and having a hole 26 extending through the sleeve. The surface of the barrel sleeve 24 adjacent the ribbon 12 is flat and the hole 26 forms sharp corners with the surface of the barrel sleeve. As will be hereinafter explained, the barrel sleeve 24 is to act in the manner of a die to cut a disc or flyer from the ribbon 12, and hence, it is important that the barrel sleeve have sharp edges around the hole 26, be formed of a hard material, and be firmly mounted. To this end, the barrel sleeve 24 is mounted in a cup 28 pressing against the bridge assembly 18.
Aligned with the hole 26 of the barrel sleeve 24 is the explosive charge 32 that in the form shown is divided into three sections 34, 36, and 38. The first section or pellet 34 is immediately adjacent the barrel sleeve 24 and is enclosed in sealing means 40 that protect the explosive against moisture and yet are flexible to transmit the impact of the flyer to the explosive pellet 34. The block 36 of the explosive charge 32 bears against the pellet 34 so that the explosion of the pellet transmits a shock to the block 36 and in turn to the block 38. A housing 41 co-operates with the support member 22 to enclose the charge 32, the bridge assembly 18, and related elements. As seen in FIG. 2, the explosion block 38 bears against the housing 41 and a flat spring 42 between explosion blocks 36 and 38 presses block 36 against pellet 34 so that the entire explosive charge 32 and the bridge assembly 18 are firmly pressed together.
With the detonator 10 assembled as indicated in FIG. 2, operation is simple. The current to operate the detonator is conveniently stored in an adjacent capacitor (not shown) and upon closure of a suitable switch (not shown), the current in the capacitor is discharged through the bridge assembly 18. The charge in the capacitor is such that the flow of current is sufficient not only to melt the necked-down portion 16 of the foil 14 but to vaporize it. When this occurs, the pressure thereby generated forces the ribbon 12 against the barrel sleeve 24 and a disc-like portion is sheared from the ribbon 12 by the action of the barrel sleeve and the hole 26.
As the pressure from bridge assembly continues, the disc sheared from the ribbon 12 is driven toward the explosive pellet 34, hitting the pellet with sufficient force to detonate that explosive which in turn detonates the explosive blocks 36 and 38. The explosion of the charge 32 is sufficient to detonate a surrounding explosive (not shown) which is the main charge to be exploded. This main charge may be of whatever nature desired, and may be a shaped charge such as used in the drilling and operation of wells, a charge used in demolition, or any other charge where the explosion must be carefully timed.
It will be recognized that with this construction, the flyer or disc sheared from the ribbon 12 has a minimum distance to travel and the maximum kinetic energy can be transmitted to the pellet 34. Furthermore, with the pellet sealed within the sealing means 40 the possibility of moisture getting to the explosive is reduced to minimum. The explosive blocks 36 and 38 are preferably coated with a moisture resistant material so that they likewise are protected.
By using a detonator as described herein, the danger of premature explosion is greatly reduced. Consequently the possibility of damage and injury are correspondingly reduced and the effectiveness of the desired explosion can be increased. It will be understood that the present invention may take a variety of forms, and consequently the invention is not to be limited to the particular form or arrangement of parts herein described and shown except as limited by the claims.
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An exploding foil detonator for explosives in which an exploding bridge shears a foil and drives a piece of that foil against an explosive to detonate the latter.
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BACKGROUND OF THE INVENTION
This invention relates to a gun case, and more particularly, to a gun case having means for acting as a lightweight bullet resistant body garment and which is suitable for carrying light infantry weapons such as rifles, carbines, assault rifles, light machine guns, submachine guns, shotguns, machine pistols, grenade launchers and the like.
Today, the semi-automatic or automatic rifle, a long-time standard military issue weapon, has become a necessary weapon in the arsenal of law enforcement personnel in connection with anti-terrorist activities and riot containment. In addition, the higher fire power of a light infantry weapon may be employed by law enforcement personnel in respect to other dangerous situations that arise from time to time. Such weapons are generally not used in every day activities. Some weapons may be issued on a daily basis so as to be on hand when an emergency occurs. Other weapons may be maintained at a central location in a combat ready condition. In either case, it is desirable to store the weapon in a gun case in order to provide protection from dirt and corrosion. In addition, it is preferable to pad the gun case in order to protect the weapon from rough handling.
The typical situation in which an anti-terrorist or riot weapon is employed represents a high amount of risk of personal injury to the law enforcement agent. Accordingly, a so-called bulletproof vest may be issued in conjunction with the weapon. Various vest and jackets are known in the art.
Military personnel are often similarly provided with so-called light infantry weapons including rifles, carbines, assault rifles, shotguns, light machine guns, submachine guns, machine pistols, grenade launchers and the like. In combat situations, military personnel are likewise afforded personal protection through the wear of flak jackets.
With the issuance of separate encased weapons and vest or jackets, there is a risk that the vest or jacket may be left behind in the confusion and rapid deployment that often surrounds unexpected hostile activity. Moreover, it may be inconvenient and dangerous for law enforcement agents or military personnel to have to carry a gun case and a separate vest or jacket since this precludes the holding of other equipment or otherwise limits mobility.
SUMMARY OF THE INVENTION
The invention relates to an improved gun case which also serves as a lightweight bullet-resistant, protective body garment or shield.
In accordance with the invention, the gun case is made of a flexible padded material. The case includes a waterproof outer shell and an inner linear.
In a first embodiment, the inner linear is detachable or detachable in part from the outer shell. Hence, the inner linear is removably held to the inside of the shell by interlocking strips, a separating zipper, or other means such as buttons, snap fasteners and the like. The inner liner is backed with a cushion of polyurethane foam, synthetic pile, sheepskin or other types of padding. The cushion may be permanently attached to the inner liner or loosely located behind the liner. A removable insert, composed of multiple layers of a bullet-resistant fabric such as Kevlar, is fitted between the outer shell and the removable inner liner. Means are provided for fixing the insert in a precise location between the inner liner and outer shell.
In a second embodiment, the bullet-resistant material is integrally formed with the inner liner to take the place of the cushioning material.
The gun case, per se, may be expeditiously opened and the entire case utilized as a bullet resistant body garment.
A carrying strap may be provided with the gun case to be utilized as a sling for carrying the gun case and also as a belt and harness for suspending the gun case or the insert from the body of a user to provide protection against bullets, shot and other projectiles.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a party of this specification. For a better understanding of the invention, its operating advantages and specific objects obtained by its use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, forming a part of the specification, and in which reference numerals shown in the drawing designate like or corresponding parts throughout the same.
FIG. 1 is a perspective view illustrating a gun case embodying the invention;
FIG. 2 is a perspective view of the gun case of FIG. 1, in the open position, illustrating an embodiment of the invention in which an inner liner is detachably mounted to the outer shell of the gun case;
FIG. 3 is a schematic illustration of the use of a bullet resistant insert containable in the gun case of FIG. 1;
FIG. 4 is a schematic illustration of the use of the gun case of FIG. 1, per se, for personal protection;
FIG. 5 is a perspective view of a gun case which is composed of a bullet resistant material; and
FIG. 6 is a perspective view of the gun case of FIG. 5 in the open position.
DETAILED DESCRIPTION
Referring now to the drawings, there is shown an elongated gun case 10. The gun case includes an outer shell 12 and an inner liner 14. The outer shell 12 and inner liner 14 are interconnected by means of opposed, continuous or interrupted sections of VELCRO interlocking strips 16 which interconnect at least one of the side margins 18 of the outer shell 12 with at least one of the side margins 20 of the inner liner 14 on the inside surface of the flexible outer shell and, as well, respectively connect the top margin 22 and bottom margin of the outer shell with the corresponding top margin 24 and bottom margin of the inner liner 14.
In accordance with a first embodiment of the invention, the inner liner 14 is totally separable from the outer shell 12. The inner liner 14 can be designed to be only partially separable by permanently affixing one overlapping pair of the side edges of the inner liner 14 to the outer shell 12.
The inner liner 14 can include a cushioned backing made of conventional materials such as polyurethane foam, synthetic pile, sheepskin or other type of padding.
The gun case 10 is formed with means, such as a zipper 30, having mating portions 32, 34 mounted along the periphery of the outer shell 12.
Both the outer shell 12 and inner liner 14 are made of flexible materials so as to permit the gun case to be folded in half and closed along the periphery of the outer shell 12 by the zipper 30. In the folded state, the facing sections of the inner liner 14 are spaced from each other so as to form an inner compartment for housing a light infantry weapon such as a rifle or the like.
As shown in FIG. 1, the gun case may have a conventional shape, and may be designed with outside accessory pockets 40 for additional magazines, cartridge boxes, cleaning equipment, and accessory weapons such as handguns, knives or bayonets.
An illustrated in FIG. 2, a removable insert 44 of multiple layers of a bullet resistant fabric such as Kevlar is fitted between the outer shell 10 and the removable inner liner 12. The removable insert 44 may preferably have a strip 46 of VELCRO, on opposite sides, running along its central axis (spine), or its edges, or both. One strip 46 interlocks with a mating strip 48 on the inside of the outer shell 12 and the other strip mates with a mating strip 50 on the under side of the removable or partially removable liner 14. The strip 46 can, however, be omitted so that the insert 44 is merely loosely positioned intermediate the inner liner 12 and outer shell 10. Alternately, the insert can be immovably fixed by sewing or other means to either the inner liner 12 or outer shell 10 or both.
Two or more bullet resistant inserts can be provided between the inner liner 12 and outer shell 10. In such case, it will be possible to issue multiple protective garments to personnel at an emergency location, that is, to the person controlling the weapon originally carried in the case as well as to other personnel. Wearing of the gun case, per se, with the plural number of inserts will provide personal protection from higher powered weapons.
The bullet resistant layers of Kevlar material may be integrally formed as part of the inner liner 14 or outer shell 12, or both. It will be recognized by those skilled in the art, in such case, the inner liner 14 need not be removable. The gun case, per se, may be fixed to the body of a user by means of a harness and belt fittings to provide protection against frontal assault by bullets, shot and projectiles as shown in FIG. 4.
It is preferred that the outer shell 12 be coated or otherwise integrally formed with a water resistant material such as nylon coated with polyurethane or neoprene. Bullet resistant inserts of a removable nature should also be so coated in order to provide protection from wetness and soaking in a rainstorm, in a river crossing, or in similar situations. Otherwise, water can seep into the interstices of the bullet resistant material, acting as a lubricant and spreading the fibers thereof, so that a bullet can pass therethrough. Therefore, the removable inserts 44 are preferably covered with a fixed or removal water-resistant cover.
In each case, the degree of protection afforded is governed by the number of layers of bullet resistant material used to construct the removable insert 44 or formed as part of the inner liner 14 or outer shell 12, or both.
As shown in the drawings, the gun case 10 is provided with a sling 54 which may be utilized to both facilitate the carrying of the gun case, and in combination with loop fittings 52, or the like, may be used to suspend and belt the gun case to the body of a user. Alternately, the sling may be utilized to fix the removable insert 44 to the body of a user as shown in FIG. 3. A shoulder strap, harness arrangement or other support could also be attached to loop fittings 58 at the upper end of the gun case for supporting the case about the neck of a user. The stitching need not be parallel or vertically arranged as shown. The insert may be formed of a continuous sheet of anti-ballistic material, or layers of such sheets.
The insert 44 is formed into a continuous flexible pad of anti-ballistic material laminated together by sewing layers by parallel stitching 56 spaced, as shown, in parallel lines, or by other means.
The area protection provided by the case containing an integrally inserted bullet resistant pad or an insert alone will cover the user from the neck to mid-thigh region i.e., the full torso of a wearer, as shown in FIGS. 3 and 4, in the case of a typical submachine gun size case or a case large enough to carry an M-16 automatic rifle with a collapsible stock. Cases for standard rifles will protect the average user from the neck to the knee and over the full width of his body.
As shown in FIGS. 5 and 6, the combination gun case and protective apparel comprises an elongated shell 112 which, per se, is composed of a bullet resistant material. The combination is foldable along a central longitudinal axis 118 to form an inner compartment for housing a gun. Means such as a zipper 130, or other means as described in connection with FIG. 1, are provided for opening and closing the shell 112.
In many cases, the bullet resistant component also serves as the protective padding for the gun.
It will be recognized by those skilled in the art that the case can be built to accommodate two bullet resistant inserts at the same time so that when the bullet resistant insert is removed, the case will continue to have sufficient padding to protect the weapon. In such case, the secondary insert can be permanently fixed to the inside of the removable liner or to the inside of the outer shell, or both, or may also be totally removable. A plurality of cases with liners can be designed to be attached to each other in order to provide protection over doors, windows, small tents and the like.
It will be evident to those skilled in the art that changes may be made without departing from the spirit of the invention claimed. For instance, the outer shell, in a preferred embodiment, is composed of a flexible material, for example, a fabric provided with a coating comprising a water resistant surface as heretofore described. Flexible materials may be more readily conformed to the body of a user when held thereto by a strap or other means. However, it is possible to form a combination gun case and apparel having an outer shell of a lightweight rigid material. For example, a composite material of fiber-reinforced plastic resin such as a fibrous glass in an ABS (acrylonitrile, butadiene and styrene) resin, or a metal such as an aluminum alloy can be used. The rigid outer shell can be lined on its inside with an inner liner of a bullet resistant material. One or more central hinges can be provided along the central longitudinal axis of the shell and a lock or similar means can be provided for holding the case in an open position so that it can be conveniently mounted to the body of a wearer by means previously described herein or equivalents thereof.
Thus, in accordance with the invention there is provided a combination gun case and protective apparel comprising an outer shell 12, a padded inner liner 14 attached to an inside surface of the flexible outer shell 12. Releasable means, mounted along the periphery of the flexible outer shell 12, such as a zipper 30 are provided for securing the outer shell 12 and the inner liner 14 in a folded position to define a compartment for a gun to be carried therein. The compartment may contain additional paraphenilla such as a side arm. Bullet resistant means, such as insert 44, are mounted to at least one of the outer shell 12 and the inner liner 14. Means, such as a sling 54 and loop fittings 52, are provided for securing the bullet resistant means to the body of a wearer.
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The invention is directed to an improved gun case which includes a bullet resistant material, integrally formed as part of the gun case or as an insert within the gun case, so that the gun case may be converted into a lightweight shield or a personal body protector garment.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claim priority from Korean Patent Application No. 2008-0126417, filed on Dec. 12, 2008 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a non-halogen flameproof polycarbonate resin composition.
BACKGROUND OF THE INVENTION
Generally, polycarbonate resins have transparency, high impact strength, heat resistance and electrical properties. Therefore, polycarbonate resins have been widely used in the production of large injection molded products, such as electric or electronic goods and office equipment which emit a lot of heat. Accordingly, flame retardancy, heat resistance and high mechanical strength are important factors that should be considered when manufacturing a polycarbonate composition.
Conventionally to provide a polycarbonate resin with good flame retardancy, a halogen-containing flame retardant or an antimony-containing compound were used. However, halogen-containing compounds can corrode a mold due to hydrogen halide gases released during the molding process. In addition, there are safety concerns associated with the use of halogen-containing compounds because toxic gases can be liberated in the case of fire.
One method to impart flame retardancy to a polycarbonate resin without using a halogen-containing compound is to employ a phosphoric acid ester compound as a flame retardant. However, a juicing phenomenon can occur when using a phosphoric acid ester compound due to the migration of the flame retardant agent to the surface of the molded article during the molding process. Further, the heat resistance can be rapidly deteriorated.
EP 0 728 811 discloses a thermoplastic resin composition comprising an aromatic polycarbonate, a graft copolymer, a vinyl copolymer and a phosphazene. EP '811 states that no dripping occurs during combustion when using a phosphazene as a flame retardant even though an additional anti-dripping agent is not employed, and that the resin composition has excellent heat resistance and impact strength. However, in EP '811, when using phosphazene as a flame retardant, an increased amount of flame retardants should be used to maintain a certain degree of flame retardancy.
SUMMARY OF THE INVENTION
The present invention provides an environmentally friendly flameproof polycarbonate resin composition which can have good flame retardancy and heat resistance without releasing hydrogen halide gases during combustion by employing a phosphorus compound having a new structure as a flame retardant with a polycarbonate resin.
The present invention provides an excellent flameproof polycarbonate resin composition.
The present invention provides a flameproof polycarbonate resin composition which employs a phosphorus compound having a new structure as a flame retardant.
The present invention further provides an environmently friendly polycarbonate resin composition by employing a phosphorus compound having a new structure as a flame retardant which does not release hydrogen halide gases during preparation of the composition or an article therefrom or during combustion.
The present invention further provides a molded article produced from a non-halogen flameproof polycarbonate resin composition.
A non-halogen flameproof polycarbonate resin composition of the present invention comprises about 100 parts by weight of a polycarbonate resin; and about 0.5 to about 10 parts by weight of a phosphorus compound represented by the following Chemical Formula (1) or a combination thereof.
wherein R 1 and R 2 are each independently C 1 to C 6 alkyl and n is 1 or 2.
In exemplary embodiments of the invention, examples of the phosphorus compound may include without limitation 2,4-di-tert-butylphenyl diphenyl phosphate represented by the following Chemical Formula (2-1), bis(2,4-di-tert-butylphenyl)phenyl phosphate represented by the following Chemical Formula (2-2), and combinations thereof.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter in the following detailed description of the invention, in which some, but not all embodiments of the invention are described. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.
(A) Polycarbonate Resin
The polycarbonate resin used in the resin composition of the present invention may be prepared through a conventional method as known in the art. The polycarbonate resin is not limited and can be any commercially available polycarbonate.
The polycarbonate resin may be prepared by reacting a diphenol compound represented by the following Chemical Formula (1) with a phosgene, a halogen formate or a carboxylic acid diester:
wherein A is a single bond, C 1 to C 5 alkylene group, C 1 to C 5 alkylidene group, C 5 to C 6 cycloalkylidene group, —S— or —SO 2 —.
Examples of the diphenols of Chemical Formula (1) may include without limitation 4,4′-dihydroxydiphenol, 2,2-bis-(4-hydroxyphenyl)-propane, 2,4-bis-(4-hydroxyphenyl)-2-methylbutane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, 2,2-bis-(3-chloro-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane and the like, and combinations thereof. Hydroquinone, resorcinol, and combinations thereof can be used. In exemplary embodiments, the diphenol used in the present invention can be 2,2-bis-(4-hydroxyphenyl)-propane (also called ‘bisphenol-A’).
In the present invention, the polycarbonate resin can have a weight average molecular weight (M w ) of about 10,000 to about 500,000 g/mol, for example about 15,000 to about 100,000 g/mol. If the weight average molecular weight of the polycarbonate resin is less than about 10,000 g/mol, physical properties and thermal resistance may be deteriorated. If the weight average molecular weight of the polycarbonate resin is more than about 500,000 g/mol, moldability may be deteriorated.
Examples of the polycarbonate resin can include without limitation linear polycarbonate resin, branched polycarbonate resin, polyester-carbonate resin, and the like, and combinations thereof. The polycarbonate resin may be prepared by using about 0.05 to about 2 mol %, based on total quantity of diphenols used, of tri- or higher functional compounds, for example, those with three or more phenolic groups. The polyester-carbonate resin may be obtained by polymerization in the presence of an ester precursor, such as a difunctional carboxylic acid. Further, a homopolymer of polycarbonate, a copolymer of polycarbonate or a combination thereof may be used in this invention.
(B) Phosphorus Compound
The phosphorous compound of the present invention is represented by the following Chemical Formula (1):
wherein R 1 and R 2 are each independently C 1 to C 6 alkyl and n is 1 or 2. The alkyl may have a linear or branched structure.
In one exemplary embodiment, R 1 and R 2 are each independently C 3 to C 6 branched alkyl. For example, R 1 and R 2 may be each independently isopropyl, sec-butyl, tert-butyl, or isoamyl.
Examples of the phosphorus compounds can include without limitation 2,4-di-tert-butylphenyl diphenyl phosphate represented by the following Chemical Formula (2-1), bis(2,4-di-tert-butylphenyl)phenyl phosphate represented by the following Chemical Formula (2-2), and combinations thereof.
The phosphorus compound represented by Chemical Formula (1) or a combination thereof is used in an amount of about 0.5 to about 10 parts by weight, for example about 1 to about 8 parts by weight, and as another example about 3 to about 5 parts by weight, per about 100 parts by weight of a polycarbonate resin.
If the amount of the phosphorus compound represented by Chemical Formula (1) is more than about 10 parts by weight, the balance of physical properties of the resin may be deteriorated. If the amount of the phosphorus compound represented by Chemical Formula (1) is less than about 0.5 parts by weight, flame retardancy may be deteriorated.
As indicated by the following Reaction Formula I, phosphorus oxychloride can react with 2,4-dialkylphenol represented by Chemical Formula (3) to prepare a phosphate compound represented by Chemical Formula (4), and the resulting phosphate compound represented by Chemical Formula (4) can react with phenol to obtain the phosphorus compound represented by Chemical Formula (1) of the present invention.
wherein R 1 and R 2 are each independently C 1 to C 6 alkyl and n is 1 or 2.
In exemplary embodiments of the invention, the phosphate compound represented by Chemical Formula (4) can be prepared by dehydrochlorination of phosphorus oxychloride and 2,4-dialkylphenol.
Examples of the 2,4-dialkylphenol compound may include 2,4-di-tert-butylphenol represented by the following Chemical Formula (5).
An excess mole ratio of the phosphorus oxychloride can be used, per one mole of 2,4-dialkylphenol, for example 3 to 6 mole ratio phosphorus oxychloride per one mole of 2,4-dialkylphenol, as another example 4 to 6 mole ratio phosphorus oxychloride per one mole of 2,4-dialkylphenol, and as yet another example 5 mole ratio phosphorus oxychloride per one mole of 2,4-dialkylphenol.
One mole of the phosphorus oxychloride can react with a maximum 3 moles of the 2,4-dialkylphenol compound because one molecule of phosphorus oxychloride contains 3 atoms of chlorine which can participate in dehydrochlorination.
However, if an excess of the phosphorus oxychloride is used, per one mole of the 2,4-dialkylphenol compound, phosphorous oxychloride and 2,4-dialkylphenol compound can react in a mole ratio of 1 to 1 to obtain 2,4-dialkylphenyl dichlorophosphate represented by the following Chemical Formula (4-1).
wherein R 1 and R 2 are each independently C 1 to C 6 alkyl.
However, if the 2,4-dialkylphenol compound reacts with 2 chlorine atoms in one molecule of the phosphorus oxychloride, bis(2,4-dialkylphenyl) chlorophosphate represented by the following Chemical Formula (4-2) can be prepared.
wherein R 1 and R 2 are each independently C 1 to C 6 alkyl.
In exemplary embodiments of the present invention, the phosphorous oxychloride can react with the 2,4-dialkylphenol compound in the presence of a metal catalyst.
Examples of the metal catalyst can include without limitation magnesium chloride, aluminum chloride calcium chloride, and the like, and combinations thereof.
The metal catalyst can be used in an amount of about 0.01 to about 10 mole ratio, per one mole of the 2,4-dialkylphenol compound, for example, about 0.001 to about 5 mole ratio per one mole of the 2,4-dialkylphenol compound, and as another example about 0.01 to about 1 mole ratio per one mole of the 2,4-dialkylphenol compound.
The phosphate compound represented by the Chemical Formula (4) can be prepared by reacting a phosphorus oxychloride with the 2,4-dialkylphenol compound at a temperature of about 100° C. to about 150° C. for about 3 hours to about 10 hours, optionally using a metal catalyst under a nitrogen atmosphere.
After the above reaction, remaining unreacted phosphorus oxychloride can be collected or recovered.
If the 2,4-dialkylphenol compound, phosphorous oxychloride and metal catalyst react in a mole ratio of 1:3 to 6:0.001 to 10, the phosphate compound represented by the Chemical Formula (4) and remaining unreacted phosphorus oxychloride can be prepared. The temperature of the product can be reduced at about 50° C. to about 90° C., for example about 90° C. Then, the pressure of the product is released to collect the remains of the unreacted phosphorus oxychloride.
Continually, the phosphorus compound represented by the Chemical Formula (1) can be prepared by reacting the phosphate compound represented by the Chemical Formula (4) with phenol.
In exemplary embodiments, the phosphorus compound represented by Chemical Formula (1) can be prepared by reacting the product from which unreacted phosphorus oxychloride has been removed with phenol. The phenol can be added in a mole ratio of about 2 to about 3, for example about 2, per one mole of the 2,4-dialkylphenol compound represented by the Chemical Formula (3).
The phosphorus oxychloride may be reacted with the 2,4-dialkylphenol compound in the presence of an organic solvent. Examples of the organic solvent can include without limitation benzene, toluene, xylene, 1,4-dioxane, methylene chloride, ethylene chloride, and the like. The organic solvents may be used singly or in combination.
The phosphorus compound represented by the Chemical Formula (1) can be prepared by reacting the phosphate compound represented by the Chemical Formula (4) with phenol at a temperature of about 100° C. to about 150° C. for about 3 to about 7 hours under a nitrogen atmosphere.
Finally, in order to separate the phosphorus compound represented by the Chemical Formula (1) which is manufactured, water can be added to the reactor when the reaction is completed and the mixture can be stirred and evaporated under reduced pressure to remove the organic layer.
The flameproof polycarbonate resin composition of the present invention may further include other additive depending on its use. Examples of such additives may include without limitation plasticizers, heat stabilizers, anti-dripping agents, antioxidants, compatibilizers, light-stabilizer, pigments, dyes, and/or inorganic fillers and the like, and combinations thereof. Examples of the inorganic fillers may include without limitation asbestos, glass fibers, talc, ceramic, sulfates, and the like, and combinations thereof. The additive can be employed in an amount of about 30 parts by weight or less, for example about 0.001 to about 30 parts by weight, per about 100 parts by weight of the polycarbonate resin.
The flameproof polycarbonate resin composition of the present invention can be prepared by a conventional method. For example, all the components and optionally additives can be mixed together and extruded through an extruder and can be prepared in the form of pellets.
The flameproof polycarbonate resin composition according to the present invention can have good flame retardancy and can be used in the manufacture of electric or electronic goods such as TV housings, computers, audio sets, air conditioners, automobile parts, housings for office automation devices, and the like which require good flame retardancy.
Another aspect of the present invention provides an article molded from the foregoing resin composition. The resin pellets can be molded into various molded articles using molding methods such as extrusion, injection, vacuum molding, casting molding and the like, but the present invention is not limited to these methods.
The invention may be better understood by reference to the following examples which are intended for the purpose of illustration and are not to be construed as in any way limiting the scope of the present invention, which is defined in the claims appended hereto.
EXAMPLES
The components to prepare the flameproof polycarbonate resin compositions in Examples 1 to 2 and Comparative Examples 1 to 2 are as follows:
(A) Polycarbonate Resin
Bisphenol-A type polycarbonate with a weight average molecular weight (M w ) of about 25,000 manufactured by TEIJIN Co. of Japan (PANLITE L-1250WP) is used as a linear polycarbonate resin.
(B) Phosphorus Compound
Phosphorus oxychloride (767 g, 5.0 mol), 2,4-di-tert-butylphenol (206 g, 1 mol) and magnesium chloride (0.95 g, 0.01 mol) are added into a reactor and stirred at 130° C. for 6 hours under a nitrogen atmosphere to obtain 2,4-di-tert-butylphenyl dichlorophosphate and bis(2,4-di-tert-butylphenyl) chlorophosphate. The 2,4-di-tert-butylphenyl dichlorophosphate is prepared in an amount of 0.98 mol and bis(2,4-di-tert-butylphenyl) chlorophosphate is prepared in an amount of 0.02 mol.
The temperature of the product is reduced at 90° C. and the pressure of the product is released to collect remaining unreacted phosphorus oxychloride. Then, phenol (188 g, 2 mol) and toluene (1 L) are added into the reactor and stirred at 130° C. for about 5 hours under a nitrogen atmosphere. After the completion of the reaction, the temperature of the mixture is reduced to room-temperature, water is added (1 L) and the mixture is stirred. After the organic layer is removed, the mixture is evaporated under reduced pressure to obtain a mixture of 2,4-di-tert-butylphenyl diphenyl phosphate (0.98 mol) represented by Chemical Formula (2-1) above and bis(2,4-di-tert-butylphenyl)phenyl phosphate (0.02 mol) represented by Chemical Formula (2-2) above.
(C) Aromatic Phosphoric Ester Compound
Bis(dimethylphenyl) phosphate bisphanol-A made by Daihachi Chemical of Japen (product name: CR741S) is used.
Examples 1 to 2 and Comparative Examples 1 to 2
The components as shown in the following table 1 are added to a conventional mixer and the mixture is extruded through a conventional twin screw extruder at a temperature range of about 200° C. to about 280° C. to prepare pellets. The prepared pellets are dried at 80° C. for 2 hours and molded into test specimens for flame retardancy in a 6 oz injection molding machine at about 180 to about 280° C. with a mold temperature of about 40 to about 80° C. Flame retardancy is measured in accordance with UL 94 VB under a thickness of ⅛″.
TABLE 1
Examples
Comparative Examples
1
2
3
4
A
100
100
100
100
B
3
5
—
—
C
—
—
3
5
The first Average
1.0
0.6
11.5
6.1
Flame Out Time(sec)
The second Average
5.8
3.1
1.0
3.5
Flame Out Time(sec)
UL 94 flame
V-0
V-0
V-1
V-0
retardancy (⅛″)
As shown in Table 1, the resin compositions employing a new phosphorous compound show good flame retardancy and a short average flame out time.
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, 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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A non-halogen flameproof polycarbonate resin composition of the present invention comprises about 100 parts by weight of a polycarbonate resin; and about 0.5 to about 10 parts by weight a phosphorus compound represented by the following Chemical Formula (1) or a combination thereof. The present invention can provide an environmentally friendly polycarbonate resin composition which can have excellent retardancy without releasing hydrogen halide gases during preparation or combustion.
wherein R 1 and R 2 are each independently C 1 to C 6 alkyl and n is 1 or 2.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit from U.S. Provisional Application Ser. No. 60/470,196 filed May 14, 2003 which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a process and apparatus for removing catalyst from a catalyst bed.
BACKGROUND OF THE INVENTION
[0003] Catalysts are used in large acid or fertilizer plant vessels to remove products or impurities during the manufacturing process. At a certain point in the life of the catalyst, the catalyst granules have attracted all the materials they can and must be cleaned of these material. In order to clean materials from a catalyst, a process known as screening is required. Screening is the mechanical shaking or vibrating of the catalyst granules to remove the material which may be in the form of dust or chips. After screening, the dust and chips go to disposal and the cleaned regenerated catalyst is returned to the vessel to be reused.
[0004] The vessels in which such catalysts are used such as those used in acid plant vessels are relatively large vertically oriented vessels having a diameter of 15 feet or more. The catalyst may be arranged in horizontal layers and a vessel may have several beds and there may be several different layers within the catalyst beds. In order to conduct the screening process, the catalyst is manually removed from the bed within the vessel and remotely screened. The screened catalyst is then replaced within the vessel. These vessels are operated at relatively high temperature, sufficiently hot that an unprotected person cannot enter the vessel immediately following shut down. As the vessels are operated at high temperature, normally, work crews cannot enter the vessel until the vessel has cooled.
[0005] In many cases, the vessels have relatively restricted access to the area of the vessel between adjacent beds. Often the access hatch or opening to a vessel may be of the order of 2 to 3 feet square. In unusual cases, the access opening may be as large as 4 feet by 3 feet. The size of such openings will permit a person to pass through the opening but makes it inconvenient to use any type of existing powered equipment within the vessel.
[0006] When the vessel is operated at high temperature, the vessel must be allowed to cool to a temperature at which human beings may enter the vessel. If the human beings are protected by a fully enclosing protective suit which is provided with cooling means, the persons may enter the vessel at warmer temperatures. However, once in the vessel, the worker must commence the job of removing the catalyst using hand held tools. This is difficult while wearing such a protective suit and maneuvering through restricted spaces.
[0007] In other cases, the vessel is operated at cooler temperatures. However, even when cooler temperatures are used in the process, the restrictions on access remain and the vessel is none-the-less full of gases which are hazardous to health. Thus, even with a vessel operating a cooler process, a person entering the vessel must be in a protective suit and provided with a breathing air supply to protect against the hazardous conditions found within the vessel.
[0008] Accordingly, it would be advantageous, if equipment were to be developed which can gain entry into a vessel and work within such a vessel on a catalyst bed to remove the catalyst from the reactor vessel while not damaging the catalyst during removal.
SUMMARY OF THE INVENTION
[0009] The present invention provides an apparatus and method for removing catalyst from a catalyst bed. Briefly, the apparatus comprises a frame, the device includes drive means supporting the frame for propelling the frame over a granular catalyst bed. The device has traction means for contacting the bed which are activated by the drive means. The device includes a turret mounted on the frame for relative rotation of the turret relative to the frame. The device includes a boom mounted on the turret for rotation of the turret and an actuator mounted on the turret for adjusting the angle of elevation of the boom relative to the turret.
[0010] In accordance with one aspect of the invention, the invention involves a construction implement for use in reconstruction of a granular bed. The construction implement has a frame, drive means supported on the frame for propelling the frame over the granular bed, traction means for contacting the bed and actuated by the drive means, a turret mounted on the frame for rotation relative to the frame, boom means mounted on the turret for rotation about the turret and an actuator which is mounted on the turret for adjusting the angle of elevation of the boom means relative to the turret.
[0011] In accordance with a further aspect of the invention, the invention involves a process for removing a crushable catalyst from a granular bed contained within a reaction vessel without the use of human personnel within that reaction vessel. The process involves providing a construction implement as outlined above, connecting the boom means to an industrial vacuum source, placing the implement on the catalyst bed, controlling the implement from a position remote from the bed, maneuvering the implement over the bed and vacuuming the granules from the bed through the boom means.
[0012] In accordance with a preferred aspect of the invention, the implement comprises mechanical operators to control the movement of the various parts of the implement without the use of hydraulic fluids or other substances which might be susceptable to combustion at elevated temperatures so that the unit can be used in a catalyst bed which is to be regenerated before the bed has cooled to room temperature. In a particularly preferred embodiment of the invention, the operating structure of the implement is such that the implement can be used at elevated temperatures preferably in excess of 200° F. and more preferably in excess of 300° F.
[0013] In accordance with another aspect of the invention, the invention involves a construction implement for use in reconstruction of a granular bed which includes catalyst granules which are susceptible to crushing. The implement includes a frame, drive means supported on the frame for propelling the frame over the granular bed, traction means for contacting the bed and actuated by the drive means, a turret mounted on the frame for rotation relative to the frame, boom means mounted on the turret for rotation about the turret, an actuator mounted on the turret for adjusting the angle of elevation of the boom means relative to the turret, and in which the traction means have sufficient surface area to support the implement on said catalyst bed without crushing said granules.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a construction implement manufactured in accordance with a first embodiment of this invention;
[0015] FIG. 2 is a view similar to FIG. 1 of the embodiment of FIG. 1 but with a protective cover in place;
[0016] FIG. 3 is a side view of the implement shown in FIG. 1 ;
[0017] FIG. 4 is a side view similar to FIG. 3 but showing angular adjustment of one of the components;
[0018] FIG. 5 is a top view of the implement shown in FIG. 2 ;
[0019] FIG. 6 is a top view similar to FIG. 5 but showing an angular adjustment of one of the components;
[0020] FIG. 7 is a view similar to FIG. 6 but showing adjustment in an opposite direction;
[0021] FIG. 8 is a perspective view similar to FIG. 2 but with one of the components shown angularly adjusted in both the horizontal and vertical planes, and
[0022] FIG. 9 is a rear view of the implement shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0023] The device 10 is illustrated in FIG. 1 in a perspective view with a protective cover moved. The device 10 includes a frame 12 , a drive means indicated generally at 14 , traction means 16 , a turret 18 , a boom means 20 and an actuator 22 .
[0024] The drive means 14 , include a pair of electric motors 30 and a pair of gear boxes 32 . Each gear box has an output shaft on which is positioned a drive sprocket 34 , one of which is illustrated in FIG. 1 . In each case, the drive sprocket drives a chain 36 . The chain in turn drives a driven sprocket 40 attached to a drive shaft 42 (see FIG. 9 ). The drive shaft 42 transmits power to a drive wheel 44 . The drive wheel is mounted on a carrier frame 50 . The carrier frame 50 also mounts a forward idler wheel 52 (see FIG. 4 ). The device 10 is provided with traction means for contacting a granular bed for reconstruction purposes. The traction means 16 includes a pair of tracks 60 .
[0025] The device 10 is thus supported on the granular bed which is to be reconstructed by the force of the tracks 60 against the bed. The device is kept suitably small for access purposes as discussed more fully below and is also sufficiently lightweight that with the contact area provided by the two tracks 60 , there is no damage to the constituent elements of the granular bed as the device propels itself across the bed. The device is powered in the fore and aft direction by use of the two electric motors 30 . Conveniently, the electric motors may be fractional horsepower DC motors. A particularly useful motor is a one-sixth horsepower DC motor operating at 90 volts. In order to provide sufficient torque, the gear boxes 32 may include a significant reduction. In a particular embodiment, there is a reduction of 377 to 1 to accommodate the higher revs of the motor referred to above and to provide suitable torque for driving the drive wheels 44 and the tracks 60 . Steering is obtained by skid steer. That is, the two motors 30 are independently controllable such as by a joy stick control. The differential speed of the two motors then provides differential movement of the tracks so that the device can be steered. One motor may be operated in reverse while the other is operated forward to provide for turning of the device potentially within its own length. In order to ensure that damage does not occur to the material of the granular bed during such a skid steer, the tracks are of sufficient width and length to provide a sufficiently low contact pressure so that damage does not occur. In order to further support each track 60 on the drive wheel 44 and the idler wheel 52 , both drive wheel 44 and idler wheel 52 may be provided with horizontally projecting supports. The supports help to maintain the track 60 in place and help to spread out the weight carried by the drive wheel 44 and idler wheel 52 respectively, over the surface of the track 60 . The track 60 may be provided with a series of apertures 64 . The apertures 64 are driven by lugs 66 on the driven wheels 44 . Similar lugs 68 are provided on the idler wheels 52 .
[0026] The frame 12 of the device 10 includes a turret 18 which is supported on the frame 12 by a bearing. The bearing is arranged in a direction perpendicular to the general plane of the frame 12 so that the turret may rotate about an axis which is perpendicular to the general plane of the frame 12 . In use, this plane of rotation will be substantially parallel to the surface of the granular bed on which the device is working. For controlling the movement of the turret, the device 10 includes a turret motor 70 (see FIG. 9 ) mounted on the frame 12 . The turret motor 70 has an axle which is affixed to a turret drive sprocket 72 . The turret drive sprocket 72 drives a chain 74 . The chain 74 , in turn, is attached to a turret sprocket which is not illustrated, attached to the underside of the turret 72 . Operation of the turret motor 70 thus results in rotation of the turret 18 relative to the frame.
[0027] The reconstruction device 10 includes a boom means 20 . The boom means 20 comprises a hollow tubular member and has an inlet end 80 and an outlet end 82 . The boom member 20 creates a vacuum suction path from the inlet end 80 to the outlet end 82 . Advantageously, the boom member 20 is sized to meet available vacuum equipment and may have a diameter of four to six inches. The diameter of the boom member, must also be sized to accommodate the materials of the granular bed. In use, the bed materials will be drawn into the inlet end 80 , pass along the boom 20 and exit through the outlet end 82 . In use, the outlet end 82 is attached to a vacuum line. The vacuum line is not illustrated in the drawings. The vacuum line will be attached to a commercial vacuum source such as a large horse power vacuum truck which may be parked adjacent to the facility containing the granular bed to be reconstructed.
[0028] The length of the boom member 20 is selected so that the inlet end 80 may be lowered at least as low as the bottom plane of the tracks 60 so that the granular material of the bed may be drawn into the inlet end 80 . In order to move the boom means 20 from a lowered position in which it may engage the granular material of the bed to an upper position for transport or for working at a higher level, the boom means is supported on a boom support member 86 . The boom support member 86 may be a U-shaped bracket or a pair of brackets. In either case, the boom support member 86 is pinned at pin 84 to a plate 88 which is fixed to the turret 18 . The pin 84 provides a pivotal axis which is parallel to the plane of the turret 18 . In order to pivot the boom member 20 about the pivotal axis of the pin 84 , the device 10 is provided with the actuator 22 . The actuator 22 includes a ram 24 which is driven by an electric motor 26 . The ram 24 is pinned to the boom support member 86 at one end and to a turret bracket 90 mounted on the turret 18 . Operation of the motor 26 causes extension of the ram 24 thereby pivoting the boom support member 86 and the boom means 20 about the pin 84 .
[0029] As shown in FIG. 5 , the boom means 20 is oriented in a forwardly direction during initial transport onto the granular bed from an access opening. As shown in the overhead views of FIGS. 6 and 7 , by operation of the turret motor 70 , the boom means 20 can be moved to extend either right or left of the position shown in FIG. 5 . The amount of rotation may be selected so that the boom has a working sector as broadly as desired. The sector may be as large as 180°. As shown in FIG. 8 , when the boom has been rotated in the plane of the turret to the desired angle, the boom may then be raised or lowered using the actuator 22 to bring the inlet aperture 80 of the boom 20 into contact with the material to be drawn into the boom means 20 .
[0030] Typically, the device may be used in relatively confined areas such as in the catalyst beds of acid plants. Acid plants are relatively large facilities which are used to reduce sulphur emissions from exhaust gases of large metallurgical refining industries. The exhaust gas is passed through the acid bed to help remove certain constituents from the gas. The removal process in part is a chemical reaction taking place involving catalysts set out in beds within the device. A typical catalyst is vanadium oxide. The catalyst is in the form of a pellet or ring which may be of the order of about 1 inch in diameter. Often such beds have under layers which contact the support structure for the bed and may have an over layer over the active catalyst and these may be in the form of rocks or lumps of about 1 to 2 inches in diameter. All such beds may be as large as 40 or 50 feet in diameter or more, and there is usually relatively limited access to the bed. When the bed is operating, because it is dealing with flue gases from a metallurgical process, the bed may be operated at very high temperatures in the order of 400°, 500° or 600° C. When the bed requires regeneration, the catalyst is removed from the bed and passed through a screening process. The cleaned catalyst is then reinstalled in the bed and used again. In order to withdraw the catalyst from the bed and subject it to the screening process, the catalyst is withdrawn from the bed. This is accomplished by vacuuming the catalyst into the boom means and passing the catalyst along a suction hose, through a suitable vacuum, to capture the catalyst, which may then be screened.
[0031] The device 10 is used when the temperature within the bed has dropped to a level to permit use of the machine. For various metallurgical and other reasons, it is generally unacceptable to use any type of combustion motor which would emit exhaust fumes, or to introduce any kind of fuel into such a reactor, which may still be quite hot, during use of this device. Similarly, in order to provide higher temperature operation, it is typically unacceptable to the owners and operators of such catalyst bed facilities to introduce hydraulic fluid into the bed. Thus, the preferred power means is electrical motors. While the preferred power means involves use of electrical motors, some or all of the devices may involve pneumatic equipment. By way of particular example, the ram 24 may be a pneumatic ram if desired. In such a case the implement is provided with a source of compressed air to actuate such components.
[0032] As electrical motors are used for drive control of the vehicle as well as for adjustment of the angular relation of the components discussed above, it would be possible to provide on-board battery power for the vehicle. However, in order not to introduce batteries into a high temperature atmosphere, and to minimize the weight of the vehicle, the preferred source of power to the vehicle is an umbilical chord 100 (see FIG. 1 ). The umbilical chord 100 thus provides appropriate current to power each of the motors discussed above. In addition, the umbilical chord includes a control cable for controlling the operation of the motors. All of the motors may be controlled by suitable control means such as joy sticks and the like, so that the device can be operated remotely.
[0033] Further, to facilitate remote operation of the device 10 , the device 10 includes camera means 110 . The camera means 110 are oriented to view the desired work sector in front of the device so that the operator can control the location of the device and the location of the boom means 20 to draw catalyst into the inlet end 80 . Further, to facilitate vision, the device 10 includes illumination means 112 . The illumination means can include one or more high temperature lights arranged to suitably light the work sector.
[0034] In FIG. 1 , the device is shown without a cover over various components mounted on the frame 12 . As shown in FIG. 2 , the drive motors, the gear boxes and drive sprockets 34 are all enclosed within a protective cover 120 . As the device moves about a bed of granular material, it is possible that some of the constituent elements of the granular bed may become deposited on the inner or driven surface of the track 60 . Therefore, preferably, the track 60 may include one or more deflection means 130 for reducing the likelihood of granular material being deposited on the inside surface of the track.
[0035] Many large metallurgical refining processes create a significant amount of dust. In many such facilities there are large vehicle mounted industrial vacuum cleaners. The preferred mode of operation of the present device is to station such a vacuum truck as close as conveniently possible to an access hole or door to a granular bed to be regenerated. A hose is directed from the vacuum truck to the outlet end 82 . After shut down of the facility, and when the facility reaches a temperature suitable for operation of the device 10 , the device 10 is passed through an access door. Many such access doors are not larger than two feet, although some may be as large as four feet by six feet. In FIG. 9 , the circle “R” is a circle showing a scale diameter of 24 inches. As shown, the device 10 represented at the same scale fits substantially within the circle “R” illustrating that the device may be passed through the rectangular opening having dimensions 2 feet by 2 feet, or larger. The operator will then stand adjacent the access hole. The operator will hold the control console for the machine and direct the machine as it enters into the bed and begins the catalyst removal process. Because of the heat and hazardous nature of the material, the operator will, in most circumstances, be required to be in a protective suit and to have breathing oxygen supplied. However, the operator can remain outside the tank and can operate the device by a combination of view through the access opening as well as monitoring the camera picture which would be reproduced on the console. Catalyst removal can then be accomplished by vacuuming up the catalyst and/or its protective or supporting layers as desired.
[0036] Thus, in accordance with this device, there is provided a device which is capable of operating in a relatively confined area while having sufficient support area to not damage the catalyst upon which it is working. The catalyst is withdrawn through the boom means. Because the device can work at higher temperatures than a worker without the need of a cooling suit and can operate in confined spaces, the device effectively reduces or may totally eliminate the need for any worker entrance into the vessel during the removal phase of the bed reconstruction process.
[0037] While the device as discussed herein has been discussed primarily in connection with the removal of catalyst from a catalyst bed, the device is also useful in other catalyst bed operations. From time to time, maintenance is required of such catalyst beds. That maintenance may involve certain attention to the bed while not necessitating catalyst removal from the bed. Thus, there are circumstances in which the maintenance may involve raking the bed. The device as described herein is particularly suited for carrying out such a raking operation. When used in a raking operation, a suitable device having tines may be fitted to the inlet end 80 of the device. Then by using the various motors on the device, the bed may be raked so as to perform this interim bed maintenance program. Ordinarily such interim maintenance programs on the bed would be performed while the bed is at an elevated temperature. If the raking of the bed were to be performed by humans, then the bed operator is faced either with the prospect of waiting until the bed has cooled to permit ordinary human work inside the bed, or alternatively, the workers must be fitted with particularly expensive and cumbersome high temperature operating suits. The construction implement as explained herein may be utilized when the bed has cooled to such temperatures as will not be harmful to the construction implement but which may be well above the temperatures that could be tolerated by humans without such extensive protection. Again, because of the remote operating capabilities of the machine, such interim maintenance would be carried out by an operator from the remote operating console using the camera and lighting equipment mounted on the device and/or such other visual opportunities as may be available through the access portal.
[0038] Another use of the construction implement described herein involves the reconstruction of the bed after the catalyst has been regenerated. Typically, at the stage of reconstruction of the bed, the facility containing the catalyst bed may well have cooled to a relatively cool temperature approaching that of room temperature. However, rather than necessitating worker entrance into the area containing the bed and possible damage to the bed, the device in accordance with the present invention may also be used to reload the granular material into the bed. Because the granular material is relatively susceptible to damage, the material has to be reloaded relatively slowly. This can be usefully accomplished by using the boom now as a delivery conduit rather than as a suction conduit. In such circumstances, a hose capable of delivering catalyst and like granules under slight pressure may be connected to the outlet end 82 of the conduit. The catalyst may then be supplied to the boom 20 and will exit the boom at the inlet end 80 described above. By manipulating the construction implement, the catalyst may be laid down in the bed over the full extent of the bed. If additional raking is then required to reconstitute the bed, an implement may be attached to the inlet end 80 as explained above in connection with interim maintenance to help reconstitute the bed after catalyst regeneration.
[0039] Thus, it will be seen that the device discussed above has many utilitarian functions. The device is supported on tracks which have a sufficiently broad support area that the device may move about the bed without damaging the granules. Additionally, as the device may be constructed of materials which are capable of use under conditions which would otherwise be unfit for human habitation, it can be used at elevated temperatures thereby providing access to a commercial facility before cool down to room temperature has been completed. This helps speed up the beginning of catalyst regeneration thereby helping to minimize down time that would otherwise be required if the facility were to be cooled to room temperature before catalyst bed regeneration were to be commenced.
[0040] Various other modifications and changes may be made to the construction implement described herein. All such amendments and modifications are to be considered within the scope of the current invention which is defined in the following claims.
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A device for assisting in granular bed reconstruction projects such as catalyst bed construction, includes a frame, a tracked drive, a turret and a boom with an actuator to move the boom relative to the turret. The boom includes a tube for fixing to a vacuum source at one end and an opening for sucking catalyst granules out of the bed on the other end. The device can be operated remotely from a controller. The device is small enough and light weight enough to be able to gain access to the bed and to work on the catalyst without destroying the catalyst. Use of the device eliminates or considerably reduces the need to put persons within the reactor vessel for this stage of reconstruction.
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FIELD OF THE INVENTION
This invention relates to the area of devices and systems for controlling acoustic noise and/or vibration. Specifically, it relates to actively-controlled devices for controlling noise and/or vibration via Active Structural Control (ASC) methods.
BACKGROUND OF THE INVENTION
Within the prior art, various means have been developed to counter noise and/or vibration problems. These include passive treatments, passive Tuned Vibration Absorbers (TVAs), Adaptive TVAs (ATVAs), Active Noise Control (ANC), Active Structural Control (ASC), and Active Isolation Control (AIC) all of which will be briefly described herein. Passive treatments, such as sound-deadening blankets, are generally effective in attenuating higher-frequency noise, but are generally ineffective at attenuating low-frequency noise, for example, low-frequency engine tones. Notably, passive blankets must be relatively massive to reduce low-frequency noise transmission into a vehicle's cabin. Therefore, other mechanisms are generally employed for low-frequency vibration/noise suppression.
Passive Tuned Vibrations Absorbers (TVA's) are known devices which find utility in absorbing low-frequency vibration to provide local vibration reduction at their attachment point. TVAs may also be effective at cancelling low-frequency noise within a vehicle's cabin which is radiating from the surrounding structure. Although, TVAs are generally well adapted for attenuating low-frequency noise, they are generally somewhat limited in range and effectiveness. As shown in Prior Art FIG. 1, passive TVAs include a suspended tuning mass 32 which is tuned (along with a stiffness of spring 30), such that the device exhibits a resonant natural frequency (fn) which generally cancels or absorbs vibration of the vibrating structure 22 at the point of attachment thereto. The afore-mentioned disadvantage of passive TVAs is that they are only effective at a particular frequency (fn) or within a very narrow frequency range thereabouts. Therefore, TVAs may be ineffective if the disturbance frequency is changed, such that the TVA is not excited at its resonant frequency (fn). Moreover, passive TVAs may be unable to generate proper magnitude or phasing of forces needed for effective vibration suppression and/or control. In aircraft, passive TVAs may be attached to the interior stiffening rings or stringers of the fuselage or to the yoke. U.S. Pat. No. 3,490,556 to Bennett, Jr. et al. entitled: "Aircraft Noise Reduction System With Tuned Vibration Absorbers" describes a passive vibration dampening device for attachment on the yoke of an aircraft for absorbing vibration at the N1 and N2 rotational frequencies.
When a wider range of vibration cancellation is required, various adaptive TVAs may be employed. For example, U.S. Pat. No. 3,487,888 to Adams et al. entitled "Cabin Engine Sound Suppresser" teaches an adaptive TVA where the resonant frequency (fn) can be adaptively adjusted by changing the "length" of a beam, or the rigidity of a resilient cushioning material. Although, the range of vibration attenuation may be increased with adaptive TVAs, they still may be somewhat ineffective for certain applications, in that their range of adjustment may not be large enough, or they may not be able to generate large enough dynamic forces to dramatically reduce acoustic noise or vibration experienced within a vehicle's cabin, albeit, under certain circumstances they may be quite effective.
In some applications where a higher level of noise and/or vibration attenuation is desired, Active Isolation Control (AIC) systems may be used for controlling noise/vibration within the vehicle. AIC systems include "active mountings" which are attached between the engine (disturbance source) and its attachment structure (frame, pylon, etc.). Active mountings include an actively driven element therein, which provides the active control forces for isolating vibration and preventing its transmission from the engine into the vehicle's structure. The resultant effect is a reduction of annoying interior acoustic noise, as well as a reduction in vibration, in most cases. Known AIC systems include the feedforward type, in which reference signals from reference sensors are used to provide a signal indicative of the engine vibration(s) to the control process. Likewise, error sensors provide error signals indicative of the residual noise/vibration. These reference and error signals are processed by the digital controller to generate output signals of the appropriate phase and magnitude (anti-vibration) to drive an output active mounting to reduce vibration transmission from the engine to the structure, and resultantly control the interior acoustic noise and structural vibration.
U.S. Pat. No. 5,551,650 entitled "Active Mounts For Aircraft Engines" describes one such AIC system. Furthermore, commonly assigned U.S. Pat. No. 5,174,552 to Hodgson et al. entitled "Fluid Mount With Active Vibration Control" describes one type of active fluid mounting. Notably, it should be understood, that in some applications there may be insufficient space envelope to house the active elements within the active mounting. Further, there may be alternate vibration paths into the structure, or the appropriate actuation directions required for good vibration attenuation may be difficult to achieve within the space constraints of the active mount. Therefore, under these circumstances, other types of active control may be implemented, such as Active Noise Control (ANC) or Active Structural Control (ASC).
Active Noise Control (ANC) systems are also well known. ANC systems include a plurality of acoustic output transducers, such as loudspeakers, strategically located within the vehicle's cabin/passenger compartment. These loudspeakers are driven responsive to input signals from input sensors representative of the disturbance and error signals from error sensors disbursed within the vehicle's cabin. Input signals may be derived from engine tachometers, accelerometers, or the like. The output signals to the loudspeakers are generally adaptively controlled via a digital controller according to a known feedforward-type adaptive control algorithms, such as the Filtered-x Least Mean Square (LMS) algorithm, or the like. Copending U.S. patent application Ser. No. 08/553,227 to Billoud entitled "Active Noise Control System For Closed Spaces Such As Aircraft Cabins" describes one such ANC system. Further discussions of ANC systems may be found in U.S. Pat. No. 5,526,292 to Hodgson et al. entitled "Broadband Noise And Vibration Reduction." ANC systems have the disadvantage that they do not address any mechanical vibration problem that may exist, and may be difficult to retrofit in certain vehicles. Furthermore, as the frequency of the noise increases, larger numbers of error sensors and speakers are required to achieve sufficient global noise attenuation.
Certain ASC systems utilizing AVAs, known in the prior art, may solve this problem of needing a large number of error sensors by attacking the vibrational modes of the vehicle's structure directly. For example, by attaching a vibrating device, such as an inertial shakers or AVAs to the interior surface of the fuselage, as described in U.S. Pat. No. 4,715,559 to Fuller, global attenuation can be achieved with a minimal number of error sensors. However, the modifications necessary to retrofit AVAs in this manner may be prohibitive, as the interior trim may have to be removed and structural modifications made have to be made to the stringers or stiffening-ring frames. Furthermore, for control of higher order tones, a large number of AVAs may be needed, thereby requiring large power requirements for each AVA and associated amplifier. Therefore, prior art ASC systems are necessarily difficult to retrofit and may require the use of many inertial shakers to effectuate control of higher-order tones. U.S. Pat. No. 5,310,137 to Yoerkie, Jr. et al. describes the use of AVAs to cancel high-frequency vibrations of a helicopter transmission. Notably, Yoerkie, Jr. et al. is a feedback-type system.
As described in Prior Art FIG. 2, Active Vibration Absorbers (AVAs) comprise a tuning mass 32, a housing 28, a spring 30 flexibly supporting the tuning mass 32, and a force actuator 40 (coil and magnet assembly or the like) for actively driving the tuning mass 32 along its acting axis A--A. The stiffness of spring 30 and mass of tuning mass 32 may be tuned such that the AVA is more easily driven at its predominant frequency. Prior Art FIG. 3 describes a Multiple-Degree-of-Freedom Active Vibration Absorber (MDOF AVA). MDOF AVAs include an extra flexible member 26. The mass of housing 28 and stiffness of additional flexible member 26 are tuned to provide a second resonant frequency. Further descriptions of AVAs and MDOF AVAs can be found in Copending U.S. application Ser. No. 08/322,123 entitled "Active Tuned Vibration Absorber", copending PCT application PCT/US95/13610 (WO 96/12121) entitled "Active Systems and Devices Including Active Vibration Absorbers (AVAs)", U.S. Ser. No. 08/698,544 entitled "Active Noise and Vibration Control System", U.S. Ser. No. 08/693,742 entitled "Active Structural Control System and Method Including Active Vibration Absorbers (AVAs), and U.S. Ser. No. 08/730,773 entitled "Hybrid Active-Passive Noise and Vibration Control System for Aircraft." FIG. 4 illustrates one prior art preferred implementation for achieving active forces in multiple directions. The AVAs (which could also be MDOF AVAs) are attached to rigid bracket 38 which attaches to structure 22 via fastener shown. The inertial shakers/AVAs 25, 25' shown are actively driven along their acting axes at the appropriate frequency, amplitude, and phase to appropriately control noise and/or vibration.
The individual AVAs described above suffer from the problems that they are either mass inefficient, incapable of multiple direction actuation, or require large amounts of electrical power. Therefore, there is a long felt and recognized need for an AVA assembly which provides multi-directional active vibrational forces to effectively control vibration within the structure, which is efficient, and which minimizes mass and power requirements for generating the needed cancellation forces.
SUMMARY OF THE INVENTION
Therefore, in light of the advantages and drawbacks of the prior art, the present invention is an Active Vibration Absorber (AVA) assembly of the type useful for control of noise and/or vibration caused by a source of vibration. The AVA assembly comprises a casing, a first tuning mass flexibly supported by the casing which is actively vibratable in a first direction, a second tuning mass flexibly supported by the casing which is actively vibratable in a second direction substantially orthogonal to the first direction, and a flexible member flexibly supporting the casing.
It is an advantage of the present invention AVA assembly that it can be easily retrofitted, in the field, without extensive modifications to the structure.
It is an advantage of the present invention AVA assembly that it can control vibration over a wider frequency range, thereby controlling unwanted and annoying acoustic noises within the vehicles cabin over a wider frequency range.
It is an advantage of the present invention AVA assembly that it can control vibration in multiple directions.
It is an advantage of the present invention AVA assembly that it can generate large dynamic forces with a less massive device.
It is an advantage of the present invention AVA assembly that it is efficient, thus reducing size and power requirements.
It is an advantage of the present invention AVA assembly that it can control multiple vibrational frequencies.
The abovementioned and further features, advantages, and characteristics of the present invention will become apparent from the accompanying descriptions of the preferred and other embodiments and attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which form a part of the specification, illustrate several key embodiments of the present invention. The drawings and description together, serve to fully explain the invention. In the drawings,
FIG. 1 is a cross-sectional side view of a prior art Tuned Vibration Absorber (TVA),
FIG. 2 is a cross-sectional side view of a prior art Active Vibration Absorber (AVA),
FIG. 3 is a cross-sectional side view of a prior art Multi-Degree-of-Freedom Active Vibration Absorber (MDOF AVA),
FIG. 4 is a cross-sectional side view of a prior art AVA installation,
FIGS. 5 and 6 are partial cross-sectional side and bottom views, respectively, of the present invention multi-directional AVA assembly,
FIGS. 7 and 8 are partial cross-sectional side and end views, respectively, of another embodiment of the multi-directional AVA assembly,
FIG. 9 is a partial cross-sectional side view of another embodiment of a multi-directional AVA assembly, and
FIG. 10 is a partial cross-sectional side view of several multi-directional AVA assemblies installed in an Active Structural Control (ASC) system.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the Drawings where like numerals denote like elements, in FIGS. 5 and 6, shown generally at 20, is a first embodiment of the present invention AVA. This invention has particular applicability for controlling vibration and noise in aft-fuselage-mounted turbofan aircraft, such as the DC-9 aircraft. The AVA 20 is comprised of a casing 24 flexibly supporting a first tuning mass 32 which is oriented such that it is actively vibrated by active force actuator 40 in a first direction (along axis A--A) and a second tuning mass 32' operatively and actively vibrated along a second direction (along axis B--B) which is substantially orthogonal to said first direction, and at least one flexible member 26 flexibly supporting the casing 24. The AVA 20 attaches to the structure 22 (e: a frame, pylon, etc.) by way of a fastener or the like, but preferably screws into the structure via a single fastener 38. The flexible member 26 shown is preferably a metal cantilever beam, whereby the stiffness thereof is tuned by adjusting the length 1, diameter d, and modulus of the material used. Other embodiments will be described herein wherein the flexible member 26 comprises multiple flexible beams or flexible elastomer sections.
In this embodiment, the casing 24 is comprised of housings 28, 28' of inertial actuators 25, 25'. Each inertial actuator 25, 25' comprises a tuning mass 32, 32', and at least one, and preferably a plurality of springs 30, 30' supporting the tuning masses 32, 32' relative to the housings 28, 28', and active force generators 40, 40' for actively driving the tuning masses 32, 32' at the appropriate frequency, amplitude, and phase to accomplish the control task, i.e., controlling vibration or noise. It should be understood that the stiffnesses of springs 30, 30', flexible member 26, 26', the mass of tuning mass 32, 32', and the masses of casing 24 would be chosen such that the appropriate resonant frequencies f1 and f2 are achieved. By way of example, f1 might be tuned to be at about 120 hz while f2 might be tuned at about 186 hz.
FIGS. 7 and 8 illustrate an embodiment of AVA assembly 20a that was reduced to practice and tested experimentally. This AVA assembly 20a comprises first and second inertial shakers 25a, 25a' which are securely attached to an intermediate plate 34a. The respective axes (A--A, B--B) of the shakers 25a, 25a' are arranged substantially orthogonally. The intermediate plate 34a is then flexibly supported relative to a base plate 36a which attaches to structure 22a, preferably via a single threaded fastener 38a. The means for flexibly supporting the intermediate plate 34a relative to the base plate 36a preferably comprises a plurality of flexible beam members 26a, 26a', 26a", 26a'". Preferably, there are four beams spaced at the corners, although more than four may be used as well. By utilizing multiple beam-type flexible members 26a, 26a', 26a", 26a'", the movement of the intermediate member 34a in the frequencies of interest can be restricted to generally planar movement, in a plane generally parallel to the plane of the base plate 36a.
Each of the inertial shakers 25a, 25a' comprises a housing 28a, 28a' which is secured to intermediate plate 34a via brackets, bolts, or the like. The shakers 25a, 25a' include inertial tuning masses 32a, 32a' supported by at least one spring, and preferably two springs 30a, 30a', 30a", 30a'". The masses of tuning masses 32a, 32a' and spring stiffnesses of springs 30a, 30a', 30a", 30a'" are chosen in conjunction with the stiffness of flexible member 26a-26a'" and mass of casing 24a to arrive at the appropriate resonant frequencies f1 and f2. The means for constraining the interior tuning masses 32a, 32a' to move only axially comprises stiff radial flexures, bearings, or the like, which are very stiff radially and sufficiently soft axially to provide the appropriate motion and axial frequency tuning. A more detailed description of this type of actuator used as an inertial shaker may be found in U.S. Pat. No. 5,231,336 to van Namen entitled "Actuator for Active Vibration Control."
It should be understood that by appropriate actuation of tuning masses 32a, 32a' via electrically energizing leads 42a, 42a', thereby energizing first and second coils 44a, 44a', 46a, 46a' that forces may be generated along the respective A--A and B--B axes. Appropriate phasing of these forces can produce forces along axis A--A, along axis B--B or along any other axis in the same plane as axes A--A and B--B. By way of example and not by limitation, the primary mass (casing 24a) is approximately 5 kg and the primary stiffness of flexible members 26a, 26a', 26a", 26a'" combined is approximately 25,000 lb./in. (4,375,000 N/m). Likewise, the tuning masses 32a, 32a' are preferably approximately 1 Kg each and the combined stifffiesses of the springs 30a acting on masses 32a, 32a' are approximately 5,000 lb./in. (875,000 N/m). Therefore, the predominant resonant frequencies are about f1=120 hz and f2=186 hz. Each of the masses 32a, 32a' of inertial shakers comprise permanent magnets 45a, 45a' and pole pieces 47a, 47a', 49a, 49a' for directing the magnetic flux.
FIG. 9 illustrates another embodiment of AVA assembly 20b which comprises a first inertial shaker 25b having an first housing 28b and a first predominant axis of vibration B--B (the axis is into and out of the paper), a second inertial shaker 25b' having a second housing 28b' rigidly secured relative to said first housing 28b and exhibiting a second predominant axis of vibration (A--A) which is oriented substantially orthogonally relative to said first predominant axis (B--B), and a flexible member 26b flexibly suspending said first and second housings 28b, 28b'. Preferably, the shakers 25b, 25b' are secured to intermediate plate 34b. Further, attached between intermediate plate 34b and second shaker 25b may be optional supports 48, 48b'. In this embodiment, the flexible member 26b is a planar elastomer section which is bonded between the base plate 36b and the intermediate plate 34b. The base plate 36b preferably includes a single threaded member for securing into structure 22b. The shakers 25b, 25b' may include coil and magnet assemblies for driving the tuning masses therein. Alternatively, piezoelectric or magnetostrictive actuators may be implemented to drive the tuning masses.
FIG. 10 illustrates several AVA assemblies 20c, 20c' included within the environment of an Active Structural Control (ASC) system 66c. Shown is an engine 56c attached to a yoke assembly 50c by engine mounts 58c, 58c'. The yoke assembly 50c attaches to pylon structure 52c which then interconnects to the fuselage 54c of the aircraft. The AVA assemblies 20c, 20c' attach at the base portion of the yoke assembly 50c where the yoke assembly 50c attaches to the pylon 52c. A reference signal is provided to the preferably digital controller 62c by the reference sensor 60c. The reference sensor 60c may be an accelerometer, tachometer, or the like and provides a signal representative of the disturbance (frequency, phase and/or amplitude). Error sensors 64c strategically located in the cabin supply error signals to the controller 62c indicative of the residual noise level in the aircraft's cabin.
The controller 62c processes the reference signal and the error signals and provides drive signals to the AVA assemblies 20c, 20c' to actively drive the tuned masses (32a, 32a' of FIGS. 7, 8) and casing 24a (FIGS. 7, 8) therein. Control algorithms such as Filtered-x LMS, or the like, may be used to control the assemblies 20c, 20c'. Because the inertial shakers within the assemblies are substantially smaller than the AVAs shown in prior art FIG. 4, the mass of the system is less and the amplifiers 68, 68c' may be made smaller. Therefore, the power requirements to drive the AVA assemblies 20c, 20c' are also reduced.
In summary, it should be apparent from the foregoing that the present invention comprises an AVA assembly including a first inertial shaker having a first housing and a first predominant axis of vibration, a second inertial shaker having a second housing rigidly secured relative to the first housing and a second predominant axis of vibration which is oriented orthogonally relative to the first predominant axis, and a flexible member suspending the first and second housings.
While several embodiments including the preferred embodiment of the present invention have been described in detail, various modifications, alterations, changes, and adaptations to the aforementioned may be made without departing from the spirit and scope of the present invention defined in the appended claims. It is intended that all such modifications, alterations, and changes be considered part of the present invention.
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An Active Vibration Absorber assembly (20) including a casing (24), a first tuning mass (32) supported relative to the casing (24) which is actively vibratable by a force generator (40) in a first direction (along an A--A axis), a second tuning mass (32') supported relative to said casing (24) which is actively vibratable by a force generator (40') in a second direction (along axis B--B) generally orthogonal to the first direction, and a flexible member (26) flexibly supporting the casing (24). In a first embodiment, the tuning masses (32, 32') are vibratable by a magnet and coil assembly within shakers (25, 25') and the flexible member (26) is a beam. In other embodiments, multiple beams are employed to restrict the vibration of casing (24) to substantially planar motion. The AVA assembly (20) finds application in Active Structural Control (ASC) systems for actively canceling vibration or noise in vehicle cabins (example: automobiles, aircraft).
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BACKGROUND OF THE INVENTION
A variety of methods and devices for replacement of a cloth beam are known. However, none of these methods and devices has proven completely satisfactory, due to the fact that an extra press roll and other means to start up the winding, such as adhesive tape, hooks, suction openings, and so forth, are required by the prior methods and devices, and also because the prior methods and devices usually require interruption of the weaving process during replacement of the beam.
SUMMARY OF THE INVENTION
The present invention concerns a method and device for replacing a cloth beam in weaving machines, in particular for replacing a cloth beam by an empty cloth beam.
In particular, the invention concerns a method and device offering the advantage that the replacement of the cloth beam can be executed in a relatively simple manner, as no extra press roll or any other means to start up the winding such as adhesive tape, hooks, suction openings, etc. is required.
The invention also concerns a method and device having the advantage of simple replacement of the cloth beam with the additional advantage that the weaving does not need to be interrupted during the replacement of the cloth beam.
To this end, the method according to the invention includes the steps of removing a cloth beam to be replaced from a winding device, pressing an empty cloth beam against the fabric, and putting the empty cloth beam against a guide piece stretching out along the width of the fabric such that the fabric is turned over the guide piece and extends around substantially the entire circumference of the cloth beam, and from there extends towards the winding device, enveloping the portion of the fabric extending towards the winding device that is turned over the guide piece and lies between the extending portion and the guide piece. The inventive method also includes the steps of releasing the part of the fabric that is situated, according to the moving direction of the fabric, beyond the empty cloth beam, driving the empty cloth beam such that the part of the fabric that is situated beyond the empty cloth beam such that the part of the fabric that is situated beyond the empty cloth beam according to the moving direction of the fabric is wound between the guide piece and the fabric stretching out towards the winding device, and mounting the empty cloth beam in the winding device.
In preference, the fabric is to be kept taut since the cloth beam to be replaced is removed and is not cut loose until the empty cloth beam makes contact with the guide piece.
In order to realize the method according to the invention, use should be made of a device which includes means for removing a cloth beam to be replaced from a winding device, a guide piece stretching out according to the width of the fabric, a guide piece stretching out according to the width of the fabric, means to put the empty cloth beam against the fabric and against the guide piece such that the fabric is turned over the guide piece, extends over substantially the entire circumference of the cloth beam, and from there extends towards the winding device, the portion extending towards the winding device enveloping the fabric that lies in between that portion and the portion which is already turned over the guide piece. The device for implementing the inventive method also includes means for placing the empty cloth beam in the winding device, means for releasing the part of the fabric that is situated beyond the empty cloth beam according to the moving direction of the fabric; and drive means for driving the empty cloth beam.
In preference, the guide piece consists of a slat attached to elastic, arched connecting pieces.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better explain the characteristics of the invention, by way of example only and without being limitative in any way, the following preferred embodiments are described with reference to the accompanying drawings where:
FIG. 1 is a schematic diagram of a device according to the invention;
FIGS. 2 to 6 represent different stages of the method according to the invention for the part indicated in FIG. 1 as F2;
FIGS. 7 to 9 show a view to a larger scale of different positions of the part indicated in FIG. 6 as F7;
FIG. 10 is a schematic diagram of yet another stage of the method;
FIG. 11 shows a practical embodiment of the device according to the invention;
FIGS. 12 and 13 show views according to the arrows F12 and F13 in FIG. 11;
FIG. 14 shows a view according to arrow F14 in FIG. 13;
FIG. 15 is a cross-section according to line XV--XV in FIG. 14;
FIG. 16 shows a view according to arrow F16 in FIG. 11;
FIG. 17 represents a variant of the device according to the invention;
FIGS. 18 to 20 show the device represented in FIG. 17 in various positions;
FIG. 21 represents a variant of the part indicated in FIG. 7 as F21.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematic diagram of a weaving machine 1 and a device 2 according to the invention. As is known, the produced fabric 3 is wound on a cloth beam 4 so as to form a cloth roll 5.
The cloth beam 4 may be mounted, as shown in FIG. 1, in a separate winding device 6 of the weaving machine 1, whereby the cloth beam 4 is supported by means of two support rolls 7, at least one of which is driven.
According to a variant, the winding device 6 for the cloth beam 4 may also be directly mounted in the frame 8 of the weaving machine 1.
Whenever the cloth beam 4 needs to be replaced, it is removed and replaced by an empty cloth beam 9. According to the present invention this is to be done as schematically represented in FIGS. 2 to 10. For clarity's sake, a number of parts of the device have been omitted in these figures, however they are described further on by means of a practical embodiment according to the invention.
As indicated in FIG. 2, use is made of a transport element 10 to supply the empty cloth beam 9 and to remove the full cloth beam 4 in order to realize the method according to the invention. A guide piece 11 stretching out diagonally with respect to the fabric 3 and which is fixed onto the transport element 10 is an important element for implementing the method.
As shown in FIG. 3, according to the first stage of the method, the cloth beam 4 to be replaced and which is usually also full, is to be removed out of the winding device 6 and placed in the transport element 10. The fabric 3 between the winding device 6 and the full cloth beam 4 is kept taut.
At the following stage, the empty cloth beam 9 as represented in FIG. 4 is pressed against the taut fabric, somewhere between the weaving machine and the removed cloth beam 4, and put over the edge of the guide piece 11 together with this fabric, such that the situation is as shown in FIG. 5. At this time, it is possible to remove fabric 3 from the cloth roll 5.
Subsequently, the full cloth beam 4 is emptied. To this end, at least according to the embodiment described, the fabric 3 between the guide piece 11 and the full cloth beam 4 is cut by means of a cutting device 12, for example as close as possible to the guide piece 11. Thus, as indicated in FIG. 6, a free end 13 is formed on the fabric 3, the other end of which is connected to the weaving machine.
As shown in FIG. 7, the fabric 3 stretches out from the free end 13 to the guide piece 11, and makes a turn of practically 180 degrees over its free edge, to subsequently stretch out substantially around the circumference of the empty cloth beam 9, back over the guide piece 11 and towards weaving machine, in particular winding device 6, thus enveloping the fabric 3 that lies in between and is turned over the guide piece. The empty cloth beam 9 is pressed with a predetermined force F1 against the guide piece 11. The enveloping of fabric 3 that lies in between the extending portion and guide piece 11 is made possible as the portion of fabric 3 which stretches out towards the winding device 6 of the weaving machine 1 presses onto the portion of fabric 3 that lies in between the cloth beam and guide piece with a force F2, in particular onto part 14 of the fabric 3 which is situated between the guide piece 11 and part 15 of the fabric 3 which stretches out to the winding device 6. Parts 11, 14 and 15 are collectively referred to by the reference numeral F21 because a variation of these parts is shown in FIG. 21, described below.
At the following stage, the empty cloth beam 9 is driven according to a winding sense A such that the fabric 3 is wound on the empty cloth beam 9. Of course, the winding sense A of the empty cloth beam 9 is the same as the winding sense of the cloth beam in the winding device 6. Hence, the intermediate part 14 of the fabric 3 is carried along at the height of the guide piece 11 resulting from friction with the opposite part 15, as shown in FIGS. 8 and 9, as a result of which the free end 13 is wound on the empty cloth beam 9. The intermediate part 14 is hereby carried along by the part 15 as the friction between the part 14 and the part 15 is greater than the friction between the part 14 and the guide piece 11. It is clear that such frictions result from the above-mentioned enveloping of the part 14.
Finally, the empty cloth beam 9 is put back in the winding device 6, while the winding device is driven in the direction of arrow A so as to keep the fabric 3 between the empty cloth beam 9 and the weaving machine 1 is taut, as shown in FIG. 10. It is clear that in this case the empty cloth beam 9 has already been provided with some windings. Subsequently, the full cloth beam 4 can be carried off by means of a transport element 10.
A practical embodiment of the above-mentioned device 2 is hereafter described in connection with FIGS. 11 to 16. The device is at least made up of means for carrying off a cloth beam 4 to be replaced and to supply an empty cloth beam 9 to a weaving machine 1, a guide piece 11 stretching out diagonally in respect to the fabric 3; means for subsequently putting the empty cloth beam 9 against the fabric 3 and the guide piece 11 such that the fabric 3 is turned over the guide piece 11 and stretching out along most part of the circumference of the empty cloth beam 9 and again over the guide piece 11 towards the weaving machine, thus enveloping the fabric 3 that lies in between the guide piece 11 and the portion of cloth 3 extending towards the weaving machine 1. The preferred device also includes means for releasing the part of the fabric 3 which was formerly conducted to the full cloth beam 4; and drive means 16 to drive the empty cloth beam 9 which still has to be mounted in the weaving machine 1.
The means to carry off the full cloth beam 4 and to supply the empty cloth beam 9 include a transport element 10, and one or more mechanisms for removing a cloth beam 4 to be replaced from the weaving machine 1, in particular from the winding device 6, for putting cloth beam 4 in the transport element 10 on the one hand, and for installing the empty cloth beam 9, which is fixed in a holder or magazine 17 in the transport element 10, in place of the full cloth beam 4 in weaving machine 1. According to FIG. 11, two separate mechanisms 18 and 19 are used to this end.
The transport element 10 includes a carriage driven by a motor 20. Of course, the device as a whole is provided with the necessary means to call the transport element 10 and position it in front of the winding device 6 which contains the cloth beam 4 to be replaced. These means may for example include a detector 21 at the winding device 6 to detect a full cloth beam 4, a central control unit 22 which is connected, via an inductive rail 23 and a detector 24 in the transport element 10, to a control unit 25 which commands the motor 20 and the mechanisms 18 and 19. Whenever a cloth beam 4 is full, the detector 21 emits a signal as a result of which the transport element 10 automatically moves to the weaving machine 1 in question, following the inductive rail 23.
The above-mentioned mechanism 18 to carry off the full cloth beam 4 may consist for example of two telescopic arms 26, which can be horizontally extended, and a drive 27 by which the arms 26 can be vertically removed. At the far ends of the arms 26, seatings 28 have been applied in which a cloth beam 4 can be contained. The mechanism 18 allows for the arms 26 to be presented with the seatings 28 under the far ends of the cloth beam 4. By moving the arms 26 upward, the cloth beam 4 is lifted from the winding device 6 of the weaving machine 1, and by sliding in the telescopic arms 26, cloth beam 4 is placed in the transport element 10.
The above-mentioned mechanism 19 to put an empty cloth beam 9 in a weaving machine 1, and more particularly in the winding device 6, preferentially includes two telescopic arms 29 ends 30 of which are pivotally attached onto the frame 31 of the transport element 10, and ends 32 of which are each provided with a gripper element 33 to take up and remove the empty cloth beam 9. The telescopic arms 29 can be turned by means of pressure cylinders 34 or other known arm turning devices.
As shown in FIGS. 13 to 15, the gripper elements 33 may include a hook-shaped part 35 with an opening 36 in which the far end of cloth beam 9 fits and a locking element 37 to prevent the far end of the cloth beam 9 from coming loose from the hook-shaped part 35 in which it has been mounted. The locking elements 37 may include slides which move in guide pieces 38 of arms 29 and which are removed by means of pressure cylinders 39.
The above-mentioned means to press the empty cloth beam 9 against the fabric 3 and against the guide piece 11 are also formed by the mechanism 19 described above in the embodiment represented in FIGS. 11 to 15. It is clear that the mechanism 19 allows one to both take an empty cloth beam 9 from the magazine and holder 17 and to remove it as shown in FIGS. 4, 5 and 10.
The above-mentioned guide piece 11 preferably includes a thin slat with a smooth surface and which is attached onto the frame 31 of the transport element 10 by means of arched connecting pieces 40, as shown in FIGS. 7, 8, 9, 11 and 12. The connecting pieces 40 may be either elastic or not elastic.
If the connecting pieces 40 are elastic, the guide piece 11 and the cloth beam 9 make full contact over their entire length as the cloth beam 9 is pressed according to the situation shown in FIG. 7, and alignment mistakes can be adjusted. According to a variant, the slat which forms the guide piece 11 may consist of a leaf spring.
The above-mentioned means to release the fabric 3 from the full cloth beam 4 include a cutting device 12 which operates parallel to the guide piece 11, as shown in FIGS. 11 and 12. To this end, the cutting device 12 has been attached to the bottom side of the connecting pieces 40. They include a V-shaped knife 41 which can be removed by means of a cable 42 and a motor 43 as is schematically represented in FIG. 16. According to this method, the fabric 3 automatically comes within reach of the cutting device 12. As the telescopic arms 26 are slid in, the cloth beam 4 is unwound while it remains in the seatings 28, as a result of which the fabric 3 is kept taut. It is clear that in order to keep the fabric 3 taut, a certain friction is required between the cloth beam 4 and the seatings 28. Also as the empty cloth beam 9 is pressed against the fabric 3, the latter remains taut such that it will always stretch out from the bottom of the guide piece 11 to the cloth beam 9, and will always come within reach of the cutting device 12.
The above-mentioned drive means 16 consist of a motor 44, for example an electrical motor, with which a cloth beam 9 mounted in the gripper elements 33 can be turned. As shown in FIGS. 13 to 15, the motor 44 has been attached on one of the arms 29 of the mechanism 19 and drives a sliding coupling which may be formed of for example a drive wheel 45 which may cooperate with a wheel 46 on the cloth beam 9. The drive wheel 45 may include a rubber wheel, whereas the wheel 46 may have a smooth surface.
It is clear that all drive means, such as the motors 20, 43 and 44, the telescopic arms 26 and 29 and the pressure cylinders 34 and 39 are controlled by means of control unit 25 such that the cycle as shown in FIGS. 1 to 10 is automatically carried out.
It should be noted that after the situation in FIG. 5 has been realized, the fabric 3 hangs looser as indicated in FIG. 6 by means of the dashed line X, at least when no extra clamping means have been provided, and when the weaving on weaving machine 1 continues. For this reason, the guide piece 11 should in preference be attached on top of the frame 31, as a result of which the fabric's 3 own weight provides the necessary tension to carry along the part 14 during the winding, as shown in FIG. 8. In this case, the opening 47 of the arched connecting pieces 40 is also pointed to the top.
FIGS. 17 to 20 show a variant for replacing the cloth beam 4 which is attached to winding device 6 mounted in the frame 8 of weaving machine 1. It differs from the above-mentioned embodiment in that the winding sense B is in this case usually opposite to the winding sense A of a separating winding device 6. The guide piece 11 and the connecting pieces 40 should be assembled accordingly.
In the embodiment according to FIGS. 17 to 20, the guide piece 11 is situated under the transport element 10, whereas the holder 17 for the empty cloth beam 9 is situated at the top. The opening 47 of the arched connecting pieces 40 is pointed to the bottom.
By way of example, the means to carry off the cloth beam 4 to be replaced and to supply the empty cloth beam 9 to the weaving machine 1, as well as the means to put the empty cloth beam 9 subsequently to the fabric 3 and the guide piece 11 is formed by one and the same mechanism 48. This mechanism 48 consists of two folding arms 49 which are attached onto frame 31 in a hingeable manner. Each arm can be hinged and can be driven by means of drive mechanisms 50 and 51 respectively. The free end of each of arms 49 is provided with a gripper element 33 as shown in FIGS. 13 to 15.
The cutting device 12 has now been mounted at the top side of the arched connecting pieces 40.
The device is also provided with a drive 52 to turn the cloth beam 4 once it has been placed in the transport element 10. As shown in FIGS. 17 to 20, this drive may consist of an electrical motor 53, a transmission 54 and sliding coupling 55. The sliding coupling 55 may consist of a rubber wheel 56 which cooperates with a supporting roller mechanism 57 for the cloth beam 4.
The supporting roller mechanism 57 is part of a support 58 intended to permit the cloth beam 4 to be replaced after it has been removed from the weaving machine 1.
In order to clearly show the position of the empty cloth beam 9, the arms 49 in FIGS. 19 and 20 are only partly represented.
The operation of the device can easily be derived from the different positions in FIGS. 17 to 20.
According to FIG. 17, the full cloth beam 4 is taken up by the mechanism 48. Subsequently, it is moved and put in the support 58, which results in a situation as shown in FIG. 18, after which the mechanism 48 moves to the holder 17 to take up an empty cloth beam 9.
The empty cloth beam 9 is pressed against the fabric 3 and put in the opening 47 of the arched connecting pieces 40, as shown in FIG. 19. Subsequently, the empty cloth beam 9 is pressed against the guide piece 11. Hereby, the fabric 3 is constantly kept taut by switching on the drive 52.
Subsequently, the fabric 3 is cut loose from the full cloth beam 4 by means of the above-mentioned cutting device 12. Immediately hereafter, the empty cloth beam 4 is driven such that the fabric 3 can be wound in an analogous manner as indicated in FIGS. 7, 8 and 9.
In this case, the connecting pieces 40 are in preference elastic, such that the empty cloth beam 9 can be tightened against the guide piece 11, against the resilience, by winding up the full cloth beam 4. This offers the advantage that the fabric 3 which stretches out from the empty cloth beam 9 to the weaving machine 1 remains taut for a while, as the connecting pieces 40 spring back, even when the weaving is continued while the cloth beam is being replaced. The resilience effectively replaces the force supplied in the embodiment according to FIG. 7 by the fabric's own weight.
It is clear that the drive of the empty cloth beam 9 by the motor 44 does not necessarily have to be assured via the above-mentioned sliding couplings. Use may also be made of for example a gear transmission or such. In this case, the drive wheel 45 may consist of a gear wheel, for example, which may cooperate with a wheel 46 on the cloth beam 9 which in this case consists of a gear wheel, and the motor 44 may consist of, for example, a motor with a constant torque.
FIG. 21 shows a variant according to which the guide piece 11 is formed by a slat 59 equipped with rotatable needles 60, needles 60 having been applied a the side 61 of the slat 59 pointed towards the fabric 3 which stretches out to the winding device 6. As a result, the friction between the part 14 and the guide piece 11 is reduced, which makes it easier for the part 14 to be carried along by the part 15.
It is clear that the guide piece 11 does not necessarily need to be fixed onto the frame of the transport element 10, but that the guide piece 11 can also be fixed onto the frame of another element such as for example the winding device 6 of the weaving machine 1.
It is clear that the width of the device according to the invention may be adjusted to the width of the cloth beam to be replaced.
The present invention is in no way limited to the embodiments described by way of example and shown in the accompanying drawings; on the contrary, such a method and device for replacing a cloth beam in weaving machines can be made in all sorts of variants while still remaining within the scope of the invention.
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A method and a device for replacing a cloth beam in a weaving machine utilize the steps of removing a cloth beam from a winding device, pressing an empty cloth beam against a fabric and against a guide piece such that the fabric is turned over the guide piece, subsequently releasing the fabric, and driving the empty cloth beam such that the fabric is wound thereon, and finally mounting the empty cloth beam in the winding device.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention generally relates to the field of construction materials. More specifically, this invention relates to textured wallboards, as might be used in new construction or home remodeling, and the methods for their manufacture.
[0003] 2. Description of Related Art
[0004] Various types of wallboards have been used for years in the construction trades. The most common form of wallboard used today is drywall, which is also known as plasterboard, gypsum board and sheetrock. Drywall is formed of gypsum plaster pressed between two sheets of relatively thick paper. Drywall itself is not structural and requires the building of an underlying wall, typically formed from a framework of 2×4 lumber, to which the drywall is secured. After securing the drywall on the wall, seams between adjacent sheets of the drywall must be taped, mudded and sanded, and the smooth, unfinished exterior surface must thereafter be primed and painted. If a textured surface is desired, the texture is applied after the drywall is hung, either before or after the priming of the exterior surface, by spraying on the texture material or other means.
[0005] Another form of wallboard is cement board. Cement board has either wood flakes or cellulose fiber, bonded together by cement, to form the panel. Texture is applied to cement board in similar fashion, but usually cement board is used as a backing board and is covered with tile.
[0006] A further type of wallboard is one made of magnesium oxide, and which is often referred to as magnesia board. These boards are often used in place of drywall and are not a paper faced panel. In addition to being fire resistant, these boards are also not susceptible to mold and mildew. For the latter reasons, magnesia boards are often used in place of drywall. Magnesia boards can also be incorporated into preformed wall systems, such as the insulated wall systems often used in the remodeling trade for refinishing basements.
[0007] One method of applying a texture to this type of wallboard involves providing a series of generally parallel textile strands, yarns or strings that are laid upon and adhesively secured to the board's surface. After the adhesive dries, the strands are trimmed. The textured panel can thereafter be primed and painted. Issues can arise, however, should one of the stands become dislodged from the board surface, either during manufacturing and installation or after installation.
SUMMARY
[0008] In overcoming the enumerated drawbacks and other limitations of the related art, the present invention provides a novel method for forming a panel or board having a textured surface.
[0009] In one aspect of the invention, a method is provided for manufacturing a substrate having a textured surface, the method including the steps of: providing a substrate having a surface; applying a coating material onto the surface of the substrate; texturing the coating material on the surface of the substrate to form a textured coating; and exposing the textured coating on the substrate to ultraviolet light for a duration of time sufficient to fully cure the textured coating on the substrate and thereby form a fully cured textured surface on the substrate.
[0010] In another aspect, the step of applying the coating material to the surface of the substrate includes the step of first applying the coating material to a pair of counter rotating rollers.
[0011] In a further aspect, the step of applying the coating material to the surface of the substrate includes contacting at least one roller with the surface of the substrate thereby transferring coating material from the roller to the surface of the substrate.
[0012] In yet another aspect, the step of applying the coating material to the surface of the substrate includes roll coating the substrate in a coating station.
[0013] In still a further aspect of the invention, the surface of the substrate is planar.
[0014] In another aspect, the invention includes moving the substrate along a conveyor system during the coating, texturing and curing steps.
[0015] In a further aspect of the invention, the step of texturing the coating material on the surface of the substrate includes drawing the substrate with the coating material thereon past a doctor blade or board, the doctor blade having a profiled edge and the profiled edge contacting at least the coating material and thereby forming a texture in the coating material that corresponds with the shape of the profiled edge.
[0016] In a still further aspect of the invention, the profiled edge has a series of recesses formed therein.
[0017] In yet another aspect of the invention, the series of recesses is a random series of recesses.
[0018] In still another aspect of the invention, the series of recess is a repeating series of recesses.
[0019] Further objects, features and advantages of this invention will become readily apparent to persons skilled in the art after a review of the following description, with reference to the drawings and claims that are appended to and form a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view of production line for forming textured wall boards according to the principles of the present invention;
[0021] FIG. 2 is an enlarged view of the coating station and the texturing station seen in FIG. 1 ;
[0022] FIG. 3 is a downstream view of the doctor blade of the coating station showing the profiled edge that imparts the pattern or texture onto the coating on the surface of the substrate; and
[0023] FIG. 4 is a perspective view of a resultant wallboard manufactured in accordance with the principles of the present invention.
DETAILED DESCRIPTION
[0024] Referring now to the drawings, a production line for practicing a method in accordance with the principles of the present invention is illustrated therein and generally designated at 10 . The production line 10 , which is best seen in FIG. 1 , is configured to continuously apply and fully form a texture surface on planar substrates 12 . As such, the production line 10 has various stations for achieving this process. These stations principally include an in-feed station 14 , a coating station 16 , a texturing station 18 , a curing station 20 and an out-feed station 22 . While described herein as having specific stations, it will be readily apparent to those skilled in the art that variations on the stations are possible, as is the incorporation of additional stations and components into the production line 10 .
[0025] At the initiation of a method in accordance with the principles of the present invention, the substrates 12 are loaded onto a conveyor assembly 24 , such loading occurring either by an automated transfer mechanism or manually. The conveyor assembly 24 then carries the substrates 12 along the production line 10 and through the in-feed station 14 , the coating station 16 , the texturing station 18 , the curing station 20 and the out-feed station 22 The conveyor assembly 24 may utilize various means to convey the substrates 12 through the stations 14 - 22 . In a preferred embodiment, the conveyor assembly 24 employs an endless conveyor belt 26 that is driven by an electric motor (not shown) about a series of rollers 30 . With the substrates 12 loaded onto the conveyor assembly 24 , the substrates 12 are advanced by the conveyor belt 24 from the in-feed station 14 into the coating station 16 .
[0026] The coating station 16 is a roll coater having a pair of rollers, which are herein referred to as a nip or coating roller 32 and a conditioning or doctor roller 34 . Driven by an electric motor (not shown), the nip roller 32 and the conditioning roller 34 are counter-rotating relative to one another such that, as seen in the illustrated drawings, the nip roller 32 rotates in a clockwise direction (the bottom of the roller 32 adjacent to the conveyor belt 26 moving in the direction of movement of the belt 26 ) and the conditioning roller 34 rotates in a counter clockwise direction. While the nip roller 32 and the conditioning roller 34 may be constructed from a variety of materials, a preferred material for the nip roller 32 is ethylene propylene diene monomer (EPDM) and the preferred material for the conditioning roller 34 is chrome plated steel, each rollers 32 , 34 being formed so as to have a smooth exterior surface.
[0027] At the upper side of the rollers 32 , 34 (the side of the rollers away from the conveyor belt 26 ) a trough 36 is defined by the adjacent curvatures of the rollers 32 , 34 . This trough 36 may therefore be described as the generally triangular space between the nip roller 32 and the conditioning roller 34 , where the two rollers rotate toward one another.
[0028] With the rollers 32 , 34 counter rotating, a viscous coating material 38 is dispensed into the trough 36 . The coating material 38 may be dispensed into the trough 36 at a central location, or it may be dispensed at multiple locations along the length of the trough 36 . Accordingly, a wide variety of dispensing mechanisms (not shown) could be used for this purpose. The dispensing mechanism also can either continuously supply the coating material into the trough 36 or only periodically dispense the coating material 38 . The rate at which the material 38 is provided into the trough 36 will depend, at least in part, on the rate at which the material 38 is being transferred to the substrate 12 .
[0029] At least when received centrally in the trough 36 , because of its viscous nature, the coating material 38 will initially pool in the central region of the rollers 32 , 34 . This collected pool of coating material 38 will eventually elongate, as a result of the rotating action of the nip and conditioning rollers 32 , 34 . The elongated coating material 38 forms a log 42 within the trough 36 that extends approximately the entire length of the nip and conditioning rollers 32 , 34 . As the coating material 38 is elongated by the counter rotating action of the rollers 32 , 34 , a certain amount of the coating material 38 adheres to the nip roller 32 . The coating material's affinity for the chrome plated steel of the conditioning roller 34 is less than that for the EPDM material of the nip roller 32 and, therefore, a lesser amount of the coating material 38 adheres to the conditioning roller 34 .
[0030] The nip roller 32 is positioned such that the nip roller 32 contacts the upper surface 44 of the substrate 12 , as the substrate 12 is being conveyed on the conveyor belt 26 through the coating station 16 . It is therefore desirable for the rotational speed of the nip roller 32 to correspond with the speed at which the substrates 12 are being conveyed in the production line 10 . In a preferred embodiment, substrates 12 are being conveyed by the conveyor belt 26 at the rate of about 16 feet/minute. By contacting the upper surface 44 of the substrate 12 , an amount of the coating material 38 is transferred from the nip roller 32 to the upper surface 44 of the substrate 12 .
[0031] With the coating material 38 applied to the upper surface 44 of the substrate 12 , this coated substrate 12 next encounters the texturing station 18 of the production line 10 . In the texturing station 18 , the coating material 38 on the substrate 12 is provided with a texture or pattern that becomes the ultimate surface texture/pattern on the resulting wall board 13 . In the illustrated embodiment, this is achieved by providing a doctor blade 46 downstream of the nip roller 32 and before the curing station 20 .
[0032] As noted above, the doctor blade 46 imparts the textured/pattern into the coating material 38 on the substrate 12 . To achieve this, the doctor blade 46 has a profiled lower edge 48 that is encountered by the coating material 38 . This is more readily seen in FIGS. 2 and 3 . The peripheral edge 48 is provided with a series of recesses 50 that correspond to the desired pattern or texture that is to be formed in the coating material 38 on the substrate 12 . The recesses 50 may have common depths or be of different depth, and may be equally spaced on the profiled edge 48 or spaced at different or repeating intervals. Additionally, the recesses 50 themselves can have a variety of shapes, including, without limitation, semi-circular, oval, ellipsoidal, rectangular or another polygonal shape, and partial portions thereof. The recesses 50 may also be provided along the profiled edge so as to define either a random series of recesses or a repeating series of recesses.
[0033] As the coated substrate 12 is conveyed past the doctor blade 46 , the recesses 50 of the profiled edge 48 shape the coating material 38 , which results in the pattern of the profiled edge 48 being transferred to the coating material 38 . To achieve this, the profiled edge 48 of the doctor blade 46 brought into contact the upper surface 44 of the substrate 12 . The profiled edge 48 may, however, only contact the coating material 38 in order to form the texture therein.
[0034] If the texture is to form a linear design on the wall board 13 , then the doctor blade 46 is maintained stationary relative to the passing substrate 12 . However, in an alternative embodiment, the doctor blade 46 need not remain stationary. Rather, it can be moved either transversely relative to the movement of the substrates 12 or it can be moved in a vertical direction (normal to the surface 44 of the substrate 12 ) to form a non-linear pattern or uneven surface.
[0035] It should also be noted that the doctor blade 46 can be provided in different configurations. For example, the doctor blade 46 could be provided in the form of an additional roller having a patterned surface which imprints the coating material 38 with the texture. In a further embodiment, the doctor blade 46 could be provided as a plate having a pattern formed on its surface, and which is periodically pressed into the coating material 38 so as to form a texture therein.
[0036] Once the texture has been formed in the coating material 38 on the substrate 12 , the substrate 12 is then transferred to the curing station 20 . The curing station 20 of the present invention uses ultraviolet (UV) light within a UV oven 52 to cure the coating. While the term “oven” is used herein, it should be understood that the UV oven 52 need not necessarily develop or provide heat, other than that which is incidentally formed in the UV oven 52 by the UV lamps. To achieve this, the UV oven 52 is provided with series of UV lamps or sources 54 that emit an amount of ultraviolet light that is sufficient to fully or substantially fully cure (dry and harden) the coating material 38 within the time period that the substrate 12 is located within the UV oven 52 , which may be only about 15 to 30 seconds. As a result of this photochemical process, upon exiting the UV oven 52 the coated substrate 12 has been converted into the wallboard 13 and has a hardened, textured surface provided thereon. From the UV oven 52 of the curing station 20 , the wall board 13 proceeds to the out-feed station 22 where the wallboard 13 may be stacked and packaged for shipment or transferred for further process. As an example of further processing, the finished wallboard 13 may be transferred to another production line where the textured surface of the wallboard 13 has a primer or paint coating applied to it. Notably, these primer/painting stations could be fully integrated with the production line 10 of FIG. 1 , if desired.
[0037] The substrates 12 utilized in the present invention are generally planar and are constructed of a material that is suitable for the desired purpose, which as described herein is for use as wallboard, although the invention is not intended to be limited the manufacture of products only for such purposes. Once preferred substrate 12 is a board or panel known as a magnesia board or a magnesium oxide board. As the later name implies, this substrate 12 includes magnesium oxide as one of its principal components. In such a board, magnesium oxide is combined with a cement product, and a variety of other materials, the combination of which is then cast to form a rigid panel. Since the manufacturing of magnesium oxide boards is well known, further discussion of this technology is not provided herein.
[0038] As it is apparent from the prior discussion, the coating material 38 used in the present invention is a UV curable material. Such materials are often based upon epoxy, acrylates, urethane acrylates, polyester acrylates, polyether acrylates, amino modified polyether acrylates, acrylic acrylates and various other acrylates. Such coatings can also be based upon unsaturated polyester with styrene, for example. The above identification of chemical families is only intended to be illustrative and should not be considered as limiting the chemical family upon which the UV coating materials used with the present invention can be based. The particular composition of the UV coating material will ultimately depend on the intended end use of the wallboard 13 and the desired performance characteristics.
[0039] As a person skilled in the art will readily appreciate, the above description is meant as an illustration of implementation of the principles this invention. This description is not intended to limit the scope or application of this invention in that the invention is susceptible to modification, variation and change, without departing from spirit of this invention, as defined in the following claims.
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A method for manufacturing a substrate having a textured surface. The method including the steps of: providing a substrate having a surface; applying a coating material onto the surface of the substrate; texturing the coating material on the surface of the substrate to form a textured coating; exposing the textured coating on the substrate to ultraviolet light for a duration of time sufficient to fully cure the textured coating on the substrate; and thereby forming a fully cured textured surface on the substrate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The field of the invention is AC induction motor drives and more specifically the area of injecting high frequency voltage signals into an AC induction motor and using high frequency feedback signals to identify stator frequency and flux position.
Induction motors have broad application in industry, particularly when large horsepower is needed. In a three-phase induction motor, three phase alternating voltages are impressed across three separate motor stator windings and cause three phase currents therein. Because of inductances, the three currents typically lag the voltages by some phase angle. The three currents produce a rotating magnetic stator field. A rotor contained within the stator field experiences an induced current (hence the term “induction”) which generates a rotor field. The rotor field typically lags the stator field by some phase angle. The rotor field is attracted to the rotating stator field and the interaction between the two fields causes the rotor to rotate.
A common rotor design includes a “squirrel cage winding” in which axial conductive bars are connected at either end by shorting rings to form a generally cylindrical structure. The flux of the stator field cutting across the conductive bars induces cyclic current flows through the bars and across the shorting rings. The cyclic current flows in turn produce the rotor field. The use of this induced current to generate the rotor field eliminates the need for slip rings or brushes to provide power to the rotor, making the design relatively maintenance free.
To a first approximation, the torque and speed of an induction motor may be controlled by changing the frequency of the driving voltage and thus the angular rate of the rotating stator field. Generally, for a given torque, increasing the stator field rate will increase the speed of the rotor (which follows the stator field). Alternatively, for a given rotor speed, increasing the frequency of the stator field will increase the torque by increasing the slip, that is the difference in speed between the rotor and the stator fields. An increase in slip increases the rate at which flux lines are cut by the rotor, increasing the rotor generated field and thus the force or torque between the rotor and stator fields.
Referring to FIG. 1, a rotating phasor 1 corresponding to a stator magneto motive force (“mmf”) will generally have some angle α with respect to the phasor of rotor flux 2 . The torque generated by the motor will be proportional to the magnitudes of these phasors 1 and 2 but also will be a function of their angle α. Maximum torque is produced when phasors 1 and 2 are at right angles to each other whereas zero torque is produced if the phasors are aligned. The stator mmf phasor 1 may therefore be usefully decomposed into a torque producing component 3 perpendicular to rotor flux phasor 2 and a flux component 4 parallel to rotor flux phasor 2 .
These two components 3 and 4 of the stator mmf are proportional, respectively, to two stator current components: i q , a torque producing current, and i d , a flux producing current, which may be represented by quadrature or orthogonal vectors in a rotating or synchronous frame of reference (i.e., a reference frame that rotates along with the stator flux vector) and each vector i q and i d is characterized by slowly varying DC magnitude.
Accordingly, in controlling an induction motor, it is generally desired to control not only the frequency of the applied voltage (hence the speed of the rotation of the stator flux phasor 1 ), but also the phase of the applied voltage relative to the current flow and hence the division of the currents through the stator windings into the i q and i d components. Control strategies that attempt to independently control current components i q and i d are generally referred to as field oriented control strategies (“FOC”).
Generally, it is desirable to design FOC strategies that are capable of driving motors of many different designs and varying sizes. Such versatility cuts down on research, development, and manufacturing costs and also results in easily serviceable controllers. Unfortunately, while versatile controllers are cost-effective, FOC controllers cannot control motor operation precisely unless they can adjust the division of d and q-axis currents through the stator windings to account for motor-specific operating parameters. For this reason, in order to increase motor operating precision, various feedback loops are typically employed to monitor stator winding currents and voltages and/or motor speed. A controller uses feedback information to determine how the inverter supplied voltage must be altered to compensate for system disturbances due to system specific and often dynamic operating parameters and then adjusts control signals to supply the desired inverter voltages.
To this end, in an exemplary FOC system, two phase d and q-axis command currents are provided that are calculated to control a motor in a desired fashion. The command currents are compared to d and q-axis motor feedback currents to generate error signals (i.e., the differences between the command and feedback currents). The error signals are then used to generate d and q-axis command voltage signals which are in turn transformed into three phase command voltage signals, one voltage signal for each of the three motor phases. The command voltage signals are used to drive a pulse width modulated (PWM) inverter that generates voltages on three motor supply lines. To provide the d and q-axis current feedback signals the system typically includes current sensors to sense the three phase line currents and a coordinate transformation block is used to transform the three phase currents to two phase synchronous dq frame of reference feedback currents.
In addition to requiring two phase signals and three phase signals to perform 2-to-3 and 3-to-2 phase transformations, respectively, a precise flux position angle estimate θ′ m is also required. One common way to generate a flux angle feedback estimate is to integrate a stator frequency. A stator frequency can be determined by adding a measured rotor frequency (rotor speed) and a calculated slip frequency. In the case of drives that do not include a rotor speed sensor, it is necessary to estimate both the rotor frequency and the slip frequency to determine the flux angle. Thus, these drives require precise knowledge of motor parameter values.
In an effort to reduce system costs and increase reliability, the controls industry has recently developed various types of sensorless or self-sensing induction machine systems that, as the labels imply, do not include dedicated speed sensing hardware and corresponding cabling but that, nevertheless, can generate accurate position, flux and velocity estimates. Techniques used for operating parameter estimation can be divided into two groups including techniques that track speed dependent phenomenon and techniques that track spatial saliencies in system signals. These techniques generally use disturbances in d and q-axis feedback currents to identify the operating parameters of interest and hence provide additional functionality which, in effect, “piggy-backs” on feedback signals that are obtained for another purpose (i.e., dq current components are already required for FOC).
Because speed dependent techniques depend on speed in order to generate an identifiable feedback signal, these techniques ultimately fail at zero or low (e.g., below 5 Hz) excitation frequency due to lack of signal. In addition, because these methods estimate operating parameters from voltage and current, these techniques are sensitive to temperature varying system parameters such as stator resistance, etc.
One type of saliency tracking technique includes injecting or applying a known high frequency “injection” voltage signal in addition to each of the command voltage signals used to drive the PWM inverter and using feedback current (or voltage) signals to identify saliencies associated with the flux angle. To this end, an exemplary system converts a high frequency command signal into a high frequency phase angle and generates a first injection signal that is the product of a scalar and the sine of the high frequency phase angle. Second and third injection signals are also generated, each of the second and third signals phase shifted from the first signal by 120 degrees. A separate one of the first, second and third signals is then added to a separate one of the three voltage command signals that are used to drive the PWM inverter.
One injection type saliency tracking algorithm to generate a flux position angle estimate without a rotor speed sensor employs a negative sequence of the high frequency current component and is described in an article that issued in the IEEE Transactions on Industry Applications publication, vol. 34, No. 5, September/October 1998 by Robert Lorenz which is entitled “Using Multiple Saliencies For The Estimation Of Flux Position, And Velocity In AC Machines” (hereinafter “the Lorenz article”). The algorithm in the Lorenz article is based on the fact that when a high frequency voltage signal (referred to in the Lorenz article as a “carrier signal”) is injected into a rotating system, a resulting high frequency field interacts with system saliency to produce a “carrier” signal current that contains information relating to the position of the saliency. The carrier current consists of both positive and negative-sequence components relative to the carrier signal voltage excitation. While the positive sequence component rotates in the same direction as the carrier signal voltage excitation and therefore contains no spatial information, the negative-sequence component contains spatial information in its phase. The Lorenz article teaches that the positive sequence component can be filtered off leaving only the negative-sequence component which can be fed to an observer used to extract flux angle position information.
Unfortunately, algorithms like the algorithm described in the Lorenz article only works well if an induction machine is characterized by a single sinusoidally distributed spatial saliency. As known in the art, in reality, motor currents exhibit more than a single spatial saliency in part due to the fact that PWM inverters produce a plethora of harmonics. As a result, the phase current negative sequence comprises a complicated spectrum that renders the method described in the Lorenz article relatively inaccurate.
Injection type saliency tracking algorithms employ a zero sequence high frequency current or voltage component instead of the negative sequence current component. One such technique is described in an article that issued in the IEEE IAS publication, pp. 2290-2297, Oct. 3-7, 1999, Phoenix Ariz., which is entitled “A New Zero Frequency Flux Position Detection Approach For Direct Field Orientation Control Drives” (hereinafter “the Conseli article”). The Conseli article teaches that the main field of an induction machine saturates during system operation which causes the spatial distribution of the air gap flux to assume a flattened sinusoidal waveform including all odd harmonics and dominated by the third harmonic of the fundamental. The third harmonic flux component linking the stator windings induces a third harmonic voltage component (i.e., a voltage zero sequence) that is always orthogonal to the flux component and that can therefore be used to determine the flux position. Unfortunately, the third harmonic frequency is low band width and therefore not particularly suitable for instantaneous position determination needed for low speed control.
The Conseli article further teaches that where a high frequency signal is injected into a rotating system, the injected signal produces a variation in the saturation level that depends on the relative positions of the main rotating field and high frequency rotating field. Due to the fundamental component of the main field, the impedance presented to the high frequency injected signal varies in space and this spatial variance results in an unbalanced impedance system. The unbalanced system produces, in addition to the fundamental zero sequence component of air gap flux and voltage, additional high frequency components having angular frequencies represented by the following equation:
ω oh1 =ω h ±ω 1 Eq. 1
where:
ω oh1 =the high frequency voltage zero sequence component frequency;
ω h =the high frequency injection signal frequency;
ω 1 =fundamental stator frequency first harmonic frequency; and
where the sign “±” is negative if the high frequency “injected” signal has a direction that is the same as the fundamental field direction and is positive if the injected signal has a direction opposite the fundamental field direction.
In this case, referring to FIGS. 2 a and 2 b , a zero sequence air gap flux component λ ohf that results from the complex interaction of the zero sequence flux produced by the fundamental component and the impressed high frequency injected signals induce a zero sequence voltage component V ohf on the stator winding that always leads the zero sequence flux component λ ohf by 90°. The maximum zero sequence flux component λ ohf always occurs when the main and high frequency rotating fields are aligned and in phase and the minimum zero sequence flux component λ ohf always occurs when the main and high frequency rotating fields are aligned but in opposite phase. Thus, in theory, by tracking the zero crossing points of the high frequency zero sequence component V ohf and the instances when minimum and maximum values of the high frequency zero sequence voltage component V ohf occur, the position of the high frequency rotating field Θ h can be used to determine the main air gap flux position Θ m .
For instance, referring to in FIGS. 2 a and 2 b , and also to FIGS. 9 and 10, at time t 1 (see FIG. 9) when voltage V ohf is transitioning from positive to negative and crosses zero, the main field F m is in phase and aligned with the high frequency flux λ ohf (i.e., field F h ) which lags voltage V ohf by 90° and therefore main field angle Θ m is Θ h −π/2 (where Θ h is the high frequency injected signal angle). As indicated in FIG. 2 b , at time t 1 voltage V ohf has a zero value. Nevertheless, in FIG. 9 voltage V ohf is illustrated as having a magnitude so that angle Θ h is illustrated as having a magnitude so that angle Θ h can be illustrated. Similar comments are applicable to FIG. 10 and time t 3 .
At time t 2 where voltage V ohf reaches a minimum value, the main field F m and flux λ ohf are in quadrature and therefore main field angle Θ m can be expressed as Θ h −π (i.e., 90° between signal V ohf and flux λ ohf and another 90° between flux λ ohf and main field f m for a total of π). At time t 3 (see FIG. 10) where voltage V ohf is transitioning from negative to positive through zero, the main field is out of phase with flux λ ohf and therefore main field angle Θ m can be expressed as Θ h −3π/2. Similarly, at time t 4 voltage V ohf reaches a maximum value with the main field F m and flux λ ohf (i.e., field F h ) again in quadrature and main field F m leading flux λ ohf and therefore main field angle Θ m is equal to high frequency angel Θ h .
Unfortunately, as in the case of the negative current component signal employed by Lorenz, high frequency zero sequence feedback signals contain a complicated harmonic spectrum mostly due to the PWM technique employed where the spectrum can be represented by the following equations:
ω oh1 =±ω h ±ω 1 Eq. 2
ω oh2 =±ω h ±ω 2 Eq. 3
ω oh4 =±ω h ±ω 4 Eq. 4
ω oh6 =±ω h ±ω 6 , etc. Eq. 5
where:
ω oh1 , ω oh2 , ω oh4 , etc., are components of a harmonic spectrum of a high frequency current (or voltage) zero sequence signal and ω 1 , ω 2 , ω 4 , etc., are the 1 st , 2 nd , 4 th , etc harmonic frequencies of the fundamental stator frequency. The ± signs are determined according to the convention described above with respect to Equation 1. The complicated zero sequence spectrum renders the method described in the Conseli article relatively inaccurate.
In light of the shortcomings of existing sensorless control systems, it would be advantageous to have a relatively inexpensive and simple method and apparatus that generates an accurate flux position estimate for use in induction motor control systems without requiring a rotor speed sensor and that is preferably implemented in software.
BRIEF SUMMARY OF THE INVENTION
When a high frequency injection signal is injected into an induction based system which is operating at a stator fundamental frequency, the high frequency signal interacts with the stator field to generate a resulting high frequency current (and corresponding voltage) that has a complicated initial high frequency spectrum. Not surprisingly, the initial spectrum includes a component at the injection frequency as well as components (hereinafter “sideband components”) at various frequencies within sidebands about the injection frequency that are caused by inverter harmonics as well as interaction between system saliencies and the injected signals. The sideband components are at frequencies equal to the injection frequency plus or minus multiples of the fundamental frequency. For instance, where the injection frequency is 500 Hz and the fundamental frequency is 2 Hz, the sideband components may include frequencies of 494 Hz, 496 Hz, 498 Hz, 502 Hz, 504 Hz, 506 Hz, etc.
In addition, it has been recognized that, given a specific motor control system configuration (i.e., specific hardware and programmed operation), a dominant sideband frequency has the largest amplitude. This dominant sideband frequency for the system configuration always corresponds to the sum of the injection frequency and a specific harmonic of the fundamental where the specific harmonic number is a function of system design and operating parameters. For instance, given a first system configuration, the system specific dominant sideband frequency may be the sum of the injection frequency and the 4th harmonic of the fundamental while, given a second system configuration, the system specific dominant sideband frequency may be the sum of the injection frequency and the 2nd harmonic of the fundamental frequency. The harmonic with the largest amplitude that is added to the injection frequency to obtain the dynamic sideband frequency corresponding to a specific system is referred to hereinafter as the system specific dominant harmonic number (DHN). For instance, in the two examples above the system specific DHNs are 4 th and 2 nd , respectively.
Moreover, it has been recognized that during a commissioning procedure, the system specific DHN can be determined using a FFT analysis or using a spectrum analyzer or some other similar type of device. Thus, in the case of the first and second exemplary systems above, the 4th and 2nd harmonics would be identified, respectively, as corresponding system specific DHNs.
In light of the above realizations, the present invention has been designed to strip the injection frequency value out of each initial spectrum frequency thereby generating a low frequency spectrum including a separate frequency corresponding to each of the initial spectrum frequencies. For instance, in the above example where the fundamental and injection frequencies are 2 Hz and 500 Hz, respectively, and assuming sideband frequencies within the initial spectrum at 494 Hz, 496 Hz, 498 Hz, 502 Hz, 504 Hz and 506 Hz, after stripping, the low frequency spectrum includes modified sideband frequencies at −6 Hz, −4 Hz, −2 Hz, 2 Hz, 4 Hz and 6 Hz.
After the low frequency spectrum value has been generated, the low frequency spectrum value is mathematically combined with the system specific DHN and the resulting combination is the stator frequency value (i.e., the fundamental frequency). More specifically, the low frequency spectrum value is divided by the system specific DHN thereby generating a modified frequency spectrum where the dominant frequency value is the fundamental frequency (i.e., fundamental frequency value has the largest amplitude).
More specifically, at least one embodiment of the invention filters out the positive sequence components of the high frequency feedback currents and generates stationary high frequency α and β-axis negative-sequence components. These stationary components are orthogonal and together include the noisy initial spectrum about the high injection frequency.
As well known in the art, in the case of any stationary to synchronous component signal conversion, an angle that corresponds to the rotating components must be known. Where the angle is accurate, the resulting synchronous d and q-axis components are essentially DC values. However, where the angle is inaccurate, the resulting components fluctuate and the resulting d and q-axis components are not completely synchronous.
In the exemplary embodiment of the invention, a phase locked loop (PLL) adaptively generates a high frequency angle estimate that includes components corresponding to all high frequencies in the stationary α and β-axis negative sequence components. The angle estimate is used to convert the stationary high frequency α and β-axis negative-sequence components to synchronous d and q-axis negative-sequence components. Thereafter, one of the d or q-axis components is negated and the resulting negated or difference value is fed to a PI controller or the like to step up the difference value and generate the low frequency spectrum.
The angle estimate is adaptively generated by adding the high injection frequency and the low frequency spectrum to generate a combined frequency spectrum and then integrating the combined frequency spectrum. Thus, the angle estimate is accurate when the combined frequency spectrum matches the actual frequency spectrum that exists in the stationary α and β-axis negative sequence components and, where there is a difference between the combined frequency spectrum and the stationary α and β-axis components, that difference is reflected in the synchronous d and q-axis components which adaptively drive the PI regulator and adjusts the low frequency spectrum.
The low frequency spectrum is combined mathematically with the system specific dominant harmonic number to generate a stator fundamental frequency estimate. After the stator frequency is identified, the stator frequency can be integrated to generate an air gap flux angle estimate Θ m and other operating parameters of interest in control systems.
Thus, it should be appreciated that the present invention provides a simple solution for quickly identifying an accurate stator frequency estimate despite a harmonic feedback signal. The solution described here is inexpensive and can be implemented in software and performed using conventional control system hardware.
According to another embodiment of the invention, instead of employing the three phase feedback currents to identify the complex frequency spectrum, a zero sequence voltage signal may be employed. To this end, unlike the case where the high frequency current is resolved into quadrature d and q-axis components, the zero sequence embodiment includes a feedback loop that only senses and feeds back a single common mode component. Nevertheless, to drive a PLL it is advantageous to regulate quadrature signal sets.
With the zero sequence voltage feedback signal being a stationary α-axis signal, an artificial stationary β-axis signal can be generated by integrating the α-axis signal to generate an integrated signal, low pass filtering the integrated signal to generate a filtered signal and subtracting the filtered signal from the integrated signal thereby providing the high frequency component of the integrated signal as the β-axis signal. Consistent with the high frequency current example described above, after the α and artificial β-axis components are generated, the stationary α and β-axis signals are converted to synchronous high frequency d and q-axis signals and one of the d or q-axis signals is used to drive the PLL. Operation of the PLL in this embodiment is similar to operation of the embodiment described above.
Yet one other embodiment of the invention includes substituting a current zero sequence feedback loop for the voltage zero sequence feedback loop but operates in the same fashion as described above (i.e., generates an artificial stationary β-axis component to drive the PLL along with the zero sequence current component as the α-axis component).
More specifically, the invention includes a method for determining a stator fundamental operating frequency in a three phase induction machine where the machine is characterized by a system specific dominant harmonic frequency number. Here, the method comprising the steps of injecting a high frequency voltage signal having a high frequency into the machine thereby generating a high frequency current within the stator windings, identifying stationary two phase high frequency feedback signal components that includes stator field position information, identifying a low frequency spectrum corresponding to the feedback signal components, mathematically combining the low frequency spectrum and the system specific dominant harmonic number to generate a stator fundamental frequency estimate.
In at least some embodiments the step of identifying the feedback signal includes identifying the stationary two phase negative sequence components of the high frequency stator winding current. Here the high frequency signal is characterized by a high frequency phase angle and the step of identifying the stationary two phase negative sequence components of the high frequency stator winding current may include the steps sensing two of the three-phase currents from the stator windings, converting the two three-phase currents to synchronous two phase currents using the high frequency phase angle, filtering the synchronous currents to generate intermediate synchronous two phase negative-sequence components and converting the intermediate components to stationary two phase negative sequence components using the high frequency angle. The filtering step may be either a high or low pass filtering step.
In some embodiments the step of identifying a low frequency spectrum includes converting the stationary components to synchronous two phase negative sequence components using a high frequency angle estimate, subtracting one of the synchronous negative sequence components from a DC value to generate a difference value and stepping up the difference value to generate the low frequency spectrum. Here, the angle estimate may be determined by adding the low frequency spectrum and the high frequency to generate a combined frequency spectrum and integrating the combined frequency spectrum.
The method may also include the step of identifying the system specific dominant harmonic number during a commissioning procedure and storing the dominant harmonic number for subsequent use.
In other embodiments the step of identifying the feedback signal includes identifying one of a high frequency zero sequence voltage component and a high frequency zero sequence current component as a first of the two phase components, integrating the first component to generate an integrated signal, low pass filtering the integrated signal to generate a low frequency component and subtracting the low frequency component from the integrated signal to generate the second of the two phase components.
The invention also includes an apparatus to be used with the aforementioned methods and, to that end, includes an apparatus for determining a stator fundamental operating frequency in a three phase induction machine where the machine is characterized by a system specific dominant harmonic frequency number. Here, the apparatus comprises a generator for injecting a high frequency voltage signal having a high frequency into the machine thereby generating a high frequency current within the stator windings, a module for identifying stationary two phase high frequency feedback signal components that includes stator field position information, a module for identifying a low frequency spectrum corresponding to the feedback signal components, a module for mathematically combining the low frequency spectrum and the system specific dominant harmonic number to generate a stator fundamental frequency estimate.
The module for identifying the feedback signal may include a module for identifying the stationary two phase negative sequence components of the high frequency stator winding current. Here, the high frequency signal is characterized by a high frequency phase angle and the module for identifying the stationary two phase negative sequence components of the high frequency stator winding current may include a sensor for sensing at least two of the three-phase currents from the stator windings, a converter for converting the three-phase currents to synchronous two phase currents using the high frequency phase angle, a filter for filtering the synchronous currents to generate intermediate synchronous two phase negative-sequence components and a converter for converting the intermediate components to stationary two phase negative sequence components using the high frequency angle.
The module for identifying a low frequency spectrum in some embodiments includes a converter for converting the stationary components to synchronous two phase negative sequence components using a high frequency angle estimate, a summer for subtracting one of the synchronous negative sequence components from a DC value to generate a difference value and a controller for stepping up the difference value to generate the low frequency spectrum. The apparatus may further include a summer for adding the low frequency spectrum and the high frequency to generate a combined frequency spectrum and an integrator for integrating the combined spectrum to generate the angle estimate.
In other embodiments the module for identifying the feedback signal includes a module for identifying one of a high frequency zero sequence voltage component and a high frequency zero sequence current component as a first of the two phase components, an integrator for integrating the first component to generate an integrated signal, a low pass filter for filtering the integrated signal to generate a low frequency component and a summer for subtracting the low frequency component from the integrated signal to generate the second of the two phase components.
These and other objects, advantages and aspects of the invention will become apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made therefore, to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a schematic view in cross section of an induction motor showing instantaneous locations of a rotor flux, a stator mmf and the torque and flux components of the stator mmf;
FIGS. 2 a and 2 b are related graphs where FIG. 2 a illustrates an exemplary high frequency angle and FIG. 2 b illustrates corresponding high frequency zero sequence voltage and flux signals;
FIG. 3 is a schematic diagram of a motor control system according to the present invention;
FIG. 4 is a schematic illustrating one embodiment of the flux angle and position determiner of FIG. 3;
FIG. 5 is similar to FIG. 4, albeit of a second embodiment of the determiner identifier of FIG. 3;
FIG. 6 is a flow chart illustrating one inventive method;
FIG. 7 is a flow chart illustrating one of the method steps of FIG. 6 in greater detail and corresponds to the configuration illustrated in FIG. 4;
FIG. 8 is similar to FIG. 7 albeit corresponding to the embodiment illustrated in FIG. 5;
FIG. 9 is a phasor diagram illustrating the relationship between various system operating parameters in a system including a high frequency injection voltage; and
FIG. 10 is similar to FIG. 9 albeit at a different instant in time.
DETAILED DESCRIPTION OF THE INVENTION
In the description that follows, an “*” superscript denotes a command signal, an “f” subscript denotes a feedback signal, an “h” subscript denotes a high frequency signal, an “i” denotes that a corresponding signal relates to a current signal, a “V” denotes that a signal relates to a voltage signal, an “r” subscript denotes a signal relates to a motor rotor, an “s” subscript denotes a signal relates to a motor stator, a “d” subscript denotes that a signal corresponds to a synchronous d-axis, a “q” subscript denotes that a signal corresponds to a synchronous q-axis, “u”, “v” and “w” subscripts denote that corresponding signals relate to each of first, second and third system phases, an “n” subscript denotes that a signal is a negative sequence signal, a “0” subscript denotes that a signal is a zero sequence signal, an “α” subscript denotes a stationary α-axis signal and a “β” subscript denotes a stationary β-axis signal.
While the following description details various blocks, steps, and functions, it should be remembered that all of these elements are meant to be implemented in software as computer programs and represent algorithms for execution by a conventional-type digital processor adapted for industrial applications.
Referring now to the drawings wherein like reference characters represent similar elements and signals throughout the several views and, more specifically, a referring to FIG. 3, the present invention will be described in the context of an exemplary motor control system 10 including a plurality of summers 12 , 14 , 20 , 22 and 24 , a plurality of multipliers 34 , 36 and 38 , a current regulator 16 , a 2-3 phase and synchronous to stationary frame transformer 18 , a PWM inverter 26 , a three phase motor 28 , an integrator 30 , a sign table 32 , an A-D converter 40 , a 3-2 phase and stationary to synchronous frame transformer 42 , a flux angle position-speed determiner 46 , a scalar 41 and at least one notch filter 52 . In addition, depending on the system configuration employed, the system may further include one of a voltage zero sequence determiner 69 , a current zero sequence determiner 67 and a band pass filter 50 . A first embodiment of the invention to be described includes bandpass filter 50 and does not include identifiers 69 and 67 . Subsequently described embodiments include one of identifiers 67 and 69 .
Generally, system 10 receives two phase current command signals i* q and i* d and, based thereon, generates three phase voltages on motor supply lines linked to motor 28 to drive motor 28 in a desired fashion. The three phase voltages V* u , V* v and V* w together generate currents within each of the three motor phases. At least two of the three phase currents are sensed using hall effect sensors or some other suitable sensors (not numbered) and are provided as feedback currents to a feedback loop that is provided to eliminate the difference between the command currents i* q and i* d and the resulting currents delivered to motor 28 .
Command currents i* q and i* d are provided to summers 14 and 12 , respectively. The three phase motor currents are converted in a manner which will be described in more detail below to two phase d and q access feedback currents i df and i qf , respectively, the two phase feedback currents i df and i qf being provided to summers 12 and 14 , respectively. Summer 12 subtracts the d-axis feedback current i df from the d-axis command current i* d to generate a d-axis error signal, which is provided to regulator 16 . Similarly, summer 14 subtracts the q-axis feedback current i qf from the q-axis command current i* q to generate an error signal, which is provided to regulator 16 . Regulator 16 converts the current error signals to command voltage signals V* q and V* d , which are provided to 2-3 phase and synchronous to stationary frame transformer 18 .
Transformer 18 receives an electrical phase angle Θ c from determiner 46 and, using the received angle, coverts the command voltages V* q and V* d to three phase command voltages V* u , V* v and V* w . The three phase command voltages are provided to summers 20 , 22 and 24 , respectively. Each of summers 20 , 22 and 24 also receives a high frequency injection voltage signal. Generation of the high frequency injection voltage signals is described in more detail below. Summer 20 adds the received signals (i.e., command signal V* u and the high frequency injection voltage signal) and generates a modified single-phase voltage signal V um , which is provided to inverter 26 . Similarly, each of summers 22 and 24 adds their respective received signals and provides an output modified voltage signal V vm and V wm , respectively, to inverter 26 . Inverter 26 uses the modified voltage signals V um , V vm and V wm to generate the three phase voltages V v , V u and V w on the motor supply lines.
Referring still to FIG. 3, in addition to command currents i* q and i* d , two other values are provided as inputs to system 10 and are specifically used to generate the high frequency injection voltage signals that are added to the three phase command voltages V* u , V* v and V* w via summers, 20 , 22 and 24 . Specifically, a peak high frequency magnitude signal V hpeak and a high frequency signal ω h are provided. High frequency signal ω h is provided to determiner 46 and to integrator 30 , which integrates the received signal and provides a high frequency angle signal Θ h to sine table 32 . Sine table 32 has first, second and third outputs which are linked to multipliers 34 , 36 and 38 , respectively. On the first output (i.e., the output linked to multiplier 34 ), sine table 32 provides the sine of high frequency angle Θ h . On the second output (i.e., the output linked to multiplier 36 ), sine table 32 provides the sine of (Θ h +2π/3). On the third output (i.e., the output linked to multiplier 38 ), sine table 32 provides the sine of (Θ h +4π/3). Thus, sine table 32 generates three outputs where the outputs are the sines of angles that are separated by 120°.
The peak high frequency amplitude signal V hpeak is also provided to each of multipliers 34 , 36 and 38 . Multiplier 34 multiplies its received signals to generate the high frequency injection voltage signal provided to summer 20 . Similarly, each of multipliers 36 and 38 multiplies their respective received signals together to generate high frequency injection signals that are provided to summers 22 and 24 , respectively. As indicated above, summers 20 , 22 and 24 add the high frequency signals to the three phase command signals V* u , V* v and V* w to generate the modified voltages V um , V vm and V wm to drive inverter 26 .
Referring still to FIG. 3, the feedback currents from the two of the three motor phases are provided to the analog to digital converter 40 and scalar 41 which convert the received signals to digital signals and step up the signals where appropriate by a scalar number. Scalar 41 provides current feedback signals i v and i w to notch filter 52 . In addition, in the first embodiment of the invention (e.g., the embodiment including bandpass filter 50 ), scalar 41 provides the feedback current signals to bandpass filter 50 . Band pass filter 50 passes only the high frequency feedback components i vhf and i whf to flux angle position/speed determiner 46
Notch filter 52 provides three-phase feedback currents i vf and i wf including components only within a specific notch range. More specifically, the notch range will typically exclude the high frequency ω h provided to integrator 30 . In this manner, the injected high frequency currents should be filtered out and should not directly effect the comparison of command and feedback currents by summers 12 and 14 .
The three phase currents output by notch filter 52 are provided to the three to two phase and stationary to synchronous frame transformer 42 . As well known in the controls art, any two phases of the three are enough for the three to two phase conversion and therefore, transformer 42 uses any two of the three phase feedback currents (e.g., i uf and i wf ) and electrical angle Θ′ e provided by position-speed determiner 46 to generate the d and q-axis feedback currents i df and i qf , respectively. As described above, the d and q-axis feed back currents i df and i qf , respectively, are provided to summers 12 and 14 and are subtracted from corresponding command current signals I′ q and i′ d .
Referring now to FIGS. 3 and 4, position-speed determiner 46 includes a plurality of components arranges to generally form three separate sub-assemblies including a filter module 109 , a stator frequency module 106 and a process module 136 . filter module 109 includes a stationary to synchronous converter 100 , a high pass filter 102 and a synchronous to stationary converter 104 . The stationary to synchronous converter 100 receives the two three-phase feedback currents i vhf and i whf from filter 50 and converts those currents to intermediate two-phase synchronous currents i dh and i qh using the high frequency angle Θ h . The intermediate currents i dh and i qh , consistent with the meaning of synchronous, rotate at the phase angle Θ h . Intermediate currents i dh and i qh are provided to the high pass filter 102 .
The stationary to synchronous converter 100 generates a DC positive-sequence signal component and a negative-sequence component having a frequency twice as large as the stationary frequency. Therefore, the positive-sequence component is filtered out by the high pass filter 102 and filter 102 generates synchronous d and q-axis negative sequence components i dhn and i qhn , respectively. Synchronous to stationary converter 104 receives the negative-sequence components i dhn and i qhn and also receives high frequency angle Θ h and uses angle Θ h to convert the negative-sequence components i dhn and i qhn to stationary α and β-axis negative sequence components i αhn and i βhn . Stationary components i αhn and i βhn are AC signals and includes components that correspond to the current frequency spectrum including the saliencies that occur as a result of interaction between the fundamental stator flux field and the high frequency injected voltage signal. Components i αhn and i βhn are provided to frequency module 106 .
Module 106 includes a stationary to synchronous converter 110 , a memory location 108 , first and second summers 112 and 116 , an integrator 114 , a PI controller 118 , a second memory location 120 and a multiplier 121 . The stationary negative-sequence current components i αhn and i βhn are provided to the stationary to synchronous converter 110 . Converter 110 also receives a high frequency angle estimate Θ′ h from integrator 114 and uses the angle estimate Θ′ h to convert the stationary components i αhn and i βhn to synchronous high frequency d and q-axes negative sequence current components (only d-axis component i′ dhn shown). In the illustrated embodiment, the d-axis synchronous component i′ dhn is provided to summer 112 . It should be appreciated that, instead of employing the d-axis component i′ dhn , the q-axis component (not illustrated) maybe provided to summer 112 .
Summer 112 also receives a DC value from memory location 108 . In the illustrated example, the DC value is zero. As illustrated, summer 112 subtracts the synchronous d-axis component i′ dhn from the zero value and provides its output as a difference value to PI controller 118 . As well known in the art, PI controller 118 steps up the difference value and provides a stepped up output.
In the present configuration, the stepped up output is the low frequency spectrum ω low . The low frequency spectrum ω low is provided to summer 116 which also receives the high frequency signal ω h . Summer 116 adds the low frequency spectrum ω low and the high frequency signal ω h and provides its output as a combined frequency spectrum to integrator 114 . Integrator 114 integrates the combined spectrum to generate the high frequency angle estimate Θ′ h which is in turn provided the stationary to synchronous converter 110 . Referring still to FIG. 4, the low frequency spectrum signal ω low is also provided to multiplier 121 .
Referring still to FIGS. 3 and 4, during a commissioning procedure, prior to operating the system illustrated in FIGS. 3 and 4, a FFT analysis or a spectrum analyzer can be used to identify a system specific DHN. Exemplary and common dominant harmonic numbers may be in the range of the first or fundamental harmonic, the second harmonic, the fourth harmonic, the sixth harmonic, etc. The DHN is stored in memory location 120 and is used during subsequent motor operation.
Multiplier 121 divides low frequency spectrum signal ω low by the system specific DHN which is stored in memory location 120 to generate a modified frequency spectrum ω mod . The modified spectrum ω mod is then filtered (e.g., averaged) by filter 119 thereby generating the stator frequency estimate ω′ s which is provided to module 136 . Multiplier 121 divides low frequency spectrum signal ω low by the system specific DHN which is stored in memory location 120 to generate the stator frequency estimate ω′ s which is provided to module 136 .
Module 136 includes an integrator 126 , first and second summers 124 and 134 , a divider 128 , first and second multipliers 135 and 137 and first and second memory locations 130 and 132 , respectively. Integrator 126 receives the estimated stator frequency ω′ s and integrates the estimated stator frequency signal ω′ s to generate an air gap flux angle estimate Θ′ m . Divider 128 receives the d and q-axis command signals i* d , i* q and divides the q-axis command signal i* q by the d-axis command signal i* d providing an output signal to multiplier 135 .
In addition to identifying and storing the system specific DHN during the commissioning procedure, other system parameters and combinations of parameters may be determined and stored in memory locations 130 and 132 . For instance, a rotor leakage inductance L ρr , a rotor inductance value L r and a rated torque value T r are identified. The rotor leakage inductance L ρr is divided by the rotor inductance L r and the resulting value is stored in memory location 130 . The torque value T r is inverted and the inverted value is stored in memory location 132 .
Referring still to FIG. 4, multiplier 135 multiplies the output signal received from divider 128 by the value in memory location 130 to generate an angle estimate Θ′ mr which corresponds to an estimated angle between the rotor flux and air gap flux in the system. The estimated angle Θ′ mr is provided to summer 124 . In addition to receiving estimated angles Θ′ m and Θ′ mr , summer 124 also receives an initial angle value Θ 0 . Summer 124 adds all three of the received signals to generate a rotor flux angle estimate Θ′ e . As seen in FIG. 3, angle Θ′ e is provided to various transformers (e.g., 18 , 42 , etc.) within the larger control system for performing 2-to-3 and 3-to-2 transformations.
Referring yet again to FIG. 4, the output of divider 128 is also provided to multiplier 137 which multiplies the output signal from divider 128 by the content of memory location 132 to generate a slip frequency estimate ω′ slip . Summer 134 subtracts the slip estimate ω′ slip from the stator frequency estimate ω′ s thereby generating a rotor speed estimate ω′ r . Referring again to FIG. 3, rotor speed estimate ω′ r is provided as an output of determiner 46 .
Referring now to FIG. 5, a second embodiment of the filter module 109 in FIG. 4 is illustrated. Because the embodiment in FIG. 5 performs a similar function to the filter embodiment 109 in FIG. 4, the embodiment of FIG. 5 is identified by the same numeral 109 . However, to distinguish the embodiment of FIG. 5 from the embodiment of FIG. 4, the number 109 in FIG. 5 is followed by a“′”.
Referring also to FIG. 3, this second embodiment includes the zero sequence voltage identifier 69 and would not include either of the bandpass filter 50 or identifier 67 . Identifier 69 receives voltage feedback signals from all three of the motor phases and is also linked to a neutral point of inverter 26 . Identifier 69 includes a bandpass filter to generate the high frequency portion of voltage zero sequence. Operation of identifiers like identifier 69 is well known in the art and therefore will not be explained here in detail. Suffice it to say here that identifier 69 generates zero sequence high frequency voltage signal V ohf that is provided to determiner 46 .
Referring still to FIG. 5, module 109 ′ receives the zero sequence signal V ohf and uses the received signal V ohf to generate stationary high frequency quadrature α and β-axis signals identified as S αh and S βh signals, respectively, where the quadrature signals S αh and S βh include the frequency spectrum corresponding to the overall system illustrated in FIG. 3 .
As illustrated, the high frequency zero sequence feedback voltage V ohf is directly provided as the α-axis signal S α . To generate the β-axis signal S β , module 109 ′ includes an integrator 150 , a summer 154 and a low pass filter 152 . Integrator 150 receives the feedback signal V ohf and integrates that signal thereby providing an integrated signal including a high frequency component S βh and a low frequency component S βl . The integrated signal S βh +S βl , is provided to low pass filter 152 , which, as its label implies, low pass filters the signal so that its output comprises the low frequency component S βl . Summer 154 receives the integrated signal S βh +S βl and subtracts the low frequency component S βl therefrom thereby generating S β which includes the high frequency component S βh . Signal S β is in quadrature with signal S α . Referring now to FIGS. 4 and 5, stationary quadrature signals S α and S β are provided to stator frequency module 106 which operates in a manner described above to generate the stator frequency estimate ω′ s .
Referring again to FIGS. 3, 4 and 5 , in yet another embodiment of the invention, the system 10 would include zero sequence current identifier 67 and would not include identifier 69 or filter 50 . In this case, identifier 67 provides a zero sequence high frequency feedback current I ohf instead of zero sequence voltage V ohf , to module 109 ′ in FIG. 5 . Here module 109 ′ operates in the fashion described above to generate signals S α , and S β that are provided to module 106 .
Referring now to FIG. 6, a flow chart 220 , illustrating operation of the present invention is provided. Beginning at block 224 , during the commissioning procedure, the system specific DHN is identified as well as the rotor leakage inductance L ρr , the rotor inductance L r , the initial angle Θ 0 and the rotor Time Constant T r and those values are stored in the memory locations described above (e.g., 108 , 120 , 130 , 132 , etc.). At block 128 , feedback signals are obtained from the system supply lines. As described above, depending on which embodiment of the invention is configured, the feedback may include either a zero sequence high frequency voltage signal V ohf , a zero sequence high frequency current signal I ohf or two of the three-phase current signals (i.e., I wh and I vh ).
At block 230 , the feedback signals are converted into high frequency two-phase stationary signals that include flux field position information. At block 234 the high frequency two-phase stationary signals are provided to the PLL (see 106 in FIG. 4) and the PLL converter 110 converts the stationary signals to two-phase synchronous signals using the high frequency angle estimate Θ′ h . At block 236 , either the d or q-axis high frequency signal is negated and then at block 238 , the negated signal is provided to PI controller 118 which steps up the received signal thereby generating a low frequency spectrum signal ω low .
Continuing, at block 240 summer 116 adds the high frequency injection signal ω h and the low frequency spectrum signal ω low to provide the combined frequency signal. At block 242 integrator 114 integrates the combined frequency signal to generate the high frequency angle estimate Θ′ h which is provided to converter 110 thereby completing the PLL loop.
Referring still to FIG. 6 and also to FIG. 4, at block 244 , multiplier 121 divides the low frequency spectrum signal ω low by the system specific DHN thereby generating a stator frequency estimate ω′ s . Finally, at block 246 , the stator frequency estimate ω′ s is integrated to generate the air gap flux angle estimate Θ′ m .
Referring now to FIG. 7, the process step of block 230 in FIG. 6 corresponding to a system using two high frequency three-phase feedback signals is illustrated in greater detail. To this end, at block 233 , referring also to FIG. 4, the two high frequency three-phase feedback currents are converted into two-phase quadrature synchronous currents I dhf and I qhf using the high frequency command angle Θ h . Next, at block 231 , the two-phase synchronous current components I dh and I qh are filtered (e.g., either high or low pass filter depending upon how angle Θ h was applied in step 233 ) to generate two-phase synchronous negative sequence high frequency components I dhn and I qhn , respectively. At block 232 , the two-phase synchronous negative sequence components are converted into two-phase stationary negative sequence components using the high frequency current angle Θ h .
Referring now to FIG. 8, the process step 230 in FIG. 6 corresponding to a system that uses a zero sequence high frequency feedback signal is illustrated. To this end, referring also to FIG. 5, at block 250 , integrator 150 integrates the zero sequence high frequency feedback signal to generate an integrated signal S βh +S βl . At block 252 , the integrated signal is low pass filtered by filter 152 thereby generating a low frequency signal S βl which is provided to summer 154 . At block 254 , summer 154 subtracts the low frequency signal S βl from the integrated signal to generate the S β signal where the S β signal is in quadrature with the high frequency zero sequence feedback signal (e.g., V ohf or I ohf ). Continuing, at block 256 , the zero sequence signal S α and the S β signal are provided to the stationary-to-synchronous converter (e.g., see 110 in FIG. 4) in the PLL.
It should be understood that the methods and apparatuses described above are only exemplary and do not limit the scope of the invention, and that various modifications could be made by those skilled in the art that would fall under the scope of the invention.
To apprise the public of the scope of this invention, the following claims are made:
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A method and apparatus for estimating flux angle position in an induction machine, the method including the steps of providing high frequency injection voltage signals to a three-phase motor, obtaining frequency feedback signals from machine supply lines, converting the feedback signals to two-phase stationary high frequency signals, converting the stationary signals to synchronous signals using a high frequency angle estimate, negating one of the resulting synchronous signals, stepping up the negated signal to generate a low frequency spectrum signal, adding the low frequency spectrum signal and the high frequency injection signal to generate a combined spectrum signal and integrating the combined spectrum signal to generate the high frequency angle estimate, dividing the low frequency spectrum by a system specific DHN to generate a stator frequency estimate and integrating the stator frequency estimate to generate the flux angle estimate.
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RELATIONSHIP TO OTHER APPLICATION
This application is a continuation-in-part patent application of U.S. Ser. No. 12/150,754, filed Apr. 29, 2008, now U.S. Pat. No. 7,680,565. U.S. Ser. No. 12/150,754 is a continuation-in-part of U.S. Ser. No. 11/728,214 filed on Mar. 23, 2006, now U.S. Pat. No. 7,366,590, that claims the benefit of U.S. Provisional Patent Application Ser. No. 60/785,080, filed Mar. 23, 2006, the disclosures all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to methods of annunciating impending failure and failure in actuators and drive train components, as well as aircraft control systems.
2. Description of the Prior Art
There are present in the prior art a variety of vibration test systems that enable vibration analysis of operating mechanical systems to determine machine conditions and operating characteristics. In some of these known systems, a handheld device has an associated probe that is touched to an operating machine. The vibrations of the operating machine cause vibrations sensors in the probe to issue corresponding electrical responses that are analyzed by the handheld monitoring device. Although useful in the determination of the operating characteristics of an operating machine, the known vibration test systems are of only limited utility in determining the operating characteristics of mechanical systems that spend little or no time in steady-state modes of operation.
It is a characteristic of actuators, drive train components, vehicle braking systems, that a significant portion of operation time is spent in transient mode. For example, in a screw drive arrangement of the type used for controlling aircraft control surfaces, the operation of the screw drive arrangement is bidirectional over a limited extent. Therefore, this type of drive spends considerable portions of its operating cycles in bidirectional ramp-up and ramp-down transient conditions. Only a small portion of the operating cycle, if any, is spent in a steady-state condition.
In the case of drive train components, it is known that these mechanical systems can be tested in steady-state condition on a bench. However, in actual use, these mechanical systems are operated in acceleration, deceleration, and reverse modes of operation. Again, the known vibration test systems are inadequate to analyze the operating characteristics of drive train components in actual use.
Vehicle braking systems are mechanical arrangements that clearly operate in transient modes. In conventional use, the vehicle brakes are applied while the vehicle is operating at speed, and almost immediately the rate of operation is reduced by deceleration. The effects of such transients are multiplied in vehicle braking systems that are subjected to the stresses of automatic braking systems (ABS).
There is a need in the art for an on-board vibration test system that monitors the operation of a mechanical system of the type that operates principally in transient modes, and develops trend, or historical, data that reflects changes in the operating characteristics of the mechanical system. There is additionally a need for such a system to be useful in the tracing back of the changes in the overall response of the mechanical system to a change in the operating characteristic of a specific component of the mechanical system.
In addition to the foregoing, in embodiments where the mechanical system is a ball screw arrangement, there is a need to determine the health of the bearing balls and the bearing balls recirculation system. One mode of failure of the mechanical system occurs when the bearing balls escape. In such a failure mode, the load is transferred to a secondary nut that operates in an acme mode.
A further form of failure occurs when the balls are seized within the recirculation system. In effect, the ball screw operates in an acme mode, and the load is not transferred to the secondary load path, which often is an acme nut, until the bearing balls become dangerously worn.
A still further form of ball screw failure occurs when the bearing balls become scuffed, which results in accelerated wear. A ball screw arrangement that is operating with scuffed bearing balls is an unhealthy mechanical system that may soon fail.
There are numerous aerospace applications in which redundancy is employed in the design of flight critical mechanisms, by duplicating the load path used to transmit motion. This is achieved through individual sets of components connected in series (chained together), forming independent load paths, intertwined to provide fail safe solutions. These load paths are typically known as Primary Load Path and Secondary Load Path. In certain designs used in pilot controls (for example Helicopter pilot controls), there is a third redundant load path provided, in case both primary and secondary load paths fail.
Statistically, studies indicate that the likelihood of having consecutive failures (for example shearing/fracture of material due to impurities/inclusions in the material matrix, cracks from wrongful heat treatment, fatigue or improper machining, etc.), leading to loss of primary load path and shortly followed by a failure of the secondary load path within the same flight is small, but nevertheless possible.
The mechanisms that are designed with redundant load paths typically control flight critical systems, wherein failure of both load paths is catastrophic. These include, for example, flaps, HSTA, pilot controls linkages, and the like.
A significant problem with some critical control systems, such as flaps, is that the forces applied to the control actuators in use can cause the actuators themselves to become damaged, or to become separated from either the support structure or the flap being controlled.
Current annunciation systems indirectly deduce whether one of the load paths has failed. These known systems reason that there is present a possibility of load path failure by disconnection (separation), by processing other system parameters such as the flap panel position angles at different locations of the wing, and computing the aero-elasticity of the airframe materials (cables, rods, spars, aircraft skin, etc.), at various air speeds, ambient temperatures, and pressures, and through complex algorithms combined with empirical (experimental) data, to define and declare the failure.
The known systems are somewhat reliable, but they use assemblies of expensive components, such as linkages and high precision transducers, and are subject to the engineering design team's capability to assess subjectively or empirically the contributing factors, such as aero-elasticity, material flexibility, and torsional and linear deflections in response to loads applied at various temperatures and pressure. An empirical formula is created that characterizes the state of the mechanism, and defines the step function for the failure diagnostic criteria that will assist in the determination of a declarable failure. By way of example, this could include a function that calculates and allowable degree of angular asymmetry.
There is, therefore, a need in the art for a system and methodology that monitors the health of actuator arrangements that control critical control systems.
There is need in the art for a system that signals failure of a primary control system, whereby the aircraft control system being controlled appears to function normally, but is in fact being controlled by a redundant system, and therefore the aircraft control system is significantly nearer to catastrophic failure.
There additionally is a need in the art for a system that signals the an actuator or a support element for an aircraft control system is being, or has been, subjected to excessive load forces.
There is also a need in the art for a system and methodology that facilitates the vibrational analysis of mechanical systems that operate largely in transient modes.
There is additionally a need for a system that facilitates the determination of impending failure of mechanical systems that operate largely in transient modes.
There is additionally a need for a system that facilitates the determination of actual failure of mechanical systems that operate largely in transient modes.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a system for announcing failure of a mechanically actuated arrangement. A first coupler arrangement couples an actuator to a structural element that is desired to be controlled. A first force sensor coupled to the first coupler arrangement, and the first coupler arrangement and the first force sensor constitute a primary load path. A second coupler arrangement is also provided for coupling the actuator to the structural element that is desired to be controlled. A second force sensor is coupled to the second coupler arrangement, whereby the second coupler arrangement and the second force sensor constituting a secondary load path. Changes in the forces experienced by said first and second force sensors are monitored by a controller/monitor system.
In one embodiment of the invention, the first force sensor is arranged serially with the first coupler arrangement. Similarly, the second force sensor is arranged serially with the second coupler arrangement. In some embodiments, however, the forces experienced by only one of the load paths is monitored.
There is provided in an advantageous embodiment of the invention a connector arrangement having a screw shaft portion for inclusion in the primary load path and a tie rod for inclusion in the secondary load path. Preferably, the tie rod is preloaded. In a highly advantageous embodiment, the tie rod is arranged coaxially with respect to said screw shaft portion.
Axial forces are generated by the actuation of a drive motor. In one embodiment, the drive motor comprises a ball screw arrangement. In a still further embodiment of the invention, there is provided a system for monitoring operating impulses generated by the ball screw arrangement during a predetermined interval of operation.
The controller compares the magnitude of the forces experienced by at least one of the first and second force sensors to a predetermined force value. For example, if a failure should occur in the primary load path, a preload in the secondary load path will be released, and the corresponding change in the forces experienced by the secondary load path will cause a signal to be issued that indicates primary load path failure.
The present invention provides reliable real time load path health monitoring, failure detection and annunciation. This is achieved by employing strain-gage transducers that are incorporated in at least one structural element that has been mounted in series with the load paths.
More specifically, the present detection technology includes the modification of at least one of the load carrying components in the load path. Instrumentation of the structural elements of the load path with strain-gages that will convert the forces applied through the load path component into electrical signals that are proportional thereto.
The force monitoring system of the present invention directly reports information corresponding to the integrity, the health condition, the load carrying capability, and of course failure of a component in a load path under load. This is performed on flight critical mechanisms, such as an aircraft flap system. It is known that during all flight profiles of a flap system (i.e., landing approach flight patterns and take off procedures), the forces developed in the flap actuation mechanism are continuously fluctuating, varying between tension and compression domains, but always at values other than zero. Thus, real time recording and monitoring of flap actuator forces and comparing same with known vital signs, will provide a means to distinguish whether or not the measurements are showing a normal characteristic of a healthy system.
A healthy system will show that the absolute values of the forces being propagated through an actuator, over given period of time, will always be greater than a minimum value. The force monitoring system will record in real time data on the load path forces going through an actuator. The last recorded value (e.g. n), will continuously be monitored and analyzed and compared against a base value. The electronic control unit monitoring and analyzing the load path forces can then determine whether there has been separation of a load path using a simple algorithm. For example, if the forces are below a certain minimum threshold (for example 300 lbf absolute value), for a defined period of time (for example 30 consecutive seconds), the load path is declared to be “disconnected” and a corresponding signal is delivered to the pilots. Flap system operation should in some embodiments of the invention be disabled to avoid actuation of a failed system that could then lead to an enhanced, or catastrophic, failures. A cockpit warning light will be illuminated, and a procedure established that the operation of the flaps should not be overridden without ground maintenance intervention after landing.
The system of the present invention is simple and reliable, and in some embodiments employs only one load sensing component mounted in the actual load path in the form of a force sensing fastener. Such a force sensing fastener can, in some embodiments of the invention, be a known interface adapter, or fastener in the form of a bolt or a pin, that is redesigned to be instrumented with strain-gage transducers that will report in real time the loads (forces) being applied to the particular structural mechanical element.
In some embodiments, the force sensing element is in the form of a bracket, or bolt, or pin, and is designed, built, and calibrated in a laboratory prior to being assembled on the aircraft to levels of accuracy that are appropriate for each application. It is important that measurement of forces be as precise as required by the application, and not necessarily as precise as possible.
In the case of outboard flaps panels that are each controlled by two actuators and designed with single load path, the loss of one actuator by separation/fracture of a load carrying component, will not lead to a crash, because the other actuator is designed to be able to keep the flap panel attached to the aircraft wing. Some flap actuator systems require that each actuator be designed to handle the maximum flap load on its own. Thus, depending upon the type of failure that will lead to the loss of the first actuator, it is possible that the second actuator is still operational and will be able to retract (stow), and extend the flap panel. The continuation of flight activity without knowledge of load path failure of the first actuator (through component fracture, ball bearings loss, trunnions shear, etc.), can result in catastrophic failure of the flap system. This can happen particularly if the second actuator that controls the subject flap panel fails by separation, followed by an imminent complete separation (detachment) of the flap panel. The loss of a flap panel can result in a crash due to the asymmetry in lift forces between the aircraft wings. More particularly, the wing that has lost a flap panel will produce a reduced lift force relative to the opposite wing that has its associated flap panel in place. This unbalance in wing lift forces will cause an uncontrolled rolling moment around the longitudinal axis of the airplane. Since the flap systems are typically used at close proximity to the ground, such as to assist in reducing the speed for landing, such uncontrolled rolling motion is typically catastrophic.
Advantages of the system of the present invention include:
The root cause of the failure mode in question is addressed, i.e., whether or not the actuator connected or not. Simplicity, in that no additional components (fasteners redesigned to host strain gages). Greater reliability, maintainability, safety than RVDT. Less Expensive than RVDT, and can easily also be implemented into the inboard flap control system. Straight forward indication. It is not be necessary to conduct complex tolerance and dimensional analysis study, including aero-elastic deflection of surfaces, winding of flex shafts, etc., in order to determine whether a disconnect has occurred, and to differentiate the disconnect failure condition from normal operating deflections in the surfaces. Ensures detection through simple means of monitoring the force (load) in the actuator at take-off and/or landing (weight on wheels+flap actuators deployed). Pass criteria: Average Force [Avg (F)>0], over predetermined period of time (10 seconds, 30 seconds, or as determined by system designers). Alternatively, the rate of change of the force over time greater than zero (F/t>0), can be monitored, and when the system becomes quiet or inactive, it is deemed to have ceased to be a load path for load transferring from the spar to the flap panel. It provides finite indication of failure location, and can precisely identify the attachment point where a pin sheared. It provides impending failure detection. If one of the two pins that attaches the gimbal to the rear spar fractures (shears) is detected to have failed, the actuator might still be functioning and the load could be transmitted through the second pin. The load limiter mechanism can accurately be tested with a custom piece of ground equipment (e.g., a turnbuckle), that would lock the actuator, and upon running the test, an exact reading of the load at which the actuator dumped the load (load limiter triggered) can be provided. If during a flight mission one of the actuators reaches its load limit and the load limiter is triggered, the force sensing pins can provide simple monitoring with precise indication of where the incident occurred and the attendant circumstances (e.g., correlated to altitude, speed, etc.). A conventional pop-out indicator could identify that an actuator was overloaded, but the aircraft operator would not know circumstances of the failure.
The foregoing notwithstanding, a disadvantage of the system of the system herein presented is that it does not provide flap position indication, as does the known RVDT arrangement.
This aspect of the present invention detects impending significant latent failures and announces same to the crew and/or maintenance personnel. More specifically, disconnection of one of the load paths, either primary or secondary, is achieved while the system is still operational. Appropriate personnel are therefore advised that redundancy is no longer available, and that the airplane is flying on single load path. This is a condition that but is one failure away from a hazardous or catastrophic event.
In addition to the foregoing, the invention disclosed herein provides a method of determining variations in operating characteristics of a mechanical system having a rotatory mode of operation. In accordance with a first method aspect of the invention, there are provided the steps of:
first monitoring operating impulses generated by the mechanical system during a first interval of operation;
first analyzing the operating impulses obtained during the first interval to determine the intensity and frequency of the operating impulses;
first correlating the operating impulses obtained during the first interval to corresponding angular positions of the rotatory mode of operation;
first producing a first record of the intensity and frequency of the operating impulses obtained during the first interval correlated to the corresponding angular positions of the mechanical system;
second monitoring operating impulses generated by the mechanical system during a second interval of operation;
second analyzing the operating impulses obtained during the second interval to determine the intensity and frequency of the operating impulses;
second correlating the operating impulses obtained during the second interval to the corresponding angular positions of the rotatory mode of operation of the mechanical system;
second producing a second record of the intensity and frequency of the operating impulses obtained during the second interval correlated to the corresponding angular positions of the mechanical system;
comparing the first and second records to determine differences in the operating impulses obtained during the respective first and second intervals correlated to the corresponding angular positions of the mechanical system; and
vibration monitoring of the bearing balls recirculation system.
In one embodiment, there are provided the further steps of:
further monitoring operating impulses generated by the mechanical system during subsequent intervals of operation of the mechanical system;
further analyzing the operating impulses obtained during the subsequent interval to determine the intensity and frequency of the operating impulses of the mechanical system during respective subsequent intervals;
further producing a plurality of further records of the intensity and frequency of the operating impulses obtained during respective ones of the subsequent intervals correlated to the corresponding angular positions of the mechanical system; and
comparing the first, second, and further records to determine a trend in the differences in the operating impulses obtained during the respective first, second, and subsequent intervals.
In a highly advantageous embodiment, there is further provided the step of identifying a cause in the mechanical system for the trend in the differences in the operating impulses obtained during the respective first, second, and subsequent intervals. In mechanical systems that are rotatory, there is provided the step of identifying a cause in the mechanical system for the trend in the differences in the operating impulses obtained during the respective first, second, and subsequent intervals comprises the further step of acquiring rotatory position data of the mechanical system. Such a rotary mechanical system is, in some embodiments, a ball screw system, an acme screw system, a vehicle drive train, a flight control actuator, or a vehicle braking system.
In a specific illustrative embodiment of the invention, the bearing balls within the bearing balls recirculation system have respectively discernible characteristics that is identified by a bearing balls recirculation system vibration monitoring system and correlated to specific ones of the bearing balls. In this manner, not only is the health of each of the bearing balls determinable, but also the direction of bearing balls travel within the bearing balls recirculation system.
In a still further embodiment of the invention, there is further provided the step of quantifying the trend in the differences in the operating impulses obtained during the respective first, second, and subsequent intervals comprises the further step of acquiring rotatory position data of the mechanical system into respective qualities of operation of the mechanical system. Such quantification may include, for example, good, acceptable, and bad operating conditions that are associated with respective levels of required maintenance. More detailed data responsive to the health of the mechanical system is obtained at an output of a processor.
The monitoring that is effected during the practice of the present invention may be any form of monitoring, such as acoustic signal monitoring, vibration signal monitoring; or displacement signal monitoring. The monitored signals, responsive to operating impulses generated by the mechanical system during the respective intervals of operation, are subjected to a Fourier analysis.
In accordance with a further method aspect of the invention directed to a flight control actuator, there are provided the steps of:
first monitoring operating impulses generated by the flight control actuator during a first interval of operation;
first analyzing the operating impulses obtained during the first interval to determine the intensity and frequency of the operating impulses;
first correlating the operating impulses obtained during the first interval to corresponding angular positions of the rotatory mode of operation;
first producing a first record of the intensity and frequency of the operating impulses obtained during the first interval;
second monitoring operating impulses generated by the flight control actuator during a second interval of operation;
second analyzing the operating impulses obtained during the second interval to determine the intensity and frequency of the operating impulses;
second correlating the operating impulses obtained during the second interval to the corresponding angular positions of the rotatory mode of operation;
second producing a second record of the intensity and frequency of the operating impulses obtained during the second interval;
comparing the first and second records to determine differences in the operating impulses obtained during the respective first and second intervals of operation of the flight control actuator;
determining a vibration signature of a bearing balls recirculation system; and
determining a mechanical reason for differences in the operating impulses obtained during the respective first and second intervals of operation of the flight control actuator.
In certain embodiments of this further method aspect where the flight control actuator is of the type having bearing elements, one mechanical reason for differences in the operating impulses obtained during the respective first and second intervals of operation of the flight control actuator is deformation in the bearing elements. Additionally, in embodiments where the flight control actuator is of the type having bearing races, mechanical reason for differences in the operating impulses obtained during the respective first and second intervals of operation of the flight control actuator is deformation in the bearing races. Still further, in embodiments where the flight control actuator is of the type having a ball screw containing ball bearings, a mechanical reason for differences in the operating impulses obtained during the respective first and second intervals of operation of the flight control actuator is reduced effectiveness of the ball bearings. In yet further embodiments where the flight control actuator is of the type having an acme screw, a mechanical reason for differences in the operating impulses obtained during the respective first and second intervals of operation of the flight control actuator is increased friction.
In embodiments where the flight control actuator is of the type having a screw shaft, a mechanical reason for differences in the operating impulses obtained during the respective first and second intervals of operation of the flight control actuator is damage to the screw shaft. A further reason for differences in the operating impulses obtained during the respective first and second intervals of operation of the flight control actuator is a change in the backlash.
The vibration monitoring sensor is installed in some embodiments on the ball nut. Alternatively, however, the vibration sensor can be installed on the screw shaft, or both. In embodiments where the sensor is installed on the screw shaft, there is additionally provided a data port for issuing the impulse data responsive to the steps of first and second monitoring.
The impulse data is responsive to the steps of first and second monitoring and is made available to a user at a data display system. Some of the data from the mechanical system is transmitted using a wireless transmission system.
BRIEF DESCRIPTION OF THE DRAWING
Comprehension of the invention is facilitated by the annexed drawing, in which:
FIG. 1 is a schematic and function block representation of an annunciation arrangement for a ball screw actuator;
FIG. 2 is a schematic and function block representation of an annunciation arrangement for a ball screw actuator having incorporated therein a system for monitoring the health of bearing balls and the bearing ball return system;
FIG. 3 is a simplified schematic representation of an aircraft wing arrangement showing a flap and two actuator arrangements associated therewith;
FIG. 4 is an enlarged simplified schematic representation of an actuator that is useful in the wing arrangement of FIG. 3 ; and
FIG. 5 is a simplified schematic representation of a tie rod arrangement useful in the practice of the invention.
DETAILED DESCRIPTION
FIG. 1 is a schematic and function block representation of an annunciation arrangement 100 for a ball screw actuator. As shown in this figure, a screw shaft 110 is configured to engage a ball nut 115 , and there is provided a ball recirculating system 117 that provides a multiplication of bearing balls (not specifically designated) in the interface between the screw shaft and the ball nut. As screw shaft 110 is rotated, illustratively in the direction of torque arrow 120 , ball nut 115 is urged in the linear direction in accordance with bidirectional arrow 122 .
In this embodiment of the invention, screw shaft 110 is coupled to a rotary encoder 130 that issues electrical signals that correspond to the angular position of the screw shaft. There is additionally provided in this specific illustrative embodiment of the invention a vibration transducer 132 that is shown to be directly coupled to the ball nut. Vibration transducer 132 receives acoustic or vibrational or displacement information from the ball nut, and produces corresponding signal that is propagated to a Fast Fourier Processor (FFT) 134 . The output of the FFT 134 is propagated to a synchronizer 136 that receives the angular position signals from rotary encoder 134 . Thus, FFT “snapshots” are correlated to the angular position of the screw shaft and stored in a correlating memory system 140 . It is to be noted that in some embodiments of the invention the data from vibration transducer 132 is propagated to FFT 134 by means of a wireless transmission system. This, as noted herein, provides significant advantages in applications where the ball screw arrangement is inaccessibly disposed on the mechanical system (not shown). In applications where the present arrangement is installed in an aircraft (not shown), other items of data may wirelessly be transmitted. However, in some aircraft applications the rotary encoder data is available from the aircraft's system.
A processor 142 receives information from correlating memory system 140 , which may, in certain embodiments, contain data corresponding to historical FFT snapshots obtained during prior test intervals. Processor 142 additionally will, in certain embodiments, maintain a count of the angular position data and correlate same to linear displacement of the ball nut along the screw shaft (in the direction of bidirectional arrow 122 ). Thus, trend data responsive to angular position of the screw shaft, which corresponds to possible deflection of bending thereof, and trend data responsive to linear displacement, which corresponds to thread damage, is obtained. In some embodiments, the recirculation cycle of the bearing balls (not specifically designated) is counted to form a data cycle that will reveal damage to one or more of the bearing balls. All of the foregoing data is made available to a user (not shown) at a display 146 , in response to data and mode requests entered at an input 144 .
1. Methods of Annunciating Failure in Flight Controls and Aerospace Jack Screw Actuators (Ball Screws, Roller Screws, and ACME Screws), and Rotary Actuators.
a. Using System Vibration Signature Monitoring
A compact micro-processor controlled on-line data collection vibration signature monitoring system equipped with vibration and/or velocity and/or accelerometers allows early failure detection in jack screws.
Failure related to damage in the moving components of flight controls and aerospace electromechanical actuators, such as ball screws, roller screws, ACME screws, threads, bearing's outer races, inner races, ball bearings, rollers, cage, return tubes or return circuits, anti-backdrive devices, gear train components, clutches, motor assembly components can be diagnosed on-line by monitoring the impulses caused by material damage in these areas (features/components), measuring the intensity and frequency of the impulses, and observing the trend of these values over a period of time.
The following types of failures, without limitation, can be diagnosed using vibration monitoring:
i. deformation in the bearing elements or races; ii. increased friction (scuffing, skidding); iii. distortion or breakage of the screw shaft (shaft bending will cause unbalance in the system, therefore periodic vibrations, and the fracture of the shaft, if the actuator is still operational, would have a different resonance frequency due to the different length which would generate a different vibration signature (response) when excited by the system during actuation). iv. separation/loss of ball bearings from the ball nut (due to any reasons, especially due to failure of the ball recirculation system). v. distortion or breakage of the anti-backdrive (no back) components such as the pawl, the pawl shaft, the cage or the thrust plate.
The angular position of the mechanical system is determined from on-board encoders and resolvers that are coupled to a system shaft. In some embodiments, it is advantageous to know the RPM of the system so that the outside noise can be filtered out and a clean signal extracted for analysis.
If the failure monitoring pertains to a flight control actuator, and because vibration monitoring testing requires higher RPMs, the tests are, in certain embodiments, conducted on the ground, at predetermined maintenance cycles. In a preferred embodiment, however, the microprocessor unit is an integral part of the actuator system and, coupled with angular position determining circuitry, can be used to analyze the mechanical system during actual use in transient modes. However, depending on the test frequency, it can also be designed as aircraft ground maintenance equipment.
b. Using Strain Gages
The secondary load path elements in actuators are sometimes preloaded (e.g. tie rod mounted through the screw shaft of an actuator). The preload is necessary in some applications to increase the column buckling stability of the screw shaft under compressive stresses. The secondary load path in the case of a tie rod serves the purpose of carrying the total load in case of failure of the primary load path (e.g. screw shaft).
Detecting dormant failures of such elements is critical. The strain gage is, in some embodiments, permanently attached to a component operating under constant compressive or tension stress, and appropriate ports for effecting electrical communication can, in certain embodiments, be disposed in an accessible external socket of the actuator system. After the assembly operation is finalized and the subject component that needs to be monitored has been preloaded, an “initial condition” (“birth certificate”) reading as supplied, for example, by OEM, can be taken and recorded (electronically or manually) by connecting a data reading or data-acquisition instrument to the external socket where the strain gage is connected.
At further maintenance cycles, or during on-line live monitoring, the preload variance can be monitored, studied for trends, and used for failure diagnostic and warning indicators triggering (e.g. a fracture in a tie rod operating in tension, would indicate zero stresses after fracture and the system would announce failure after comparing this new reading with the initial calibration reading recorded at the time the system was manufactured or placed in service after maintenance).
c. ACME Screw (Square Thread, Castle Thread, Etc.) Actuators—Using Sliding Friction Threads Backlash Indicator
A probe is attached to the end face, in lieu of a sector of thread inside the of the ACME nut, or in lieu of a sector of thread on the screw. The maximum allowable backlash in the unit resulting either due to wear of the nut threads or screw threads, depending on the geometry of the thread, will determine (using basic geometry and trigonometry math formulas), a set distance to the flanks of the threads.
Any excessive wear in the threads will cause the probe to engage with the threads and the failure to be detected.
Many faults and types of damage in linear and rotary actuator systems lead to mechanical vibrations with frequencies directly related to the rotational speed of their components or rotor. Of special interests are e.g., unbalance, alignment errors, ball bearing-pass frequencies, gear mesh frequencies in gearboxes, that occur as rotor-synchronous vibrations or harmonics (orders) of the rotor's rotational frequency.
The vibration behavior that the actuator system exhibits over the entire speed range will provide important information about the resonance profile of the actuator system, which later can be used for diagnostic purposes. The FFT spectrum can be used for the faults and damage analysis of an actuator system. In a highly advantageous embodiment po the invention, FFT snapshots are correlated to angular position of the mechanical system. In addition to enabling assessment of the operation of a mechanical system that operates in transient modes, such correlation to angular position facilitates identification of a mechanical system component that is about to fail, as evidenced by changes in the angular position correlated FFT snapshots over time. By employing a precise and accurate tracking analysis, an extremely fast and selective narrowband measurement of rotor synchronous vibrations can be measured. Thus the most significant vibration signals from the actuator system can be analyzed in any operating phase: stationary operation, run-up, coast-down, reverse, or over a longer time, to account for the thermal mechanical events of the actuator system.
The operation of the present invention is enhanced in certain embodiments by archiving the data locally (in a memory chip attached to the actuator), whether while performing online monitoring or off-line measurements, the overall readings, the current value, the previous value and the relationship with the alarm value shall always be available. Based on a pass or fail criteria an alarm signal is, in certain embodiments, provided when the vibration measurement instrumentation detects out-of-range or otherwise unacceptable values, or a modified profile of the readings compared to the baseline configuration and vibration signature model stored at the beginning of life of the actuator. Various failure modes (such as ball bearing damage, ball bearing escape and separation from the assembly, gear tooth breakage, skewered roller damage, ratchet or pawl fracture, radial bearings failure, slip clutch components failure, tie rod or torsion rod failure, etc.), can be simulated and induced into the system during qualification testing of the actuator, to ensure proper calibration and understanding of the impact produced by the failure of each of the different components onto the overall vibration signature of the assembly.
The use of such vibration diagnostic annunciation system allows early detection of impending failure, before its magnitude becomes critical or catastrophic. The vibration annunciation method to the present invention is useful to detect numerous failure types such as, but not limited to, ball escape, bearing race pitting or spalling, cracking or fracture of rotary or stationary components. Problems arising from unbalance, misalignment, gear damage, bearing damage, can be recognized at an early stage. Impulses caused by damage to the outer race or inner race of a bearing surface, to the roller(s) or ball bearing(s), or corresponding cages are a good indicator of the bearing condition. Reliable monitoring of the actuator assembly condition is possible by measuring the intensity and frequency of the impulses, and observation of the trend of these values over a period of time allows accurate diagnostic of the integrity and operation readiness of the jackscrew actuator.
Flight control actuator system damage and losses related to abnormal aircraft operations (unscheduled repairs or accidents), as a result of failed actuator can be successfully avoided by monitoring the “health” (structural integrity) of the actuator system by using the vibration monitoring failure annunciation.
In general aerospace applications, and specifically in flight controls actuation, weight control and reduction is very important. The advantage of using active vibration monitoring failure annunciation consists in minimum weight increase to the actuator system, consisting of two to three pickups (accelerometers), and wiring. The rest of the diagnostic logic can be supplied in a separate enclosure dedicated to data collection and monitoring the vibration signature of the actuator system, or it can easily be integrated into the existing flight control computers of the aircraft as an additional subroutine in the complex software programs that already govern the functionality of the flight control systems with today's modern aircraft.
The accelerometer probes can be mounted on the actuator assembly housing or attached directly to various subcomponents of the system. In some cases for the evaluation of the actuator system condition, simultaneous measurements from two points on this actuator system must be considered, i.e., a simultaneous acquisition through two channels of the instrument would be required for comprehensive diagnosis of the actuator system. A dual channel operation approach will be more accurate in providing reliable measurements on the system.
For systematic acquisition evaluation of all measurements types for predictive actuator maintenance, the following types of readings can be used: amplitude phase versus speed check amplitude phase versus time.
For efficient fault detection multiband pass space filters in the frequency range of measurement can be applied. The computer instrumentation software can be tailored to various operating ranges of the actuator system, and a database archiving system can provide information for predictive actuator system diagnostic and maintenance.
The vibration diagnostic method will allow predictive actuator system maintenance, therefore higher levels of aircraft availability for flight missions (dispatchability) prevention of unscheduled repairs, limitation of flight control system components damage or flight incidents, by early fault diagnosis, lengthening of intervals between inspections and timely planning to have optimally scheduled repair actions are the basis for the cost-effective significance of this strategy for an entire company.
The prerequisite for this is continuous knowledge of the current actuator system condition during operation. Mechanical vibrations, bearing condition values, speeds and process values are authoritative indicators with which the actuator system condition can be assessed and diagnosed. Which characteristic parameters should be acquired and how often, depends not only on the complexity and absolute value of the actuator system but also on the criticality of the aircraft system that is monitored.
The characteristic parameters will be calibrated on the monitoring system and initial vibration signature certificates will be recorded at entrance into service, as mounted on the aircraft. This represents a reference data set that will be used as a baseline, and will be therefore considered a normal operating condition data set.
The periodic readings, whether online with active sensors mounted on the actuator housing or attached directly to specific components, or off-line at predetermined maintenance checks intervals, can be archived via computer software and a common database for all measured data.
Standard acceleration, velocity and displacement sensors can be used.
The measuring functions that can be employed in the vibration diagnostic, are:
Absolute bearing vibrations relative shaft vibrations bearing condition speed measurement tempted to measurement damage to the internal and external lead screw threads, failure of the ratchet pawls of the anti-backlash brake (No Back), damage to the skewed roller clutch components (rollers, cage).
It is advisable to employ instrumentation that allows flexible configurations for various setups of the high and low pass filters for broadband measurement. This guarantees optimum adaptation to the individual measurement task. It is advisable to employ an averaging function for noise influence.
Damaging the internal components of an actuator system, such as material separation from the screw or nut threads, pitting and spalling of the rollers and ball bearings, breakage of the ratchet-pawls in a slip clutch, breakage in the cage of the skewed roller clutch, would result in a beat effect which will be easily detectable when recording frequency versus time.
If unacceptably high overall vibrations, intermittent beatings or bearing conditions, are found in the process of monitoring and diagnosing actuator system health, the causes can be identified by using frequency analysis (FFT) and envelope analysis. The anomalies (increased vibrations), can be traced to unbalance, misalignment, a bearing or gear fault or some other source.
The control and failure-detection in torsion, compression, or tension stressed beams using strain gage measurement can effectively be used in preventing catastrophic failures by early detection of dormant secondary load path failures, and is mostly beneficial in difficult to access areas of the airplane, where visual or direct access inspection can be accomplished only by disassembly of a multitude of components. As example, but not limited to, the hard to access internal tie rod or torsional spring assemblies are good candidates for this monitoring method.
The early detection of upcoming failure with minimum invasive disassembly and labor, is critical in flight controls actuators. The secondary load path failure through cracking, and ultimately through fracture of the tie rod or torsion rod inside the screw shaft of an actuator can be identified and diagnosed by employing strain gauges mounted directly on the broad shaft, either by using a single probe or multiple (odd number) probes setup for a logical voting decision making process within the monitoring or diagnostic instrumentation.
The strain gauges can be attached directly to the rod that is operating under tension, compression or torsion stresses. The corresponding wiring from these strain gauges shall be then routed in a specifically designed gap between the inner diameter of the screw shaft and the outside profile of the tie rod, or in a different manner (channels on the outside surface of the rod, drilled holes in the rod, etc.), towards the end face of the rod that protrudes outside of the screw shaft, and outside of the actuator where possible. In this location the wiring is routed to a connector that is available to be used by either the maintenance personnel, equipped with an off-line piece of instrumentation, or connected on-line directly to the flight control computers of the airplane for active monitoring of the secondary load path integrity inside the screw shaft of the actuator.
The use of noninvasive methods that allow continuous on-line remote monitoring and a highly reliable operation readiness of the internal components in a flight control actuator, is beneficial because it also minimizes the probability of errors that may occur in case maintenance personnel would have to disassemble many components to expose and inspect internal features that are provided for the safety of the actuator system. The probability of errors in reassembling the components in a prescribed order to ensure proper functionality of the actuator system is reduced or eliminated by using this method (strain gauges wired to an external connector or by using strain gauges that will report wirelessly the status of the stresses at their location), therefore the system safety will be increased when employing this type of monitoring and diagnostic method.
FIG. 2 is a schematic and function block representation of an annunciation arrangement 200 for a ball screw actuator having incorporated therein a system for monitoring the health of bearing balls and the bearing ball return system. Elements of structure that have previously been discussed are similarly designated in this figure.
There is shown in this figure adjacent to ball recirculating system 117 a bearing ball sensor 230 that is configured to sense the passage of bearing balls. In particular, ball recirculating system 117 , in this specific illustrative embodiment of the invention, distinguishes between the conventional bearing balls (not specifically designated) and bearing balls 225 (marked with an “X”). Bearing balls 225 are possessed of a discernable characteristic, such as a magnetic characteristic, that is observable by ball recirculating system 117 through the bearing balls return conduit. In addition, bearing balls 225 are arranged within the train of bearing balls in accordance with a predetermined sequence, whereby the number of bearing balls and the direction of travel within ball recirculating system 117 can be determined. For example, bearing balls 225 can be staggered within the bearing balls train as two such bearing balls 225 (a first pair of bearing balls) being disposed adjacent to one another and an additional bearing ball 225 separated from the first pair. In this manner, the total number of bearing balls and their direction of travel within ball recirculating system 117 can be determined. In addition, as will be discussed below, the health of respective ones of the bearing balls can be determined by analyzing the acoustic characteristic associated with each such bearing ball.
The output of bearing ball sensor 230 is delivered to a bearing balls counter 236 that maintains a sequential count of the bearing balls. This data then is delivered to a correlating memory system 240 that, as described below, correlates each of the bearing balls to an associated acoustic signature.
The acoustic signature is derived from a signal provided by an acoustic or vibration sensor 232 . The vibration signal is propagated, illustratively wirelessly to, subjected to a frequency analysis at, an FFT 234 . The output of FFT 234 is correlated to the associated ones of the bearing balls at correlating memory system 240 , the output of which is delivered to processor 142 . In some embodiments of the invention the correlating memory systems and the FFT systems are incorporated with the processor in a single device, which may be an ASIC (not shown). In other embodiments, bearing ball sensor 230 and vibration sensor 232 are combined as a single sensor. In such embodiments where the sensors are combined, bearing balls 235 can be configured to produce a predetermined acoustic signature that is distinguishable over the acoustic signatures of the other bearing balls.
The resulting data is displayed at display 146 , which in some embodiments of the invention is a computer display, or may simply be one or more indicator lamps. In addition, a data output port may be provided for communicating the health of the ball screw and its associated bearing balls and ball recirculating system to a maintenance system (not shown).
In a still further embodiment of the invention, the health of the recirculation system is determined by analyzing a vibration characteristic of the system, and subtracting therefrom in the processor the vibration characteristic of the ball nut;
FIG. 3 is a simplified schematic representation of an aircraft wing arrangement 300 showing a flap 302 and two actuator arrangements 310 and 320 associated therewith. Actuator arrangements 310 and 320 are interconnected in this specific illustrative embodiment of the invention by a data/control cable 330 that delivers data and control signals to a controller/recorder 332 . Actuator arrangements 310 and 320 are connected to flap 302 at respective connections 312 and 322 . Connection 312 , which in this embodiment of the invention is substantially identical to connection 322 , will be described in greater detail below in relation to FIG. 4 .
FIG. 4 is an enlarged simplified schematic representation of a portion of actuator arrangement 310 that is useful in the wing arrangement of FIG. 3 . Elements of structure that have previously been discussed are similarly designated. As shown in this figure, actuator arrangement 310 is coupled to the flap at connection 312 . Connection 312 , however is comprised of a primary load path and a secondary load path. With reference to the figure, the primary load path include, in this specific illustrative embodiment of the invention, a pair of force transducers 335 and 337 . The secondary load path includes a further force transducer 340 .
Referring once again to FIG. 3 , the primary load path, in addition to incorporating force transducers 335 and 337 (not specifically designated in this figure, see, FIG. 4 ), includes a further pair of force transducers 344 and 346 . Force transducers 344 and 346 serve to couple a drive motor 350 to a support spar 352 . In response to drive signals delivered by data/control cable 330 , drive motor 350 is urged to travel in the directions of arrow 354 along a screw shaft/tie rod 356 . In embodiments of the invention where drive motor 350 is a ball screw arrangement, ball screw monitoring arrangements of the type discussed hereinabove in relation to FIGS. 1 and 2 can be employed.
FIG. 5 is a simplified schematic representation of a screw shaft/tie rod 356 useful in the practice of the invention. As shown in this figure, screw shaft/tie rod 356 contains a preloaded tie rod 360 that forms a secondary load path. The tie rod is contained, in this specific illustrative embodiment of the invention, within a screw 364 that forms a primary load path. A trunion 370 is installed on screw 364 and induces a nut 366 to produce axial loading in the directions of arrow 372 .
A load sensing element 380 is installed at the end of the tie rod, and a strain gauge transducer 382 is shown in this embodiment to be installed thereon. The strain gage transducer has an electrical connector 384 associated therewith.
Although the invention has been described in terms of specific embodiments and applications, persons skilled in the art may, in light of this teaching, generate additional embodiments without exceeding the scope or departing from the spirit of the invention described herein. Accordingly, it is to be understood that the drawing and description in this disclosure are proffered to facilitate comprehension of the invention, and should not be construed to limit the scope thereof.
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A system for announcing failure of a mechanically actuated arrangement employs a first coupler arrangement that couples an actuator to a structural element that is desired to be controlled, and a first force sensor is coupled to the first coupler arrangement. The first coupler arrangement and the first force sensor constitute a primary load path. Similarly, a second coupler arrangement is coupled to the actuator to the structural element and constitutes a secondary load path. Changes in the forces experienced by one or both of first and second force sensors are monitored by a controller/monitor system. A connector has a screw shaft in the primary load path and a preloaded tie rod in the secondary load path. Axial forces are generated by a drive motor, which can include a ball screw arrangement. Operating impulses generated by the ball screw arrangement are monitored during a predetermined interval of operation.
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This is a Continuation of International Application PCT/DE99/03776, with an international filing date of Nov. 26, 1999, which was published under PCT Article 21(2) in German, and the disclosure of which is incorporated into this application by reference.
FIELD OF AND BACKGROUND OF THE INVENTION
The invention relates to a device and method for detecting the axial play of a gearbox shaft that meshes with a gearbox output, particularly a worm shaft of a gear motor actuator that meshes with a worm gear. Such actuators with a commutator motor and an adjoining worm gear are provided in particular for motor-driven closing systems, e.g. windows or sun roofs in motor vehicles.
Actuators of the aforementioned type, particularly in mass-produced units comprising a motor enclosure and a gear case with a continuous motor/gearbox shaft, exhibit undesirable tolerance-related axial play. This can cause end stop noises of the motor/gearbox shaft at the axial end stops on both sides as the direction of rotation is reversed.
To limit impermissible axial play, it is known, for instance, from EP 0 133 527 B2 to provide a spacer disk, which has a disk thickness that is based on a prior comparison between the actual, measured axial play and the desired axial play. This spacer disk is the contact part for at least one axial end face of the gearbox shaft, which merges into the motor shaft of a motor enclosure of a commutator motor that is flanged to the gear case receiving the gearbox shaft.
OBJECTS OF THE INVENTION
An object of the present invention is to detect, with little measurement complexity, the axial play of a gearbox shaft. It is another object to check the accuracy of an adjustment in cases where the gear parts or the motor drive parts have already been mounted in the gear case or the motor enclosure and their axial play has already been adjusted.
SUMMARY OF THE INVENTION
These and other objects are attained by a device for detecting the axial play of a gearbox shaft that meshes with a gearbox output, which device includes: means for rotationally driving the gearbox shaft between axial end stops of the gearbox shaft that limit axial play of the gearbox shaft; means for blocking the gearbox output while the gearbox shaft is driven; and means for determining a translational travel of the rotationally driven gearbox shaft between the axial end stops. The objects are also achieved by a method for detecting the axial play of a gearbox shaft that meshes with a gearbox output, the method including: rotationally driving the gearbox shaft between axial end stops of the gearbox shaft that limit the axial play of the gearbox shaft; blocking movement of the gearbox output during said rotational driving of the gearbox shaft; and determining the translational travel of the rotationally driven gearbox shaft. Advantageous embodiments of the invention are the subject of the dependent claims.
Blocking, e.g. locking, the gearbox output when the gear parts or motor parts have already been mounted and the gearbox shaft is already meshing with the gearbox output causes the motor drive to displace the gearbox shaft in a translational movement while it is secured relative to the gearbox output. As a result the actual axial play can be measured and the necessary adjustment determined, or it can be checked to ensure that the adjustment has already been made. For instance, if a spacer disk failed to be inserted due to an error or, if it was inserted, was lost again during the further assembly process, particularly during greasing, this defect can be detected.
The translational travel representing the corresponding axial play can be particularly easily determined by evaluating, in particular counting, the periodicity associated with the segment interruption of the commutator motor, i.e. the pulses of the driving commutator motor current or motor voltage characteristic, which has a corresponding ripple.
Determining the position of a part that is operationally displaced by a worm gear/commutator motor drive unit and is moved translationally or rotationally via the worm shaft and the worm gear meshing therewith by analyzing the commutation-dependent ripple of the motor current is known per se, for instance, from DE 41 38 194 A1.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention as well as further advantageous embodiments of the invention set forth in the dependent claims will now be described in greater detail, by way of example, with reference to schematic embodiments depicted in the drawing in which:
FIG. 1 shows the motor current characteristic as a function of time with a high commutator-dependent ripple pulse number corresponding to an overly large axial play between the end stops of the gearbox shaft;
FIG. 2 shows the motor current characteristic as a function of time with a low commutator-dependent ripple pulse number corresponding to a specified axial play between the end stops of the gearbox shaft; and
FIG. 3 shows an arrangement for adjusting the axial play of a gearbox shaft of a worm gear/commutator motor drive unit by means of a spacer disk having a disk thickness defined in each individual case on the basis of a comparison between the actual axial play and the specified axial play, with, according to the invention, a brake provided for blocking movement of the gearbox output and an evaluation device for determining the axial play.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The window lifter gear motor for a motor vehicle depicted in FIG. 3 basically includes a half-shell type gear case part 2 and a commutator motor, with a rolled cylindrical motor enclosure part 1 , flanged onto the left side thereof. A gearbox shaft 3 , as an extension of the rotor shaft of the commutator motor, protrudes into the half-shell type gear case part 2 . On its motor-side end, this gearbox shaft 3 receives a rotor 9 and a commutator 10 , which is contacted by a brush system 11 . On its right free shaft end, the gearbox shaft 3 has a worm 6 , which operationally meshes with a gearbox output 7 in the form of a worm gear. The worm gear in turn can be coupled to further driving means (not depicted), such as a cable sheave of a cable-operated window lifter. The right free shaft end of the gearbox shaft 3 is supported in the gear case part 2 in a cup-and-ball bearing 13 . In addition, the right free shaft end is secured by a supporting bearing 8 against unallowable radial deflections arising due to the worm gear.
All the gear components can be inserted into the half-shell type gear case part 2 according to the “violin case principle.” Gear case part 2 can then be finally sealed by an additional gear case part, particularly a gear case cover (not depicted). Similarly, a spacer disk 4 , which is provided to limit or adjust a defined axial play, can, e.g. in a preassembly, be inserted into gear case part 2 between the axial shaft end of gearbox shaft 3 and the opposite gear case part 2 .
The invention provides a particularly advantageous option to determine the axial play, or to identify the measures necessary to achieve a desired, predefined axial play—such as, in particular, a spacer disk 4 to be inserted between the shaft end of the gearbox shaft 3 and the axially opposite gear case part 2 . First, the gearbox output 7 , in this embodiment the cable sheave, is blocked by a brake B indicated in FIG. 3. A current, preferably a constant current is then applied to the commutator motor, such that the gearbox shaft 3 is axially moved to its one end stop, while the gear teeth of its worm 6 are simultaneously held, or roll off, along the meshing opposite gear teeth of the gearbox output 7 . The current direction is then reversed and gearbox shaft 3 , with gearbox output 7 still blocked, is axially moved to its other end stop.
The dips in the time/current characteristic IM=f(t) shown in FIG. 1 and FIG. 2, which are due to the lamella junctions of the commutator, are counted in an evaluation device ED shown in FIG. 3 —e.g. according to the method described in DE 41 38 194 A1, which reference is incorporated into the present application by reference. The dips are, if applicable, pulse-amplified—and are processed into a control variable representing the axial play. Counting can be effected with respect to the low signals or the high signals, as well as by using a combination thereof.
FIG. 1 shows the ripple of motor current IM between a first end stop A 1 , which is represented by a first lamella junction jump in the current characteristic by a low signal after a starting current pulse at the instant of the start of a rotation of gearbox shaft 3 , and a second end stop A 2 , which is characterized by a low signal when gearbox shaft 3 subsequently comes to a stop after having traveled through the axial play path and the end of the ripple of motor current IM associated therewith.
According to one preferred embodiment of the invention, the inventive detection of the axial play is used also to monitor proper assembly of, for instance, a gear motor actuator that is provided with a spacer disk 4 , known from EP 0 133 527 B2. This is accomplished by comparing, prior to final mounting of a gear case cover to seal an otherwise fully assembled unit 2 ; 3 , the actual translational travel and a setpoint travel corresponding to a predefined axial play. This allows a determination of whether in the prior production process, particularly when gear grease was added, the pre-mounted spacer disk 4 was, e.g., inadvertently lost.
FIG. 2 shows, by way of example, a ripple profile of a test piece in which the axial play has been adjusted to be within permissible tolerances, by means of a correspondingly dimensioned spacer disk 4 . FIG. 1 shows the same test piece without the spacer disk. By comparing the two diagrams it may be seen that between the two end stops A 1 , A 2 , which correspond to the start of a ripple with the beginning rotation of gearbox shaft 3 and the end of a ripple with the completed rotation of gearbox shaft 3 , the different number of ripple pulses, as compared between FIG. 1 and FIG. 2, indicates a different translational travel of gearbox shaft 3 relative to the fixed gearbox output 7 . In particular, this translational travel is larger if the spacer is incorrectly absent.
This counting is advantageously independent of the rotational speed of the gearbox shaft, since this speed affects only the density of the counting pulses over time. Testing is advantageously carried out at a constant current to enable a simple calculation of the travel by comparing the counting pulses according to FIG. 1 on the one hand and FIG. 2 on the other hand.
The above description of the preferred embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the present invention and its attendant advantages, but will also find apparent various changes and modifications to the structures and methods disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the invention, as defined by the appended claims, and equivalents thereof.
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The axial play of a gearbox shaft ( 3 ) that meshes with a gearbox output ( 7 ) is determined by measuring the translational travel of the rotationally driven gearbox shaft ( 3 ) between the axial end stops (A 1 ; A 2 ) thereof while simultaneously blocking the gearbox output ( 7 ). The end stops define the axial play of the gearbox shaft ( 3 ). The commutator-dependent ripple of the motor current (IM) pertaining to the commutator motor which drives the gearbox shaft ( 3 ) in a drive unit ( 1; 2 ) is evaluated as the representative variable for the translational travel.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of the French patent application No. 1653575 filed on Apr. 22, 2017, and the French patent application No. 1653576 filed on Apr. 22, 2017, the entire disclosures of which are incorporated herein by way of reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to the testing of a structural component of a vehicle, more particularly for the purpose of detecting a crack in such a component. Some structural components of a vehicle, such as an aircraft, are regularly subjected to stresses during the use of the vehicle, which may result in cracks in the components. In order to use the vehicle in adequate conditions of safety, these structural components must be tested in periodic test inspections. In these test inspections, operators check whether a structural component has a crack, and, if so, must estimate certain dimensional characteristics of the crack, particularly its length. For some components, the operators may detect a crack by visual inspection or by moving a sensor over the surface of the component. However, other components are more difficult to access, and such a procedure is not feasible for the detection of a possible crack. In particular, a component to be inspected may be assembled with another component, this other component preventing both visual inspection and the movement of a sensor over the component to be inspected. For example, a structural component 10 shown separately in FIG. 1A has a crack 15 . This structural component is assembled with another component 12 , shown separately in FIG. 2A . These two components have a set of fastening holes such as the hole marked 21 in the figures. These fastening holes may be used to assemble the components by using fastening means such as bolts or rivets. FIG. 3A shows the structural component 10 and the component 12 assembled together. The component 12 prevents an operator from accessing the structural component 10 to inspect the crack 15 . FIGS. 1B, 2B, and 3B show the components 10 and/or 12 , in sections taken along the line A-A of FIGS. 1A, 2A and 3A respectively. Some structural components are also difficult for an operator to access: in some cases, the operator may touch a component, but finds it difficult to see it while manipulating the component. It would therefore be desirable to improve the methods of testing structural components, in order to facilitate the detection of a crack in a component which is difficult to access and/or is masked by another component.
SUMMARY OF THE INVENTION
[0003] An object of the present invention is, notably, to provide a solution to these problems. It relates to a method for crack testing in a structural component of a vehicle. This method is remarkable in that it comprises the following steps:
a) identifying a hole of circular cross section in the structural component and inserting into the hole a probe comprising at least one ultrasonic transducer, the probe being equipped with a rotation sensor and/or a motor; b) moving the probe rotationally in the hole so as to move the direction of emission of an ultrasound beam by the probe, and, for each angular position of the probe among a set of different angular positions of the probe, performing the following sub-steps automatically, by means of a control system: b1) controlling the emission of an ultrasound beam into the structural component; b2) measuring a signal supplied by the probe, corresponding to an echo of the emitted ultrasound beam; b3) if the amplitude of the measured signal is above a predetermined threshold: determining a distance between the probe and a point of discontinuity in the structural component, on the basis of the measured signal; determining the angular position of the probe; recording a data set comprising at least the distance between the probe and the point of discontinuity, together with a data element corresponding to the angular position of the probe, c) automatically searching, by means of the control system, among the data sets recorded for the different angular positions of the probe, for data sets corresponding to characteristic points of discontinuity of the structural component, and establishing a correspondence between the angular positions of the probe on the one hand, and an angular reference frame linked to the component on the other hand; d) on the basis of the data sets recorded for the different angular positions of the probe, automatically determining, by means of the control system, the positions in the structural component of the points of discontinuity corresponding to the angular positions of the probe for which the amplitude of the measured signal is above the predetermined threshold; e) determining at least one dimensional characteristic of a crack in the structural component on the basis of the positions of the points of discontinuity.
[0015] This method enables an ultrasound beam to be emitted in the thickness of the structural component from the hole in which the probe is inserted. By moving the probe rotationally in the hole, the direction of emission of the ultrasound beam by the probe may be oriented in a plurality of angular positions. It is thus possible to detect automatically, in the structural component, points of discontinuity corresponding to the crack which is being sought. For each detected point of discontinuity, the recording of the distance determined between the probe and this point, together with the corresponding angular position, enables the position of the point in the structural component to be determined automatically. By identifying characteristic points of discontinuity, a correspondence may be established automatically between the angular positions of the probe and an angular reference frame linked to the component: this makes it unnecessary to reference the position of the probe relative to the component, and thus facilitates the user's work. After determining the positions in the structural component of a set of points corresponding to the crack, it is thus possible to determine at least one dimensional characteristic of the crack.
[0016] According to one embodiment, the probe being equipped with a motor, in step b) the rotational movement of the probe in the hole is controlled automatically by the control system.
[0017] In a particular embodiment, the rotation sensor being a rotary encoder, in step a) the probe is inserted into the hole until the rotary encoder comes into contact with the structural component or with a component assembled onto the structural component.
[0018] According to another particular embodiment, step b) is repeated after step c).
[0019] Advantageously, step e) is executed automatically by the control system.
[0020] Advantageously, step e) comprises the determination of a length of the crack in the structural component.
[0021] According to a particular embodiment, in step a) the probe is inserted into the hole in the structural component through another component adjacent to the structural component.
[0022] According to another particular embodiment, steps a), b), c) and d) are repeated for at least two holes in the structural component.
[0023] In an advantageous embodiment, the probe being a multi-element ultrasonic probe, step b) is repeated with the ultrasound beam emitted toward a plurality of locations distributed within the thickness of the structural component.
[0024] In another advantageous embodiment, the probe being a multi-element ultrasonic probe, steps b1) to b3) are repeated with the ultrasound beam emitted toward a plurality of locations distributed within the thickness of the structural component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention will be more readily understood from a perusal of the following description and the accompanying figures.
[0026] FIGS. 1A, 2A and 3A , already described, represent in a simplified manner a structural component of a vehicle and another component assembled onto this structural component.
[0027] FIGS. 1B, 2B, and 3B , already described, show sections taken along the line A-A of FIGS. 1A, 2A and 3A respectively.
[0028] FIGS. 4A and 4B , similar to FIGS. 3A and 3B respectively, represent a structural component into which a probe according to an embodiment of the invention has been inserted.
[0029] FIGS. 5A and 5B on the one hand, and 5 C and 5 D on the other hand, show detail views of FIGS. 4A and 4B respectively.
[0030] FIGS. 6 and 7 show detail views, similar to that shown in FIG. 5A , illustrating an embodiment of the invention.
[0031] FIG. 8 shows an example of a probe equipped with a motor.
[0032] FIG. 9 shows a display on a display screen according to an embodiment of the invention.
[0033] FIG. 10 shows in a schematic manner an example of an automatic control system.
[0034] FIG. 11A shows in a simplified manner a multi-element ultrasonic probe.
[0035] FIG. 11B is a detail view illustrating the use of the probe shown in FIG. 11A , according to an embodiment of the invention.
[0036] FIG. 12A is a sectional view, in a plane perpendicular to its longitudinal axis, of a multi-element ultrasonic probe.
[0037] FIG. 12B represents a two-dimensional multi-element ultrasonic probe.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The structural component 10 and the component 12 assembled onto this structural component, shown in FIGS. 4A and 4B , are similar to those described above and shown in FIGS. 3A and 3B . A probe 35 is inserted into the hole 21 which is common to the structural component 10 and the component 12 . The probe 35 is equipped with a rotation sensor 38 . The probe 35 comprises at least one ultrasonic transducer 36 , as shown in FIG. 5B . When its emission is controlled, this ultrasonic transducer emits an ultrasound beam 37 perpendicular to a longitudinal axis of the probe. The probe 35 is positioned so that the ultrasound beam is emitted in the thickness of the structural component 10 . Preferably, a commonly used gel is applied to the probe to ensure the transmission of the ultrasound between the probe and the structural component 10 in the hole 21 . If this ultrasound beam encounters a discontinuity in the component 10 , this beam is reflected in such a way that some of the emitted ultrasound is reflected toward the transducer 36 of the probe. The time interval between the emission of the ultrasound beam and the reception by the probe of an echo corresponding to the reflected ultrasound is characteristic of the distance between the probe and the discontinuity. This discontinuity may, notably, correspond to a crack 15 in the structural component 10 . In the example shown in FIGS. 5A and 5B , the probe is oriented in the structural component 10 in such a way that the ultrasound beam is reflected at point B of the crack 15 .
[0039] When the probe 35 is inserted into the hole 21 , an operator positions the rotation sensor 38 in contact with the component 12 , as shown in FIGS. 5A and 5B . For the sake of clarity, the component 12 is not shown in FIG. 5A .
[0040] Advantageously, the rotation sensor is a rotary encoder. It comprises two parts which are rotationally movable relative to one another, namely a first part fixed to the probe 35 and a second part designed to be fixed to the component 12 when the probe 35 is inserted into the hole 21 . In one alternative, the rotary encoder is an incremental encoder; in another alternative, it is an absolute encoder. When it is linked to a control system, if the first part and the second part move rotationally relative to one another, the rotation sensor 38 delivers a signal representative of the rotation. Thus the control system determines the current angular position of the probe 35 . According to a first variant, a surface of the second part of the rotation sensor 38 , designed to be in contact with the component 12 when the probe 35 is inserted into the hole 21 , is of a non-slip type. This surface is, for example, coated with a material such as rubber. Thus the operator may move the probe 35 rotationally in the hole 21 , while applying a light longitudinal pressure to the probe or to the rotation sensor in the direction of the component 12 , without causing the rotation of the second part of the rotation sensor 38 : thus this second part remains fixed to the component 12 . In a second variant, the rotation sensor 38 comprises a fastening flange 38 f fixed to the second part, as shown in FIG. 6 . This fastening flange has a hole designed to interact with another hole in the component 12 , for example one of the holes 20 or 22 . When he positions the rotation sensor 38 on the component 12 , the operator causes this hole in the fastening flange 38 f to be superimposed on the other hole 20 or 22 in the component 12 . In the example shown in the figure, the hole in the fastening flange is superimposed on the hole 20 in the component 12 . If the other hole 20 is empty, the operator places an insert 24 into this at least one other hole, to fix the second part of the rotation sensor 38 to the component 12 : because of this insert 24 , the fastening flange 38 f , and consequently the second part of the rotation sensor 38 , cannot revolve around the probe 35 . The insert 24 is, for example, a clip made of plastic material. If the other hole 20 or 22 already contains an assembly screw or bolt, the insert 24 may be a screw head or a nut on the bolt. The above description relates to the insertion of the probe 35 into the hole 21 from the end of the hole 21 corresponding to the component 12 . This procedure is particularly useful if the other end of the hole, corresponding to the structural component 10 , is difficult or impossible to access. Without departure from the scope of the invention, if this other end of the hole is accessible, the operator could insert the probe into the hole 21 from this other end corresponding to the structural component 10 . He would then place the rotation sensor 38 in contact with the structural component 10 .
[0041] An angular position of the probe 35 in the hole 21 corresponds to a direction of emission of the ultrasound beam 37 that may be emitted by the transducer 36 of the probe. The ultrasound beam shown in FIG. 6 is reflected by the crack 15 at a point B. As mentioned above, the measurement of the reflected ultrasound may be used to determine the distance between the probe and the point B. The point B may thus be characterized by a pair of data elements corresponding, on the one hand, to the angular position of the probe determined by a control system on the basis of a signal received from the rotation sensor 38 and, on the other hand, to the distance measured between the probe and the point B. This pair of data elements forms polar coordinates in a reference frame centered on the point 21 . In an exemplary embodiment, the probe 35 is linked to a measuring instrument marketed by the company TESTIA® under the trade name “Smart U32.” This measuring instrument controls the emission of the ultrasound beam 37 by the probe, measures the reflected ultrasound, and automatically indicates the distance between the probe and the point B. Advantageously, the control system is incorporated in this measuring instrument. In fact, the measuring instrument has available communication ports, of the USB® type for example, and is based on a Windows® software environment in which special-purpose software can be installed, in addition to the basic measurement functions available in the measuring instrument. An example of a control system 55 based on this measuring instrument is shown in FIG. 10 . The control system 55 comprises a processing unit 58 , for example a processor or a microprocessor. It also comprises a display screen 50 , designed, notably, to display measurements made by means of the measuring instrument. The probe 35 is linked to the control system 55 (the measuring instrument) as indicated above. The rotation sensor 38 is also linked to the control system, if necessary via an adapter which is not shown in the figure, and which is connected to a communication port of the control system. The processing unit comprises a software function for determining the angular position of the probe 35 on the basis of signals received from the rotation sensor 38 .
[0042] In a first embodiment, in order to inspect the crack 15 in the structural component 10 , the operator moves the probe 35 rotationally in the hole 21 , the probe being linked to the aforementioned measuring instrument 55 . This rotational movement of the probe enables the direction of emission of the ultrasound beam by the probe to be varied. If the ultrasound beam is reflected by a discontinuity in the structural component 10 , such as the crack 15 , the amplitude of the signal supplied by the probe (corresponding to the reflected ultrasound) and measured by the measuring instrument is above a predetermined threshold. FIG. 9 shows an example of a display on the display screen 50 of the measuring instrument. A vertical scale A corresponds to the amplitude of the measured signal, and a horizontal scale d corresponds to the time interval between the emission of the ultrasound beam and the reception of reflected ultrasound. This horizontal scale d therefore corresponds to the distance between the probe and an ultrasound reflection point. A measured signal 54 is displayed on the screen. For distance at which the structural component has no discontinuity, the amplitude of the signal 54 is below a predetermined threshold S. However, for a distance D at which the ultrasound beam is reflected, the signal 54 has a peak amplitude 52 above this predetermined threshold. The display of the peak 52 on the screen enables the operator to read the distance D on the horizontal scale d. If no discontinuity is present in the component in the direction of emission of the ultrasound beam, the signal 54 does not have a peak 52 of this type, and its amplitude is below the predetermined threshold S over the whole of the horizontal scale. When the operator moves the probe rotationally 35 in the hole 21 , the direction of emission of the ultrasound beam by the probe varies as mentioned above, and therefore the distance D indicated by the measuring instrument on the screen 50 also varies. In practice, the operator moves the probe 35 rotationally, preferably through a rotation of at least 360°, while monitoring the display on the screen 50 . While the operator is moving the probe 35 , the control system 55 determines the current angular position of the probe 35 at different instants, by means of the software function of the processing unit 58 . Additionally, if the ultrasound beam is reflected at point of discontinuity of the structural component 10 , the distance D between the probe and this point of discontinuity is known by the control system 55 and is also displayed on the screen 50 . The processing unit 58 of the control system executes software configured to record in a memory pairs of data elements corresponding to the angular position of the probe and the distance D, for a set of points of discontinuity of the structural component 10 . In a first variant, the recording of the pairs of data elements corresponds to temporal sampling, coupled to a filtering procedure, so that the pairs of data elements are recorded only if the signal 54 measured and displayed by the measuring instrument has a peak amplitude 52 above the predetermined threshold S, this peak corresponding to a reflection of the ultrasound beam at a point of discontinuity of the structural component 10 . Because of this filtering, the pairs of data elements are recorded only if they correspond to points of discontinuity of the structural component 10 . In another variant, the recording of the pairs of data elements corresponds to angular sampling (for example, at every 1° of rotation of the probe 35 , based on its angular position determined by the control system 55 ), coupled to a filtering procedure similar to that described for the first variant.
[0043] In a second embodiment, the probe 35 is equipped with a motor 40 as shown in FIG. 8 . The motor comprises a rotor 40 r , fixed to the probe, and a stator 40 s . According to a first variant, a surface 41 of the stator 40 s , designed to be in contact with the component 12 (or with the structural component 10 ) when the probe 35 is inserted into the hole 21 , is of a non-slip type. This surface is, for example, coated with a material such as rubber. Thus, when the motor is controlled so as to move the probe 35 rotationally in the hole 21 , the operator simply has to apply a light longitudinal pressure to the stator in the direction of the component 12 in order to keep the stator fixed to the component 12 . In a second variant, the stator 40 s comprises a fastening flange, similar to the fastening flange 38 f described above for the rotation sensor. This fastening flange enables the stator 40 s to be kept fixed to the component 12 . The motor 40 is linked to the control system 55 as shown in FIG. 10 , if necessary via an adapter (not shown) which is connected to a communication port of the control system. According to a first alternative, the probe 35 is equipped with both the motor 40 and the rotation sensor 38 . According to a second alternative, the probe 35 is equipped solely with the motor 40 , and the control system 55 determines the angular position of the probe 35 on the basis of the control signals that it sends to the motor. In this second embodiment, after the probe has been placed on the component 12 (or on the structural component 10 ), the operator does not need to manipulate the probe 35 : the rotational movements of the probe are provided by the motor 40 controlled by the control system 55 . Thus the control system 55 records pairs of data elements (corresponding to the angular position of the probe and the distance D determined by the control system 55 ) as in the first embodiment, and its software is also configured to control the rotation of the probe 35 by means of the motor 40 .
[0044] In both the first and the second embodiment, after the recording of the pairs of data elements in the memory, the software of the processing unit 58 executes a function of searching for characteristic points of discontinuity of the structural component 10 . These characteristic points of discontinuity correspond to discontinuities of the structural component which are present even in the absence of a crack or defect in the component. They correspond, notably, to edges of the component, to holes pierced in the component, etc. By way of non-limiting example, the points C 1 , C 2 , C 3 and C 4 shown in FIG. 7 correspond to characteristic points of discontinuity of the structural component 10 . The coordinates of the characteristic points of discontinuity are known from a plan of the component, for example a digital model of the component. According to a first variant, these coordinates are recorded in a memory of the control system. According to another variant, these coordinates are recorded in a database, and the control system 55 interrogates the database via a data link. If these coordinates are not already expressed in an angular reference frame centered on the hole 21 , the software executes a conversion function to find the coordinates of the characteristic points of discontinuity in an angular reference frame of this type centered on the hole 21 and having its orientation determined relative to the structural component 10 , for example the angular reference frame Ra shown in FIG. 7 , the orientation of which is represented by an arrow corresponding to a direction 0. These coordinates then correspond to polar coordinates, such as the pairs of data elements recorded in the memory by the control system during the rotation of the probe. Regarding these pairs of data elements, the reference frame used is also centered on the hole 21 , but is oriented in any direction, since the rotation sensor 38 (or the motor 40 ) has not undergone an initialization procedure to fix a reference direction relative to the structural component 10 . By comparing the coordinates of the characteristic points of discontinuity (expressed in the angular reference frame Ra whose orientation is determined relative to the structural component 10 ) with the pairs of data elements recorded in the memory, the software searches for the pairs of data elements corresponding to these characteristic points of discontinuity. As a result of this, it calculates a correspondence, in the form of an angular offset, between the angular positions recorded in the pairs of data elements and the angular reference frame Ra linked to the component.
[0045] Having determined this correspondence between the recorded angular positions and the angular reference frame linked to the component, the software of the processing unit 58 executes a transformation function based on this correspondence, to transform the pairs of data elements recorded in the memory into polar coordinates expressed in the angular reference frame Ra linked to the component. These polar coordinates define the positions, in the structural component 10 , of the points of discontinuity detected during the rotation of the probe 35 in the hole 21 .
[0046] In a non-limiting specific embodiment of the invention, a new step of measurement acquisition is executed before the execution of the aforementioned transformation function. For this purpose, another rotation of the probe in the hole 21 is performed by the operator, or is controlled automatically by means of the motor 40 , and the control system records new pairs of data elements in the memory. The transformation function is then applied to these new pairs of data elements.
[0047] Preferably, after the transformation of the pairs of data elements corresponding to the points of discontinuity into polar coordinates expressed in the reference frame linked to the structural component 10 , the software executes a filtering function which eliminates all the stored points of discontinuity which correspondent to characteristic points of discontinuity. This makes it possible to retain in memory only the useful data elements corresponding to anomalies detected in the structural component 10 , for example the crack 15 . In the example shown in FIG. 7 , the useful data elements correspond to the coordinates of points B 1 , B 2 . . . B 10 located on the crack 15 . The software displays these useful data elements on the screen 50 so that the operator can become aware of the anomalies detected in the structural component 10 . In one embodiment, the software produces a report containing these useful data elements, which can be exported to a computer to make use of the data elements.
[0048] The operator may then, for example, represent the points B 1 , B 2 , . . . B 10 on a plan of the component, regardless of whether this is a paper plan or a computer plan. The measurement of the distance between one edge of the structural component 10 , near the point B 1 , and the point B 10 enables the operator to determine a length of the crack 15 in the structural component 10 .
[0049] Advantageously, the software of the processing unit 58 further comprises a calculation function configured for automatically calculating the length of the crack 15 on the basis of the useful data elements corresponding to the points B 1 , B 2 . . . B 10 , in order to display this length on the screen 50 and/or to include it in the report.
[0050] In particular, the hole 21 is a hole corresponding to a fastening which is common to the structural component 10 and the component 12 . To enable the probe to be inserted into this hole, the operator first removes this fastening, and then puts it back into position when he has finished the inspection of the crack in the structural component.
[0051] In an advantageous embodiment, the crack testing method is repeated with the probe 35 inserted into at least two holes in the structural component 10 , for example the aforementioned hole 21 and the hole 22 and/or 20 . This makes it possible to detect points of reflection of the ultrasound beam 37 from the crack which would not be accessible from the first hole 21 , for example points which would be masked by another hole in the component. This embodiment also enables a plurality of measurements to be made of the position of the same point, thereby improving the precision of the position of the crack 15 .
[0052] In an advantageous embodiment, the probe 35 is a multi-element ultrasonic probe (also known as a “phased array” in English), as shown in FIG. 11A . The probe then comprises a sensor 36 which has a plurality of transducers 36 a , 36 b . . . 36 k placed parallel to a longitudinal axis of the probe. Each of the transducers 36 a , 36 b . . . 36 k may emit an ultrasound beam 37 a , 37 b . . . 37 k respectively, as shown in FIG. 11B . Thus, the use of this multi-element probe makes it possible to emit ultrasound beams in various locations distributed through the thickness of the structural component 10 , as shown in FIG. 11B . The probe is controlled by the measuring instrument so as to emit the various ultrasound beams successively in time, so that the echoes of the beams do not interfere with one another. The use of a plurality of ultrasound beams enables a finer analysis of the crack 15 to be made. This is, notably, useful if the crack 15 affects only a limited part of the thickness of the component 10 , as in the case shown in FIG. 11B : the crack is detected by the ultrasound beam 37 k , while it is not detected by the other beams. In particular, instead of controlling the emission of a plurality of beams 37 a , 37 b . . . 37 k successively, the measuring instrument may be configured to control the probe in a mode called the angular scanning mode, making it possible to choose the trajectory of an ultrasound beam emitted into the structural component.
[0053] In a variant shown in FIG. 5C , the probe used is a multi-element probe comprising a sensor 36 as shown in FIG. 5D . Using this multi-element probe enables the structural component to be tested without moving the probe. This sensor 36 comprises a plurality of ultrasonic transducers 36 s , 36 t . . . 36 z , as shown in FIG. 12A . As the sensor 36 comprises a plurality of ultrasonic transducers ( 8 , for example), this sensor is placed inside the probe 35 rather than on its surface, for reasons of integration. The space between the sensor 36 and the surface of the probe is then filled with a material which conducts ultrasound. When it is controlled by a control system, the sensor 36 emits an ultrasound beam 37 perpendicular to a longitudinal axis of the probe. The ultrasound beam is emitted in a direction of emission which is controlled by the control system, according to what is known as an angular scanning method. The probe 35 is positioned so that the ultrasound beam is emitted in the thickness of the structural component 10 . Preferably, a commonly used gel is applied to the probe to ensure the transmission of the ultrasound between the probe and the structural component 10 in the hole 21 . If this ultrasound beam encounters a discontinuity in the component 10 , this beam is reflected in such a way that some of the emitted ultrasound is reflected toward the transducer 36 of the probe. The time interval between the emission of the ultrasound beam and the reception by the probe of an echo corresponding to the reflected ultrasound is characteristic of the distance between the probe and the discontinuity. This discontinuity may, notably, correspond to a crack 15 in the structural component 10 . In the example shown in FIG. 5C , the ultrasound beam is emitted in a direction of emission controlled by the control system, in such a way that the ultrasound beam is reflected at point B of the crack 15 .
[0054] When the probe 35 is inserted into the hole 21 , an operator positions the stop 38 against the component 12 , as shown in FIGS. 5C and 5D . For the sake of clarity, the component 12 is not shown in FIG. 5C . The stop 38 enables the longitudinal position of the probe 35 relative to the structural component 10 to be secured, so that the ultrasound beam is emitted in the thickness of the structural component 10 . The hole 21 may be a hole with a circular cross section, but this is not essential. If the hole does not have a circular cross section (for example, if it is a hole with a rectangular, square or oblong cross section), the cross section of the probe is preferably chosen to be complementary to that of the hole, as a result of which the orientation of the probe relative to the structural component 10 is fixed because of its insertion into the hole. During the manufacture of the probe, the position of the sensor 36 in the probe is then chosen in such a way that the sensor can emit an ultrasound beam in a set of directions that enables the whole of an area of interest 14 to be tested, when the probe is controlled by the control system. If the hole 21 has a circular cross section, the operator orientates the probe 35 in the hole in such a way that the probe can emit an ultrasound beam in a set of directions that enables the whole of an area of interest 14 to be tested, when the probe is controlled by the control system, without any movement of the probe.
[0055] As mentioned above, if the probe 35 is connected to a control system, this control system can control the emission of an ultrasound beam by the probe in a direction of emission controlled by the control system, using an angular scanning method. The ultrasound beam 37 shown in FIG. 6 is reflected by the crack 15 at a point B. As mentioned above, the measurement of the reflected ultrasound may be used to determine the distance between the probe and the point B. The point B may thus be characterized by a pair of data elements corresponding, on the one hand, to the direction of emission of the ultrasound beam by the probe 35 (controlled by the control system) and, on the other hand, to the distance determined between the probe and the point B. This pair of data elements forms polar coordinates in a reference frame centered on the point 21 . In an exemplary embodiment, the control system to which the probe 35 is linked is a measuring instrument marketed by the company TESTIA® under the trade name “Smart U32.” This measuring instrument controls the emission of the ultrasound beam 37 by the probe, measures the reflected ultrasound, and automatically indicates the distance between the probe and the point B.
[0056] To test for the crack 15 in the structural component 10 , the control system 55 comprises special-purpose software. This special-purpose software, executed by the processing unit 58 , is configured to control the emission of an ultrasound beam by the probe 35 in successive directions of emission of a set of directions of emission specified to test the whole of the area of interest 14 , without any movement of the probe between the measurements corresponding to the different directions of emission. In an exemplary embodiment, successive directions of emission are spaced apart angularly by an angle of 1°. If the ultrasound beam is reflected by a discontinuity in the structural component 10 , such as the crack 15 , the amplitude of the signal supplied by the probe (corresponding to the reflected ultrasound) and measured by the measuring instrument 55 is above a predetermined threshold. The software of the control system 55 is configured in such a way that, if this ultrasound beam is reflected by a discontinuity of the structural component 10 in one direction of emission, the software controls the recording in the memory of a pair of data elements corresponding to the direction of emission of the ultrasound beam by the probe and to the distance D determined between the probe and the discontinuity. Thus the software successively records in the memory a set of pairs of data elements, each corresponding to the direction of emission of an ultrasound beam by the probe and to the distance D between the probe and a point of discontinuity corresponding to this direction of emission. These pairs of data elements correspond to the set of points of discontinuity of the structural component 10 detected by the control system 55 . The recording of the pairs of data elements by the control system 55 requires no action by operator on the probe after it has been positioned in the hole 21 .
[0057] After the recording of the pairs of data elements in the memory, the software of the processing unit 58 executes a function of searching for characteristic points of discontinuity of the structural component 10 . These characteristic points of discontinuity correspond to discontinuities of the structural component which are present even in the absence of a crack or defect in the component. They correspond, notably, to edges of the component, to holes pierced in the component, etc. By way of non-limiting example, the points C 1 , C 2 , C 3 and C 4 shown in FIG. 7 correspond to characteristic points of discontinuity of the structural component 10 . The coordinates of the characteristic points of discontinuity are known from a plan of the component, for example a digital model of the component. According to a first variant, these coordinates are recorded in a memory of the control system. According to another variant, these coordinates are recorded in a database, and the control system 55 interrogates the database via a data link. If these coordinates are not already expressed in an angular reference frame centered on the hole 21 , the software executes a conversion function to find the coordinates of the characteristic points of discontinuity in an angular reference frame of this type centered on the hole 21 and having its orientation determined relative to the structural component 10 . This reference frame is called the first reference frame in the remainder of the description. The coordinates of the characteristic points of discontinuity then correspond to polar coordinates, such as the pairs of data elements recorded in the memory by the control system. Regarding these pairs of data elements, the reference frame used is also centered on the hole 21 . It is called the second reference frame in the remainder of the description. If the position of the probe 35 is fixed relative to the structural component 10 as a result of its insertion into a hole 21 having a non-circular cross section, then, unless there is an error in manipulation or measurement, this second reference frame relating to the pairs of data elements must substantially correspond to the first reference frame. If the hole 21 has a circular cross section, the operator orientates the probe in the hole in such a way that it can emit an ultrasound beam throughout the whole of the area of interest 14 . However, in this case the orientation of the probe may be imprecise, and there may be an angular offset between the first reference frame and the second reference frame. When it executes the function of searching for characteristic points of discontinuity, the software compares the coordinates of the characteristic points of discontinuity (expressed in the first reference frame) with the pairs of data elements recorded in the memory (the coordinates expressed in the second reference frame), in order to search for the pairs of data elements corresponding to these characteristic points of discontinuity. As a result of this, it calculates a correspondence, in the form of an angular offset, between the directions of emission recorded in the pairs of data elements (the coordinates expressed in the second reference frame) and the first reference frame. Having determined this correspondence, the software of the processing unit 58 executes a transformation function based on this correspondence, to transform the pairs of data elements recorded in the memory into polar coordinates expressed in the first reference frame linked to the component. These polar coordinates define the positions, in the structural component 10 , of the points of discontinuity detected by the control system 55 . The function of searching for characteristic points of discontinuity of the structural component 10 and the transformation function are especially useful when the hole 21 has a circular cross section and a template 18 is not used. However, the function of searching for characteristic points of discontinuity may also be useful outside this situation: if there is an error in manipulation or measurement, there is a risk that the function of searching for characteristic points of discontinuity may not find the characteristic points of discontinuity among the pairs of data elements recorded, and the software may then alert the operator to a problem.
[0058] Preferably, the software executes a filtering function which eliminates all the points of discontinuity stored in the memory which correspond to characteristic points of discontinuity. This makes it possible to retain in memory only the useful data elements corresponding to anomalies detected in the structural component 10 , for example the crack 15 . In the example shown in FIG. 7 , the useful data elements correspond to the coordinates of points B 1 , B 2 . . . B 10 located on the crack 15 . The software displays these useful data elements on the screen 50 so that the operator can become aware of the anomalies detected in the structural component 10 . In one embodiment, the software produces a report containing these useful data elements, which can be exported to a computer to make use of the data elements.
[0059] The operator may then, for example, represent the points B 1 , B 2 , . . . B 10 on a plan of the component, regardless of whether this is a paper plan or a computer plan. The measurement of the distance between one edge of the structural component 10 , near the point B 1 , and the point B 10 enables the operator to determine a length of the crack 15 in the structural component 10 .
[0060] Advantageously, the software of the processing unit 58 further comprises a calculation function configured for automatically calculating the length of the crack 15 on the basis of the useful data elements corresponding to the points B 1 , B 2 . . . B 10 , in order to display this length on the screen 50 and/or to include it in the report.
[0061] In an advantageous embodiment, the probe 35 is a two-dimensional multi-element ultrasonic probe, that is to say, a probe using a sensor whose ultrasonic transducers are arranged in two dimensions. An example of a sensor 36 of this type of probe is shown in FIG. 12B . The sensor comprises a set of transducers arranged in the form of a matrix in the rows 36 a , 36 b . . . 36 k and columns 36 s , 36 t . . . 36 z . Thus the sensor shown in the figure comprises 64 transducers, arranged in 8 rows and 8 columns. Other arrangements of the transducers are possible without departure from the scope of the invention. The columns of transducers 36 s , 36 t . . . 36 z are placed parallel to a longitudinal axis of the probe. Each row of transducers may be controlled by the control system to emit an ultrasound beam in a direction of emission controlled by the control system, as mentioned above. Each of the rows of transducers 36 a , 36 b . . . 36 k can thus emit an ultrasound beam when controlled by the control system. The use of this multi-element probe makes it possible to emit ultrasound beams in various locations distributed through the thickness of the structural component 10 . The probe is controlled by the measuring instrument so as to emit the various ultrasound beams successively in time, so that the echoes of the beams do not interfere with one another. The use of a plurality of ultrasound beams enables a finer analysis of the crack 15 to be made. This is, notably, useful if the crack 15 affects only a limited part of the thickness of the component 10 . In particular, instead of controlling the emission of a plurality of beams successively, the measuring instrument may be configured to control the probe in a mode called the angular scanning mode, making it possible to choose the trajectory of an ultrasound beam emitted into the structural component. As the sensor 36 is of a matrix type, the angular scanning is then controlled by the control system in two dimensions.
[0062] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.
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A method for structural component crack testing comprising: a) identifying a structural component hole and inserting a probe thereinto; b) for different emission directions, automatically performing the following: b1) controlling a probe ultrasound beam emission; b2) measuring a probe signal; b3) if the measured signal amplitude is above a predetermined threshold: determining a distance between the probe and a structural component discontinuity point; recording a data set comprising at least the distance between the probe and the discontinuity point, together with a data element corresponding to the probe emission angular direction, c) automatically searching for data sets corresponding to characteristic discontinuity points, and consequently establishing a correspondence between the probe emission angular directions and an angular reference frame linked to the component; d) based on the recorded data sets, automatically determining the discontinuity point positions; e) determining a dimensional characteristic of a crack based on the discontinuity point positions.
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TECHNICAL FIELD
[0001] The field of this invention relates to 1) the in situ genetic modification in of stem/progenitors (especially of the human nervous system) for the expression of therapeutic genes. Furthermore, this invention relates to 2) the use of any human or animal derived stem/progenitor cell (especially stem cells derived from the testis) and or their progeny as well as immortalized cell lines, for the treatment of diseases in the human nervous system whether the cells be derived ultimately from the patient or from a donor source. In both aspects, this invention relates specifically to various modifications of the stem cells which would render them and/or their progeny capable of ameliorating the effects of metabolic, degenerative, mental retardative, autoimmune, immune, ischemic, microbiological, and/or toxin-mediated disease processes, age related senescence in humans and animals especially those of the human nervous system. In another aspect, this invention relates to methods of introducing genetically-modified stem cells into the patient, especially the patient's nervous system, and methods for modification of patient's endogenous stem cells in situ, in vivo.
BACKGROUND OF THE INVENTION
[0002] Overview of Anatomy and Development
[0003] As a biological system, the mammalian nervous system represents unrivaled functional and architectural diversity. In the developing embryo, the neuroepithelium generates all of the central nervous system (CNS). Within the neuroepithelium is a population of founder neural stem cells. These stem cells divide to form progeny or daughter cells. Daughter cell fates are influenced by the immediate environment of the dividing stem/progenitor cell (including cell-cell contact, cell-matrix contact and the binding of diffusible factors to cellular receptors). On the other hand, some stem cell/progenitors appear to be indifferent to such environmental influences and demonstrate a commitment to a particular pattern of differentiation. A progenitor cell is said to be committed when it has acquired the information that ultimately dictates the phenotypes or fates of its daughter cells.
[0004] Stem/Progenitor Cells
[0005] 1) Umbilical cord blood cells:During fetal deveopment, the circulation of the mother and her child normally remain separate. The blood on the fetal side of the placenta contains highly undifferentiated cells which have been shown to proliferate and differentiate under appropriate conditions to form a variety of blood cell types. Umbilical cord blood cells are becoming an increasingly important source of blood cells for bone marrow trransplant (BMT). Typically the stem cells are introduced into appropriately matched patients through injection into the patient's circulation. However, the application of these cells, with or without genetic modification, to the treatment of clinical disease by grafting into the patient CNS or other tissues for replacement of deficient gene products or supplementation of gene products is specifically covered by this invention and has not been previously attempted or published.
[0006] 2) Bone marrow stem/progenitor cells permanently populate the vascular sinuses of flat and short bones over the entire lifetime of the animal, and divide to produce the relatively short-lived blood cells. This arrangement contrasts markedly with the nervous system where germinal zone cells are, for the most part, mitotically-active over a short period in the animal's lifetime, producing almost all of the adult complement of neurons, astrocytes, and oligodendrocytes prenatally. A pluripotent ciliated stem cell has nevertheless been isolated from the adult lateral ventricle of the forebrain as well the central canal of the rodent brain and spinal cord. These stem cells divide to form large, adherent masses of progeny cells (neurospheres (NS)) under appropriate conditions in culture. Interestingly, neural stem cells isolated from the embryonic or adult striatum can integrate into the bone marrow and produce a wide array of hematopoietic progeny. Conversely, genetically-marked hematopoietic progenitor cells have been found to be capable of producing neural oligodendrocytes and astrocytes when transplanted to the nervous system. These results are broadly interpreted as demonstrating that stem cells from various organ systems retain a tremendous potential to respond to unspecified morphogenetic factors and to produce both neural and non-neural cells after gaining access to the appropriate tissue environment.
[0007] 3) Skin progenitor cells within the basal layer of the skin are progenitor cells which divide over the entire lifespan of the individual. Such cells are readily accessible and may be cultured by a variety of culture conditions known to the art before and during genetic modification for modification for transplantation into the nervous system or other tissues.
[0008] 4) Spermatogonia and other primordial germ cells of the testis are of a special interest with regard to this application. Throughout this patent the term spermatogonia refers to all spermatogonia cells (especially spermatogonia A cells) and other primordial germ cells of the testis. Furthermore all manipulations of spermatogonia described herein should also be understood to be available for application to other stem/progenitor cells (especially, those derived from the testis, umbilical cord, blood and skin) for the same purpose.
[0009] This patent envisions isolation and preservation of spermatogonia by any method known to the art.
DESCRIPTION
[0010] The present invention covers the genetic modification of stem/progenitor for the preparation of cells resistant to intrinsic or extrinsic disease such as immune-mediated, inflammatory, viral, bacterial, autoimmune, toxin-mediated disease, aging and/or degenerative diseases. This invention also covers the preparation of cells modified genetically to alter their responsiveness to drug therapy. This patent covers genetic modification of stem/progenitor or their progeny for the purpose of extending the life of these or other cells and genetic modification of multipotent stem/progenitor and their progeny for treatment of clinical disease, especially in the human nervous system. Finally, this patent covers the transplantation of unmodified stem cells by the same methods.
[0011] Alternatively, stem/progenitor may be modified (altered gene expression) through culture techniques to produce a desired cell line, cell type or cell class. Such techniques include exposing stem/progenitor to an exogenous agent, such as retinoic acid, or dimethylsulfoxide, promoting differentiation or modification of the stem/progenitor into the desired cell line, such as, for example, a neuronal cell line, but does not exclude the use of physiologic modifiers such as steel factor or other cytokines.
[0012] There are multiple sources of exogenous stem/progenitor cells. The present invention is directed toward the use of any genetically altered stem cell, progenitor cell, embryonic stem cell (ES cell), umbilical cord blood stem cell or immortalized cell lines, and/or their progeny for the purpose of treating disease or clinical condition, especially those of the nervous system. However bone marrow stem cells, spermatogonia, and primordial germ cells of the testis are of particular interest and are specifically covered by this invention.
[0013] A stem/progenitor cell which may be induced to differentiate into a desired cell line, cell type, or cell class. In this newly differentiated state the stem/progenitor cell (and or its progeny) are considered to be modified. The stem/progenitor cell may also be modified through genetic engineering techniques using DNA or RNA, encoding protein(s) or polypeptide(s) promoting differentiation of the stem cell into a specific cell line (for example, a neuronal cell line, a muscle cell line, or a hematopoietic cell line), cell type or cell class. The DNA or RNA may encode a transcription factor found in the particular cell lines, types (e.g. neurons, glia, muscle), or classes (e.g. neural cells, hematopoietic cells, etc.).
[0014] The term genetic modification refers to alteration of the cellular genotype by introducing natural or synthetic nucleic acids into stem/progenitor or immortalized cell lines and/or their progeny by any means known to the art. Alternatively culture conditions that induce permanent changes in gene expression patterns are considered herein to represent genetic modification. Modification of stem cells, whether they be derived from the host brain, endogenous donor sources, exogenous donor sources, or cell lines, represents a feasible approach to the treatment of certain human diseases, especially those of the human nervous system.
[0015] Genetic modifications covered by this patent would include, but are not limited to: modifications that alter the activity or amount of metabolic enzymes expressed by endogenous or exogenous stem/progenitor; modifications which alter the activity, amount, or antigenicity of cellular proteins; modifications which alter the activity or amount of proteins involved in signal transduction pathways; modifications which alter the amount or activity of structural proteins; modifications which alter the amount or activity of membrane associated proteins (structural or enzymatic); modifications which alter the activity or amount of proteins involved in DNA repair and chromosome maintenance; modifications which alter the activity or amount of proteins involved in cellular transport; modifications which alter the activity or amount of enzymes; modifications which alter the activity or amount of proteins involved in synapse formation and maintenance; modifications which alter the activity or amount of proteins involved in neurite outgrowth or axon outgrowth and formation; modifications altering the amount or activity of antioxidant producing enzymes within the cell; modifications which lead to altered post-translational modification of cellular proteins; modifications which alter the activity or amount of proteins involved in other aspects of cellular repair, and alterations which increase the lifespan of the cell (such as production of telomerase). Such proteins as those mentioned above would be encoded for by DNA or RNA derived from the human genome or other animal, plant, viral, or bacterial genomes. This invention also covers sequences designed de novo.
[0016] In the first part, this invention relates to the in situ, genetic modification of stem/progenitor cells of the nervous system for the treatment of disease. Endogenous stem cells may be modified in situ by direct injection or application of DNA or RNA vectors, including viruses, retroviruses, liposomes, etc, into the substance of the tissue or into the appropriate portion of the ventricular system. We have modified thousands of stem/progenitor cells and many thousand progeny cells in this manner. Our data shows that this manner of modifying progenitor cells results in a tremendous variety of modified cell types throughout the nervous system, and has never resulted in adverse effects. We have achieved genetic modification of stem cells in situ in multiple species.
[0017] Although it may be useful to administer neurotrophins (e.g. brain-derived neurotrophic factor (BDNF), basic fibroblast growth factor (bFGF)) prior to harvesting endogenous cells or at the time of in-situ stem cell modification, it may in most instances not be necessary. Either approach is covered by this patent.
[0018] The methods of the present invention provide an alternative to pharmacological therapy for the treatment of many diseases. Nevertheless, it may be suitable as well for modifying cells to deliver pharmaceuticals beyond the blood-brain barrier for the treatment and alleviation of diseases in the nervous system including psychiatric diseases, or to increase cellular responsivity to pharmacological therapy (including neoplastic cells).
[0019] In the second part, this invention relates to stem and progenitor cells whether they be endogenous cells in situ, or exogenous cells derived from other body regions or even other individual donors. These relatively undifferentiated, self-renewing cells (herein referred to as stem/progenitor) are very rare. Nevertheless certain sources of stem cells (such as the spermatogonia and primordial germ cell of the testis) are accessible and therefore a useful source of replacement cells in the non-fetal human.
[0020] In vitro genetic modification of exogenous cells or patient's endogenous cells are performed according to any published or unpublished method known to the art (e.g. U.S. Pat. Nos. 6,432,711, U.S. 05,593,875, U.S. 05,783,566, U.S. 5,928,944, U.S. 05,910,488, U.S. 05,824,547, etc.) or by other generally accepted means. Successfully transfected cells are identified by selection protocols involving markers such as antibiotic resistance genes. Clones from successfully transfected cells, expressing the appropriate exogenous DNA at appropriate levels, will be preserved as cell lines by cryopreservation (utilizing any appropriate method of cryopreservation known to the art).
[0021] More particularly, this invention relates to progenitor/stem/spermatogonia cells and/or their progeny (and any other stem/progenitor cell) which are modified genetically with DNA and/or RNA, and or modified through culture techniques whereby such cells become capable of differentiating into a desired primary cell line or cell class, such as neurons, glia, muscle cells etc. Throughout this patent, modified spermatogonia cells and their progeny are corporately referred to as spermatogonia or as modified spermatogonia.
[0022] It is an object of the present invention to provide modified stem/progenitor (and any other stem/progenitor cell) which are capable of differentiating uniformly into a cell line, cell type, or cell class (e.g. neural cells), not achievable by previous methods.
[0023] In accordance with an aspect of the present invention, there is provided a method of producing a desired cell line, cell type, or cell class from stem/progenitor cells. Generally, the method comprises culturing spermatogonia under conditions which promote growth of the spermatogonia at an optimal growth rate. The spermatogonia then are cultured under conditions which promote cell growth at a rate which is less than the optimal rate, and in the presence of an agent promoting differentiation of the spermatogonia into the desired cell line, cell type, or cell class (e.g. neural cells).
[0024] A growth rate which is less than the optimal growth rate, is a growth rate from about 10% to about 90% (preferably 20% to 50%) of the maximum growth rate for spermatogonia. The growth rates for spermatogonia can be determined from the doubling times of the spermatogonia
[0025] In one embodiment, when the spermatogonia cells are being cultured under conditions which promote growth of the cells at an optimal growth rate, the spermatogonia are cultured in the presence of a medium including leukemia inhibitory factor (LIF), and serum selected from the group consisting of: (i) horse serum at a concentration of from about 5% by volume to about 30% by volume; and (ii) fetal bovine serum at a concentration of from about 15% by volume to about 30% by volume. In one embodiment, the serum is horse serum at a concentration of about 10% by volume. In another embodiment, the serum is fetal bovine serum at a concentration of about 15% by volume.
[0026] In yet another embodiment, when the spermatogonia are cultured at an optimal growth rate, the spermatogonia are cultured in the absence of a feeder layer of cells.
[0027] In one embodiment, the agents(s) promoting differentiation of the spermatogonia is/are selected from the group consisting of retinoic acid and nerve growth factor, and the desired cell line, cell type, or cell class is neuronal.
[0028] In one embodiment, in addition to culturing the cells in the presence of the stimulating agent selected from the group consisting of retinoic acid and nerve growth factor, the spermatogonia are grown in the presence of a cytokine. Cytokines which may be employed include, but are not limited to, any of the neurotrophins: nerve growth factor, BDNF, GGF, etc., bFGF, EGF, PDGF, reelin, Interleukin-1, Interleukin-3, Interleukin-4, Interleukin-6, colony stimulating factors such as M-CSF, GM-CSF, and CSF-1, steel factor, and erythropoietin.
[0029] In a further embodiment, the agents(s) promoting differentiation of the spermatogonia is/are selected from the group consisting of dimethylsulfoxide and hexamethylene hisacrylamide, and the desired cell line is a muscle cell line, cell type, or cell class, such as a smooth muscle cell line, or a skeletal muscle cell line, or a cardiac muscle cell line. In one embodiment, the agents is dimethylsulfoxide. In another embodiment, the agents(s) is hexamethylene bis-acrylamide.
[0030] In one embodiment, in addition to culturing the spermatogonia in the presence of agents(s) promoting differentiation of the spermatogonia into a muscle cell line, the spermatogonia also are grown in the presence of a cytokine, examples of which are described above.
[0031] In yet another embodiment, when the spermatogonia are cultured in the presence of the agents(s) promoting differentiation of the spermatogonia into a desired cell line, cell type, or cell class, the spermatogonia also are cultured in the presence of fetal bovine serum at a concentration of about 10% by volume.
[0032] In a further embodiment, when the spermatogonia are cultured in the presence of the agents(s) promoting differentiation of the spermatogonia cells into a desired cell line, cell type, or cell class, the spermatogonia also are cultured on a three dimensional supporting structure.
[0033] Thus, the applicants submit that one may produce a desired cell line, cell type, or cell class from progenitor/stem/spermatogonia cells and/or primordial germ cells of the testis by culturing the progenitor/stem/spermatogonia cells initially under conditions which favor the growth or proliferation of such progenitor/stem/spermatogonia cells at an optimal growth rate, and then culturing the cells under conditions which decrease the growth rate of the cells and promote differentiation of the cells to a desired cell type.
[0034] In a preferred embodiment, the progenitor/stem/spermatogonia cells cultured in a standard culture medium (such as, for example, Minimal Essential Medium), which may include supplements such as, for example, glutamine, and beta.-mercaptoethanol. The medium may also include leukemia inhibitory factor (LIF), or factors with LIF activity, such as, for example, CNTF or IL-6, and horse serum. LIF, and factors with LIF activity, prevents spontaneous differentiation of the progenitor/stem/spermatogonia cells, and is removed prior to the addition of the agents(s). Horse serum promotes differentiation of the progenitor/stem/spermatogonia cells into the specific cell type after the addition of the agents(s) to the medium. After the cells have been cultured for sufficient time to permit the cells to proliferate to a desired number, the cells are washed free of LIF, and then cultured under conditions which provide for cell growth at a decreased growth rate but which also promote differentiation of the cells.
[0035] Subsequently, the cells are cultured in the presence of agents(s) promoting differentiation of the progenitor/stem/spermatogonia cells into a desired cell line, cell type, or cell class, and in the presence of fetal bovine serum at a concentration of from about 5% by volume to about 10% by volume, preferably at about 10% by volume. The presence of the fetal bovine serum at a concentration of from about 5% by volume to about 10% by volume, and of the agents(s), provides for growth or proliferation of the cells at a rate which is less than the optimal rate, while favoring the differentiation of the cells into a homogeneous desired cell type. The desired cell type is dependent upon the agents(s) promoting or stimulating the differentiation of the spermatogonia. The spermatogonia also may be cultured on a three dimensional supporting network.
[0036] For example, the spermatogonia may be placed in a culture vessel to which the cells do not adhere. Examples of non-adherent substrates include, but are not limited to, polystyrene and glass. The substrate may be untreated, or may be treated such that a negative charge is imparted to the cell culture surface. In addition, the cells may be plated in methylcellulose in culture media, or in normal culture media in hanging drops.
[0037] In order to form aggregates in hanging drops of media, cells suspended in media are spotted onto the underside of a lid of a culture dish, and the lid then is placed on the culture vessel. The cells, due to gravity, collect on the undersurface of the drop and form aggregates.
[0038] In accordance with another aspect of the present invention, there is provided a spermatogonia cell that has been modified with DNA or RNA encoding protein(s) or polypeptide(s) which promote(s) differentiation of the cell into a specific cell line, cell type, or cell class.
[0039] The DNA or RNA encoding protein(s) or polypeptide(s) promoting differentiation of the spermatogonia cell into a specific cell line, cell type, or cell class is found in the specific differentiated cell line, cell type, or cell class. Preferably, the protein or polypeptide which is present in the specific cell line, cell type, or cell class is protein(s) or polypeptide(s) which generally is not present in other types of cells.
[0040] In one embodiment, the DNA or RNA encoding protein(s) or polypeptide(s) which promote(s) differentiation of the spermatogonia cell into a specific differentiated cell line, cell type, or cell class, is present in the desired cell line, cell type, or cell class.
[0041] In one embodiment, the DNA or RNA encodes a transcription factor present in neuronal cells, and the specific cell line, cell type, or cell class is a neuronal cell line.
[0042] In another embodiment, the DNA or RNA encodes a transcription factor such as the MyoD gene, present in muscle cells, and the specific cell line is a muscle cell line.
[0043] In yet another embodiment, the DNA or RNA encodes a transcription factor present in hematopoietic cells, and the specific cell line is a hematopoietic cell line.
[0044] In yet another embodiment, the DNA or RNA encodes a transcription factor DNA or RNA encodes a transcription factor present in one cell line, cell type, or cell class but the desired cell line, cell type, or class is different from that of the transcription factor.
[0045] The DNA or RNA encoding protein(s) or polypeptide(s) promoting differentiation of the spermatogonia cell into a specific cell line may be isolated in accordance with standard genetic engineering techniques (for example, by isolating such DNA from a cDNA library of the specific cell line) and placing it into an appropriate expression vector, which then is transfected into spermatogonia.
[0046] Appropriate expression vectors are those which may be employed for transfecting DNA or RNA into eukaryotic cells. Such vectors include, but are not limited to, prokaryotic vectors such as, for example, bacterial vectors; eukaryotic vectors, such as, for example, yeast vectors and fungal vectors; and viral vectors, such as, but not limited to, lentiviral vectors, adenoviral vectors, adeno-associated viral vectors, and retroviral vectors. Examples of retroviral vectors which may be employed include, but are not limited to, those derived from Moloney Murine Leukemia Virus, Moloney Murine Sarcoma Virus, and Rous Sarcoma Virus, FIV, and HIV.
[0047] Plasmid DNA containing cDNA inserts can be electroporated into spermatogonia. Cells are transfected with a plasmid that contains sequences for an antibiotic resistance gene and stable transfectants are isolated based on antibiotic resistance. Stable transfected clones are isolated and induced with an appropriate agent, or with leukemia inhibitory factor (LIF) withdrawal alone, and scored for an increased ability to differentiate in response to these induction signals. Clones also are examined to determine if they are differentiating spontaneously in the presence of LIF.
[0048] In accordance with another aspect of the present invention, there is provided a method of producing a desired cell line, cell type, or cell class from spermatogonia. The method comprises engineering spermatogonia with DNA which encodes protein(s) or polypeptide(s) promoting differentiation of the spermatogonia into a specific cell line, type, or class. The spermatogonia then are stimulated with agents(s) promoting differentiation of the spermatogonia into the desired cell line, cell type, or cell class.
[0049] In one embodiment, the DNA which encodes protein(s) or polypeptide(s) promoting differentiation of the spermatogonia into a specific cell line is DNA encodes a transcription factor present in neuronal cells and the agents(s) is/are selected from the group consisting of retinoic acid and nerve growth factor. Alternatively, the cells also may be grown in the presence of a cytokine such as those described above.
[0050] In another embodiment, the DNA which encodes protein(s) or polypeptide(s) promoting differentiation of the spermatogonia into a specific cell line, cell type, or cell class is DNA encodes a transcription factor, such as, for example, the MyoD gene, present in muscle cells and the agents(s) is/are a bipolar agent such as dimethylsulfoxide or hexamethylene bis-acrylamide. Alternatively, the spermatogonia also may be grown in the presence of a cytokine.
[0051] The spermatogonia may be engineered with the DNA or RNA and cultured under conditions described above. For example, prior to induction, the spermatogonia are engineered with DNA which encodes protein(s) or polypeptide(s) promoting differentiation of the spermatogonia into a specific cell line, cell type, or cell class. Then, the spermatogonia may be cultured under conditions which provide for a three-dimensional arrangement of such cells.
[0052] Also, it is to be understood that, within the scope of the present invention, that the spermatogonia may be used for gene therapy purposes. The spermatogonia may be engineered with DNA encoding a desired therapeutic agent. Such engineering may be accomplished by using expression vectors such as those herein above described or others. Once the cells are engineered with DNA encoding a desired therapeutic agent, the cells then are engineered with DNA or RNA which encodes protein(s) or polypeptide(s) promoting differentiation of the spermatogonia into a specific desired cell line, cell type, or cell class, and/or stimulated with agents(s) promoting differentiation of the spermatogonia into a desired cell line, cell type, or cell class. The differentiated cells then may be administered to a host, such as a human or non-human host, as part of a gene therapy procedure.
[0053] The differentiated stem cells may be employed by means known to those skilled in the art to treat a variety of diseases or injuries. For example, stem cells which have differentiated into neuronal cells may be administered to a patient, such as, for example, by transplanting such cells into a patient, to treat diseases such as Huntington's disease, Parkinson's disease, and Alzheimer's disease. Such neuronal cells also may be employed to treat spinal cord injuries or chronic pain. Also, stem cells which have differentiated into muscle cells may be employed in treating muscular dystrophy, cardiomyopathy, congestive heart failure, and myocardial infarction, for example.
[0054] The invention will now be described with respect to the following examples; however, the scope of the present invention is not intended to be limited thereby.
EXAMPLE 1
[0055] Undifferentiated progenitor/stem/spermatogonia are maintained in Dulbecco's modified Minimal Essential Medium (DMEM) supplemented with glutamine, beta.-mercaptoethanol, 10% (by volume) horse serum, and human recombinant Leukemia Inhibitory Factor (LIF). The LIF replaces the need for maintaining progenitor/stem/spermatogonia cells on feeder layers of cells, (which may also be employed) and is essential for maintaining progenitor/stem/spermatogonia cells in an undifferentiated state.
[0056] In order to promote the differentiation of the progenitor/stem/spermatogonia cells into neuronal cells, the progenitor/stem/spermatogonia cells are trypsinized and washed free of LIF, and placed in DMEM supplemented with 10% (by volume) fetal bovine serum (FBS). After resuspension in DMEM and 10% FBS, 1.times.10.sup.6 cells are plated in 5 ml DMEM plus 10% FBS plus 0.5 microM retinoic acid in a 60 mm Fisher brand bacteriological grade Petri dish. In such Petri dishes, progenitor/stem/spermatogonia cells cannot adhere to the dish, and instead adhere to each other, thus forming small aggregates of cells. Aggregation of cells aids in enabling proper cell differentiation. After two days, aggregates of cells are collected and resuspended in fresh DMEM plus 10% FBS plus about 0.5 microM retinoic acid, and replated in Petri dishes for an additional two days. Aggregates, now induced four days with retinoic acid, are trypsinized to form a single-cell suspension, and plated in medium on poly-D-lysine-coated coated tissue culture grade dishes. The stem cell medium is formulated with Kaighn's modified Ham's F12 as the basal medium with the following supplements added: 15 microg/ml ascorbic acid, 0.25% (by volume) calf serum, 6.25 microg/ml insulin, 6.25 microg/ml transferrin, 6.25 microg/ml selenous acid, 5.35 microg/ml linoleic acid, 30 pg/ml thyroxine (T3), 3.7 ng/ml hydrocortisone, 1. ng/ml Heparin 10 ng/ml somatostatin, 0 ng/ml Gly-His-Lys (liver cell growth factor), 0.1 microg/ml epidermal growth factor (EGF), 50 microg/ml bovine pituitary extract (BPE). This medium will provide for consistent differentiation of the stem cells into neuronal cells, and provides for survival of the neuronal cells for a period of time greater than 3 days, and selectively removes dividing non-neuronal cells from the population (U.S. Pat. No. 6,432,711). The poly-D-lysine promotes the attachment of the neuronal cells to the tissue culture plastic, and prevents detachment of the cells from the dish and the formation of floating aggregates of cells. The cells are cultured for 5 days. Upon culturing the cells in the above medium, a culture of cells in which greater than 90% of the cells are neuronal cells is obtained. Such neuronal cells, which express the neurotransmitter gamma amino butyric acid (GABA), then may be employed for the treatment of the neural degeneration disease Huntington's disease. Through genetic engineering, these cells can be directed to express dopamine (for the treatment of Parkinson's disease) or acetylcholine (for the treatment of Alzheimer's disease).
EXAMPLE 2
[0057] Undifferentiated progenitor/stem/spermatogonia cells are maintained in supplemented Dulbecco's modified Minimal Essential Medium as described in Example 1. The progenitor/stem/spermatogonia cells then are trypsinized and washed free of LIF and placed in 1% (by volume) dimethylsulfoxide in DMEM plus 10% horse serum. Two days after the addition of dimethylsulfoxide and plating of cells in Petri dishes to form aggregates, the aggregates are collected and resuspended in fresh medium plus 1% dimethylsulfoxide. The aggregates are then plated onto multi-well untreated culture grade dishes without trypsin treatment. One aggregate is plated per well. The aggregates are cultured for 5 days. Upon culturing of the cells in multi-well dishes, cell cultures in which greater than 90% of the aggregates contain contracting muscle cells are obtained. Such cells may be used to treat cardiomyopathies, myocardial infarction, congestive heart failure, or muscular dystrophy.
EXAMPLE 3
[0058] Progenitor/stem/spermatogonia cells can be isolated using a two-step enzymatic digestion followed by Percoll separation. Cells can then be resuspended in minimum essential medium (MEM) supplemented with bovine serum albumin to a final concentration of 10(6)/mL. In detail: Tubule fragments are accessed surgically and teased apart prior to treatment with 1 mg/ml trypsin, hyaluronidase, and collagenase, and then 1 mg/ml hyaluronidase and collagenase, in MEM containing 0.10% sodium bicarbonate, 4 mM L-glutamine, nonessential amino acids, 40 μg/ml gentamycin, 100 IU to 100 μg/ml penicillin-streptomycin, and 15 mM Hepes. Progenitor/stem/spermatogonia cells are further separated from tubule fragments by centrifugation at 30×g. After filtration through nylon filters with 77- and/or 55-μm pore sizes, cells are collected and loaded onto a discontinuous Percoll density gradient. Fractions with a purity greater than 40% progenitor/stem/spermatogonia cells are washed and resuspended to a concentration of cells equivalent to 10 6 progenitor/stem/spermatogonia cells per milliliter. Afterwards cells will be cultured and/or stored by any cryopreservation technique known to the art.
[0059] Progenitor/stem/spermatogonia cells can be maintained in media containing 5 ng/ml human recombinant leukemia inhibitory factor instead of on feeder layers. Stable transfectants can be isolated, expanded, frozen, and then stored in liquid nitrogen. 35 independent stably transfected progenitor/stem/spermatogonia cells cell lines can be isolated.
EXAMPLE 4
[0060] Genetic modification of progenitor/stem/spermatogonia cells may or may not require construction of genetic constructs such as DNA or RNA vectors. Genetic constructs will in most cases consist of a vector backbone, and a transactivator which regulates a promoter operably linked to a heterologous gene nucleic acid sequence. An example of a suitable vector would be a retroviral vector. Retroviruses are RNA viruses which contain an RNA genome. The gag, pol, and env genes are flanked by long terminal repeat (LTR) sequences. The 5 ′ and 3 ′ LTR sequences promote transcription and polyadenylation of mRNA's. The retroviral vector provides a regulable transactivating element, an internal ribosome reentry site (IRES), a selection marker, and a target heterologous gene operated by a regulable promoter.
[0061] Alternatively, multiple genes may under the control of multiple promoters. Finally the retroviral vector contains cis-acting sequences necessary for reverse transcription and integration. Upon infection, the RNA is reverse transcribed to DNA which integrates efficiently into the host genome. The recombinant retrovirus of this invention is genetically modified in such a way that some of the retroviral, infectious genes of the native virus have been removed and in certain instanced replaced instead with a target nucleic acid sequence for genetic modification of the cell. The transgene would typically be exogenous DNA, in its natural or altered form, from animal or plant species. In many instances the transgene would be altered to contain a signal sequence that directs the transgene's protein product to be secreted from the cell, possibly for uptake and utilization by adjacent, non-modified, host cells.
[0062] An example of a method of producing a virus whereby progenitor/stem/spermatogonia cells may be modified is as follows: “Packaging cell lines” derived from human and/or animal fobroblast cell lines are the result of transfecting or infecting normal cell lines with viral gag, pol, and env structural genes. On the other hand, packaging cell lines produce RNA devoid of the psi sequence, so that the viral particles produced from packaging cell do not contain the ga, pol, or env genes. Once vector DNA containing the psi sequence (along with the therapeutic gene) is introduced into the packaging cell, by means of transfection or infection, the packaging cell will profuce virions capable of transmitting the therapeutic RNA to the final target cell (e.g. a neuroblast).
[0063] The “infective range” of this engineered virus is determined by the packaging cell line. A number of amphotrophic packaging cell lines are availble for production of virus suitable for infecting a broad range of human cell types. These cell lines are nevertheless generally capable of encapsidating viral vectors derived from viruses which in nature usually infect different animal species. For the example vectors derived from the MMLV can nevertheless be packaged by amphotrophic cell lines.
[0064] An example protocol for producing a therapeutic viral supernatant will follow the generally, the protocol outlined below:
[0065] 1. Twenty micrograms of retrovirus vector should be mixed with 2-3 micrograms of viral DNA containing the selectable marker gene (e.g. antibiotic resistance gene) by gentle tapping in 0.8-1 milliliter of Hepes buffered saline (pH=7.05) in a 1.5 ml plastic tube.
[0066] 2. Seventy microliters of 2M Ca Cl2 should be added to the mixture by repeated gentle tapping.
[0067] 3. When a blue precipitate first begins to appear within the tube, the product should be gently applied to a 30% confluent layer of amphotrophic packaging cells (from any number of commercial vendors). The DNA mixture should be applied only after first removing the medium from the packaging cells.
[0068] 4. The packaging cells should be set to incubate for 20-30 minutes at room temperature (25 degrees Celsius) before transferring them back to an incubator at 36-38 degrees Celsius for 3.5 hours.
[0069] 5. Add 3.5-4 milliliters of Hepes buffered saline containing 15% glycerol for 3 minutes then wash cell with Dulbecco's Modified Eagle's Medium (DMEM)+10% FBS x2.
[0070] 6. Add back DMEM +10% FBS, and incubate cells for 20 hours at 37 degress Celsius.
[0071] 7. Remove and filter medium containing therapeutic viral particles.
[0072] (Excess viral supernatant are immediately stored or concentrated and stored at −80 degrees Celsius). Supernatant may be stored with 5-8 micrograms of polybrene which may increase the efficiency of target cell infection. Otherwise polybrene may be added just before infection.
[0073] 8. Stable producer lines are established by splitting packaging cell lines 1 to 20 or 1 to 40 and subsequently incubating these cells for up to 10 days (changing medium every three days) in medium containing selective drugs (e.g. certain antibiotics corresponding to transfected resistance genes).
[0074] 9. After 10 days isolated colonies are picked, grown-up aliquotted and frozen for storage.
[0075] Assay of Retrovirus Infectivity/Titration are achieved by application of a defined volume of viral supernatant to a layer of confluent “test” cells such as NIH 3T3 cells plated at 20% confluence. After 2-3 cell division times (24-36 hours for NIH 3T3 cells) colonies of “test” cells incubated at 37 degrees in antibiotic-containing medium are counted. The supernatant's titer are estimated from these colony cunts by the following formula:
Colony Forming Units/ ml =colonies identified×0.5(split factor)/volume of virus ( ml )
[0076] The accuracy of the estimate is increased by testing large volumes of supernatant over many plates of “test” cells.
[0077] Application of the therapeutic viral supernatant to target cells may be accomplished by various means appropriate to the clinical situation.
EXAMPLE 5
[0078] Transplantation of in vitro modified progenitor/stem/spermatogonia cells may be accomplished in the following manner: Under sterile conditions, the uterus and fetuses are visualized by ultrasound or other radiological guidance. Alternatively the uterus may be exposed surgically in order to facilitate direct identification of fetal skull landmarks. Progenitor/stem/spermatogonia cells can then be introduced by injection (using an appropriately-sized catheter or needle) or into the ventricular system, germinal zone(s), or into the substance of the nervous system. Injections may be performed in certain instances, through the mother's abdominal wall, the uterine wall and fetal membranes into the fetus. The accuracy of the injection are monitored by direct observation, ultrasound, contrast, or radiological isotope based methods, or by any other means of radiological guidance known to the art.
EXAMPLE 6
[0079] Under appropriate sterile conditions, direct identification of fetal skull landmarks are accomplished visually as well as by physical inspection and palpation coupled with stereotaxic and radiologic guidance (see example 2). Appropriate amounts of modified progenitor/stem/spermatogonia cells can then be introduced by injection or other means into the ventricular system, germinal zones, or into the substance of the nervous system. The accuracy of the injection will be monitored by direct observation, ultrasound, or other radiological guidance.
EXAMPLE 7
[0080] In certain, neurological diseases, such as Huntington's disease and Parkinson's disease, cells of a specific portion of the brain are selectively affected. In the case of Parkinson's disease, it is the dopaminergic cells of the substantia nigra. In such regionally-specific diseases affecting adults, radiologically-guided transplantation of modified progenitor/stem/spermatogonia cells can be undertaken under sterile conditions. Radiologic guidance will include CT and/or MRI, and take advantage contrast or isotope based techniques to monitor injected materials.
EXAMPLE 8
[0081] In certain neurologic diseases, such as some metabolic storage disorders, cells are affected across diverse regions of the nervous system, and the greatest benefit will be achieved by introducing modified progenitor/stem/spermatogonia cells cells (or immortalized cell lines) into the tissue in large numbers in a diffuse manner. Likewise endogenous cell modification in these disorders would place a premium on modifying a large number of endogenous cells across all affected regions. In the nervous system, these diseases would be best approached by intraventricular injections (using an appropriately-sized, catheter-like device, or needle) which would allow diffuse endogenous cell modification or diffuse engraftment of in vitro modified progenitors and cell lines. However, the modified or unmodified stem cells might also be introduced directly into visceral organs, such as the liver, kidney, gut, spleen, adrenal glands, pancreas, and thymus using endoscopic guidance and any appropriately-sized, catheter-like device, allowing specific introduction and infiltration of progenitor/stem/spermatogonia cells cells into the selected organs.
EXAMPLE 9
[0082] The ability of neuronal progenitors to produce mature blood progeny cells suggests that diseases of one organ system may be treated with genetically modified cells from a separate organ system. The treatment of blood disorders (Hereditary Spherocytosis, Sickle cell anemia, other hemoglobinopathies, etc,) for instance would involve the injection of modified progenitor/stem/spermatogonia cells directly into the circulation, by large bore intravenous needle or catheter, to “home” to the bone marrow, or directly into the bone marrow following surgical exposure of bones and introduction into the marrow space. Other diseases might be best approached by injecting modified cells directly into other organs, e.g. liver, gut, spleen, kidney, skin, lungs, etc.
EXAMPLE 10
[0083] The term lesion is non-specific and refers to any area of cell damage or death. Modified cells may provide for replacement of neural tissue damaged in various disease such as stroke, trauma, or infection with the exciting prospect that the modified exogenous cells and their progeny would differentiate in a manner appropriate to the host environment.
EXAMPLE 11
[0084] Data from animal studies suggests that memory function in mammals may be increased by altered expression of certain neurotransmitter receptors, such as the NMDA receptor. Thus injection of modified progenitors into the hippocampus and other memory related brain structures may be expected to ameliorate memory loss due to a variety of degenerative. We propose that clinically significant genes might be transferred to modified progenitor/stem/spermatogonia cells and their progeny in an analogous manner for the treatment of neurological and non-neurological disease according to the methods described here. Progeny cells modified in this manner demonstrate the exciting prospect of secreting by design or by “leak” pathways, gene products other molecules responsible for various clinical diseases.
EXAMPLE 12
In utero Injection of a Genetic Vector Such as a Retrovirus, Adenovirus, Lentivirus, or MMLV-Derived Retrovirus, for in vivo, in situ, Modification of Endogenous Cells
[0085] Modification of endogenous cells using various genetic constructs, or transplantation of in vitro modified stem/progenitor cells are accomplished by identical surgical procedures. Under sterile conditions, the uterus and fetuses are visualized by ultrasound or other radiological guidance. Alternatively the uterus may be exposed surgically in order to facilitate direct identification of fetal skull landmarks. Concentrated vectors can then be introduced by injection (using an appropriately-sized catheter or needle) or into the ventricular system, germinal zone(s), or into the substance of the nervous system. Injections may be performed in certain instances, through the mother's abdominal wall, the uterine wall and fetal membranes into the fetus. The accuracy of the injection are monitored by direct observation, ultrasound, contrast, or radiological isotope based methods, or by any other means of radiological guidance known to the art.
EXAMPLE 13
Postnatal Injection of a Genetic Vector such as a Retrovirus for in vivo, in situ, Modification of Endogenous Cells
[0086] Modification of endogenous cells or transplantation of in vitro modified stem/progenitor cells (or immortalized cell lines) are similarly accomplished in postnatal patients. Under appropriate sterile conditions, direct identification of fetal skull landmarks are accomplished visually as well as by physical inspection and palpation coupled with stereotaxic and radiologic guidance (see example 2). Appropriate doses of concentrated genetically-modifying vectors can then be introduced by injection or other means into the ventricular system, germinal zones, or into the substance of the nervous system. The accuracy of the injection will be monitored by direct observation, ultrasound, or other radiological guidance.
EXAMPLE 14
Injection of a Genetic Vector into Specific Nervous System Regions or Nuclei
[0087] In certain, neurological diseases, such as Huntington's disease and Parkinson's disease, cells of a specific portion of the brain are selectively affected. In the case of Parkinson's disease, it is the dopaminergic cells of the substantia nigra. In such regionally-specific diseases affecting adults, radiologically-guided transplantation of genetic vectors into the affected area(s) of the nervous system would be undertaken under sterile conditions. Radiologic guidance will include CT and/or MRI, and take advantage contrast or isotope based techniques to monitor injected materials.
EXAMPLE 15
Delivery of Modified or Unmodified Stem Cells by Injection in to the Circulatory Stream
[0088] In some instances, it may become apparent that stem cells may integrate on their own in sufficient numbers if they are injected into blood stream, either arterial, venous, or hepatic.
[0089] Examples of Specific Transgenes Covered by this Invention
[0090] In time we expect hundreds of diseases and clinical conditions to be treated and/or ameliorated by the present invention. The following represents an incomplete list of example transgenes which we will seek to have expressed by genetically-modified cells, but is no way limiting on the use of this invention: aspartoacylase in the treatment of Canavan's disease; hexosaminidase A (subunit alpha) in the treatment of Tay-Sach's disease; hypoxanthine guanine phosphoribosyltransferase in the treatment of Lesch-Nyhan syndrome; huntingtin in the treatment of Huntington's disease; beta-glucuronidase in the treatment of Sly syndrome; sphingomyelinase in the treatment of type A and type B Niemann Pick disease; the b-subunit of hexosaminidase A and hexosaminidase B in the treatment of Sandhoff's disease; alpha-galactosidase A in the treatment of Fabry's disease; the yet undiscovered mutated gene in the treatment of type C Niemann-Pick disease; the glucocerebrosidase gene in the treatment of Gaucher's disease; the presenilin genes in the treatment of Alzheimer's disease; the dopamine gene in the treatment of Parkinson's disease; The VHL gene in the treatment of Von Hippel Lindau's disease. alpha-, beta-, gamma-, and delta-subunits of hemoglobin for the treatment of sickle cell anemia and other thalassemias. These transgenes will generally represent the coding region or portions of the coding region of the normal genes.
[0091] It is to be understood, however, that the scope of the present invention is not to be limited to the specific embodiments and examples described above. The invention may be practiced other than as particularly described and still be within the scope of the accompanying claims.
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We propose here that endogenous stem/progenitor cells of the developing or adult nervous system be genetically modified in situ, to express therapeutically advantageous gene products. Furthermore, we propose here that endogenous or other exogenous stem cells or their progeny be genetically modified when appropriate to express advantageous gene products (and/or modified through culture techniques), and that, if exogenously derived, they be transplanted into the ventricular system of the patient nervous system, the germinal zone of the ventricular system, into postmitotic regions of the CNS or other organs.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/899,727, filed May 22, 2013, which is a continuation of U.S. patent application Ser. No. 13/010,067, filed Jan. 20, 2011, which is a continuation of U.S. patent application Ser. No. 11/542,753, now U.S. Pat. No. 7,900,402, filed Oct. 4, 2006.
BACKGROUND
[0002] This disclosure relates to portable seating systems and, more particularly, to a powered telescopic seating riser assembly for a seating system with a multiple of seating configurations drivable between at least an extended position and a stored position.
[0003] Seating risers are designed for use in auditoriums, gymnasiums, and event halls to accommodate spectators on portable seats, such as folding chairs. Depending on the intended use, a facility may require seating risers that are capable of being moved from a retracted position for storage, to an extended position for use.
[0004] Heretofore, many conventional seating riser structures have been utilized for nonpermanent seating. These conventional systems generally utilize a series of assemblies having seating risers of given heights which store within close proximity to one another.
[0005] Because of the temporary nature of the seating used by some organizations and the large storage area required to house non-permanent seating systems when not extended for use, it is desirable to provide a variety of seating configurations with a single non-permanent seating system. With conventional non-permanent seating systems, several assemblies are placed adjacent one another, for instance, to form the seating along an athletic playing surface. Although modular in this sense, conventional non-permanent seating systems have a rise always constant with respect to the run.
[0006] Some conventional non-permanent seating systems are manually deployed. Although effective, significant manpower and time is typically required to deploy and store the system. Manual deployment and storage may be further complicated by the requirement that the non-permanent seating system needs to be deployed in a generally coordinated manner, otherwise, binding or other complications may result. Since the non-permanent seating system by its vary nature is a relatively large structure, coordination during manual deployment and storage coordination may be relatively difficult.
[0007] Other conventional non-permanent seating systems drive a wheel system thereof. Such drives require friction with a floor surface such that non-uniform traction may also result in the aforementioned binding.
SUMMARY
[0008] A riser assembly according to an exemplary aspect of the present disclosure includes, among other things, a first skin and a second skin spaced from the first skin. A core is disposed between the first skin and the second skin, the core including a plurality of subpanels. A framework including a plurality of beams is disposed between the first skin and the second skin. The core is received within a space defined by the framework, and a portion of the framework is positioned laterally outside the core. Each of the plurality of subpanels is received within one of a plurality of spaces defined by the framework. The plurality of beams defines a perimeter about each of the subpanels. The first skin, second skin and framework enclose the core. The first skin and the second skin are separate and distinct from the framework.
[0009] In a further non-limiting embodiment of the foregoing riser assembly, the first skin includes a first material, the second skin includes a second material, and the core includes a third material different from the first and second materials in composition.
[0010] In a further non-limiting embodiment of the foregoing riser assembly, the third material includes an end-grained balsawood.
[0011] In a further non-limiting embodiment of any of the foregoing riser assemblies, the core comprises a honeycomb structure.
[0012] In a further non-limiting embodiment of any of the foregoing riser assemblies, an access track beam is arranged adjacent to the framework. The access track beam defines a longitudinal slot extending at least partially between each end of the access track beam. The longitudinal slot is configured to selectively receive a mountable accessory.
[0013] In a further non-limiting embodiment of any of the foregoing riser assemblies, each of the first and second skins is glued to the core.
[0014] In a further non-limiting embodiment of any of the foregoing riser assemblies, each of the first and second skins is attached to the framework.
[0015] In a further non-limiting embodiment of any of the foregoing riser assemblies, each of the first and second skins is welded to the framework.
[0016] In a further non-limiting embodiment of any of the foregoing riser assemblies, each of the first and second skins has a substantially identical cross-section profile spanning the core and the framework.
[0017] In a further non-limiting embodiment of any of the foregoing riser assemblies, the first skin, the second skin and the framework define a first deck surface. The framework extends below a second deck surface vertically spaced from the first deck surface. The framework extends substantially between a front facing edge and a rear facing edge of the second deck surface.
[0018] A riser assembly according to another exemplary aspect of the present disclosure includes, among other things, an upper framework and a lower framework spaced vertically relative to the upper framework and extending substantially between a front facing edge and a rear facing edge of the upper framework, and a deck surface. An access beam is exposed. The access beam defines a longitudinal slot together with the upper framework to receive a riser assembly accessory.
[0019] In a further non-limiting embodiment of the foregoing riser assembly, the deck surface includes a first skin.
[0020] In a further non-limiting embodiment of any of the foregoing riser assemblies, the deck surface is a first deck surface, and a second deck surface is positioned in a stepped arrangement relative to the first deck surface.
[0021] In a further non-limiting embodiment of any of the foregoing riser assemblies, the first deck surface is attached to the second deck surface to minimize relative movement therebetween.
[0022] In a further non-limiting embodiment of any of the foregoing riser assemblies, the deck surface is attached to the lower framework.
[0023] In a further non-limiting embodiment of any of the foregoing riser assemblies, the access track beam is arranged adjacent to the upper and lower frameworks. The access track beam defines a longitudinal slot extending at least partially between each end of the access track beam.
[0024] In a further non-limiting embodiment of any of the foregoing riser assemblies, the access track beam is arranged adjacent to the upper and lower frameworks. The access track beam defines a longitudinal slot extending at least partially between each end of the access track beam.
[0025] In a further non-limiting embodiment of any of the foregoing riser assemblies, a side of the access track beam is attached to the upper and lower frameworks.
[0026] In a further non-limiting embodiment of any of the foregoing riser assemblies, the access track beam defines at least one flange extending inward from the longitudinal slot.
[0027] In a further non-limiting embodiment of any of the foregoing riser assemblies, the riser assembly accessory is chair beam mounting system secured to the access beam.
[0028] In a further non-limiting embodiment of any of the foregoing riser assemblies, the longitudinal slot is defined by a first channel formed in an upper surface of the access track beam and is also defined by a second channel formed in a lower surface of the upper framework.
[0029] In a further non-limiting embodiment of any of the foregoing riser assemblies, the access track beam extends across and is attached to a plurality of ribs extending substantially between the front facing edge and the rear facing edge of the upper framework.
[0030] In a further non-limiting embodiment of any of the foregoing riser assemblies, the lower framework extends at least partially below the access track beam.
[0031] A method of supporting an accessory relative to a riser assembly according to another exemplary aspect of the present disclosure includes, among other things, selectively attaching an accessory to a longitudinal slot defined by a forward facing access track beam that is positioned in a vertical relationship relative to a first deck panel. The longitudinal slot is also defined by a framework of a second deck panel spaced vertically from the first deck panel.
[0032] In a further non-limiting embodiment of the foregoing method includes selectively attaching an accessory to a longitudinal slot defined by a forward facing access track beam that is positioned in a vertical relationship relative to a first deck panel. The longitudinal slot is also defined by a framework of a second deck panel spaced vertically from the first deck panel.
[0033] In a further non-limiting embodiment of any of the foregoing methods, the longitudinal slot is defined by a first channel formed in an upper surface of the access track beam and is also defined by a second channel formed in a lower surface of the framework.
[0034] In a further non-limiting embodiment of any of the foregoing methods, the longitudinal slot is a first longitudinal slot spaced from a second longitudinal slot also defined by the access track beam.
[0035] In a further non-limiting embodiment of any of the foregoing methods, the access track beam is attached to the framework.
[0036] In a further non-limiting embodiment of any of the foregoing methods, access track beam is separate and distinct from the framework.
[0037] In a further non-limiting embodiment of any of the foregoing methods, the access track beam extends across a plurality of ribs vertically spacing the first deck panel and the second deck panel.
[0038] In a further non-limiting embodiment of any of the foregoing methods, each of the plurality of ribs extends substantially between a front facing edge and a rear facing edge of the framework of the second deck panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
[0040] FIG. 1 is a perspective view of a non-permanent seating system in a deployed position;
[0041] FIG. 2A is an exploded view of a dual deck surface;
[0042] FIG. 2B is a perspective view of a frame of the dual deck surface of FIG. 2A ;
[0043] FIG. 2C is a sectional view through the dual deck surface illustrating an access track beam;
[0044] FIG. 2D is a side view of a section of a non-permanent seating system in a half-deployed position in which only half the seating capacity of each riser assembly is utilized but each seating row provides twice the rise;
[0045] FIG. 2E is a perspective view of the non-permanent seating system in a stored position;
[0046] FIG. 2F is a perspective view of the non-permanent seating system illustrating one arrangement of rails and stair blocks therefore;
[0047] FIG. 3A is a perspective generally bottom view of a single riser assembly;
[0048] FIG. 3B is an expanded partially exploded view of a horizontal leg of the telescopic leg assembly of the riser assembly;
[0049] FIG. 3C is a perspective generally underside view of the non-permanent seating system in a deployed position illustrating a belt drive system and the interaction of a timing belt between each of the multiple of riser assemblies;
[0050] FIG. 3D is a perspective generally rear view of a multiple of the telescopic seat riser systems illustrating the tooth timing belt location;
[0051] FIG. 3E is an exploded view of the tooth belt drive system;
[0052] FIG. 3F is an exploded view of a guide roller assembly which movably links the riser assembly with the next adjacent riser assembly;
[0053] FIG. 3G is a perspective inner view of the locations of the guide assemblies for engagement with a track on an adjacent riser assembly;
[0054] FIG. 3H is a view of the tooth belt drive system in an assembled position; and
[0055] FIG. 4 is a side view of a section of a non-permanent seating system in a fully deployed position.
DETAILED DESCRIPTION
[0056] FIG. 1 illustrates a general perspective view of a non-permanent seating system 10 having a multiple of telescopic seating riser systems 12 . The telescoping seating riser system 12 forms the fundamental building blocks of the system 10 . The system 12 may stand alone, or may stand side by side. It will be appreciated that the height thereof is dependent on design choices including the desired rise.
[0057] Each telescopic seating riser system 12 generally includes an innermost lower riser assembly 14 , and successive outer elevated riser assemblies 16 - 24 . It will be appreciated that the number of riser assemblies 14 - 24 in any given telescopic seating riser system 12 will be a matter of design requirements. Each riser assembly 14 - 24 generally includes a dual deck surface 26 and a pair of telescopic leg assemblies 28 .
[0058] Referring to FIG. 2A , the dual deck surface 26 includes a lower deck surface 30 A and an upper deck surface 30 B arranged in a stepped arrangement. The lower deck surface 30 A and the upper deck surface 30 B each establish a respective deck plane. The dual deck surface 26 generally utilizes a sandwich structure for each deck panel 32 . The deck panel 32 is manufactured of an upper and lower deck skin 34 A, 34 B which sandwiches a core 36 . The skins 34 A, 34 B are preferably manufactured of aluminum while the core 36 is formed of an end-grained balsawood or a honeycomb structure to provide a strong, lightweight and acoustically absorbent structure. The deck panels 32 are mounted to a framework 38 ( FIG. 2B ) which support a multiple of ribs 40 between a set of longitudinal access track beams 42 (also illustrated in FIG. 2C ). The core 36 may include a plurality of subpanels 37 (illustrated in FIG. 2A ) each configured to be received within a space defined by the framework 38 .
[0059] The multiple of ribs 40 provide the dual deck surface 26 by vertically separating the lower deck panel 32 L from the upper deck panels 32 U. Each riser assembly 14 - 24 includes one dual deck surface 26 with one lower deck panel 32 L and one upper deck panel 32 U to provide seating on two levels.
[0060] Referring to FIG. 2C , the longitudinal access track beams 42 include slots 44 which receive a chair beam mounting system S ( FIG. 2D ) such as that utilized in stadium seating systems such as that manufactured by Camatic Pty Ltd. of Wantirna, Australia. The access track beams 42 are arranged in a vertical relationship between each deck panel 32 L, 32 U to provide space for the seating system 10 when in a stored position. The slots 44 are longitudinally located within the access track beams 42 to provide communication passages for, for example only, aisle lighting, and attachment of, for example only, rails R ( FIG. 2F ), stair blocks B ( FIG. 2F ) and the aforementioned chair beam mounting system S.
[0061] Referring to FIG. 3A , each telescopic leg assembly 28 includes a horizontal leg 50 and a vertical leg 52 . It should be understood that although only a single leg assembly will be described, it should be understood that each leg assembly on each dual elevated riser assemblies 14 - 24 is generally alike. Notably, each riser assembly 14 - 24 telescopes under the next higher riser assembly 14 - 24 .
[0062] Each vertical leg 52 is attached to the rear of the dual deck surface 26 through a bracket 54 . The vertical leg 52 is preferably manufactured of square tubing, however, other shapes may likewise be usable with the present invention.
[0063] A set of rear cross members 56 are connected to the vertical leg 52 at their lower end and to the dual deck surface 26 at their upper end through a central bracket 58 . The rear cross members 56 further stabilizes each riser assembly 14 - 24 . The central bracket 58 is connected to another central bracket 58 ′ on the next riser assembly 14 - 24 through an articulatable linkage 60 which articulates in response to telescopic movement of the riser assemblies 14 - 24 . The linkage 60 preferably provides a passage for the communication of power cables, electronic control and the like.
[0064] The horizontal leg 50 is supported on wheels 62 . Preferably, four wheels 62 are mounted within each of the horizontal legs 50 to allow each riser assemblies 14 - 24 to readily travel over a floor surface.
[0065] Referring to FIG. 3B , each horizontal leg 50 of each leg assembly 28 supports a toothed belt drive system 64 . The belt drive system 64 includes an electric motor 66 , an inner pulley 68 , an outer pulley 70 and a toothed timing belt 72 therebetween. The toothed belt drive system 64 provides the interface between each adjacent riser assembly 14 - 24 ( FIG. 3C ) and the motive force to extend and retract the riser system 12 in a telescopic manner. The toothed timing belt 72 is continuous in this example. That is, the toothed timing belt 72 is a loop lacking a defined end.
[0066] The electric motor 66 is mounted directly aft of the vertical leg 52 in a readily accessible location. Notably, the power cable 67 from the electric motor 66 is preferably threaded through the associated rear cross members 56 to communicate with the central bracket 58 and a controller C preferably on the uppermost riser assembly 24 .
[0067] The inner pulley 68 and the outer pulley 70 include a toothed surface to engage the toothed belt with a minimum of slippage. The example toothed surface includes a plurality of vertically extending teeth 73 . The inner pulley 68 and the outer pulley 70 rotate about respective axes generally parallel to the vertical leg 52 . The electric motor 66 includes a shaft 75 directly connected to the inner pulley 68 . The shaft 75 rotates about an axis A that is perpendicular to the direction of movement I of the toothed timing belt 72 . The direction of movement I establishes a belt plane associated with the toothed timing belt 72 . The toothed timing belt 72 preferably faces away from, but is engaged with, each adjacent horizontal leg 50 of the next inner riser assembly 14 - 24 ( FIG. 3D ). That is, the toothed timing belt 72 of the belt drive system 64 on the horizontal leg 50 of the outermost riser assembly 24 faces inward toward its own horizontal leg in direction II. The belt 72 , however, is engaged with the horizontal leg 50 of the next inner riser assembly 22 through a belt clamp 74 ( FIG. 3H ).
[0068] The toothed timing belt 72 engages the belt clamp 74 located on an outer surface of the adjacent next inner riser assembly 14 - 24 ( FIG. 3E ). Preferably, the belt clamp 74 is located adjacent the intersection of the horizontal leg 50 and the vertical leg 52 and includes a toothed surface which matches the toothed timing belt 72 for engagement therewith. The belt clamp 74 provides the engagement between the toothed timing belt 72 of the outer next inner riser assembly 14 - 24 with the next inner riser assembly 14 - 24 such that rotation of the toothed timing belt 72 drives the next inner riser assembly 14 - 24 relative the associated outer riser assembly 14 - 24 .
[0069] Referring to FIG. 3B , a guide assembly 76 along the length of the horizontal leg 50 further guides the inner riser assembly 14 - 24 relative the associated outer riser assembly 14 - 24 . Preferably, a track 78 and guider roller assembly 80 ( FIG. 3G ) provides an effective low friction interface between one inner riser assembly 14 - 24 and the next associated outer riser assembly 14 - 24 . It should be understood that various guide assemblies 76 may be utilized with the present invention.
[0070] In operation, the pair of each electric motors 66 on each riser assembly 14 - 24 are driven simultaneously by the controller C to fully extend the seating riser system 12 from the storage position ( FIG. 2E ). The controller C provides for programmed stops of each riser assembly 14 - 24 such that the telescopic seating system 10 may be readily deployed to the fully extended position ( FIGS. 1 and 4 ) or to the half-deployed position ( FIG. 2D ). The half-deployed position utilizes only half the seating capacity of each riser assembly 14 - 24 but provides twice the rise between each seating row to thereby accommodate particular venues. The controller C also communicates with each motor 66 such that the telescopic seating system 10 can be assured of straight tracking through torque sensing. Furthermore, the belt drive system 64 assures coordinated deployment as the toothed timing belt 72 minimizes the likelihood of slippage.
[0071] It will be appreciated that seating system is a load bearing structure intended to hold many people and equipment, such as portable seating, above a floor surface. Therefore, the telescopic seating system is suitably constructed. For instance, the structural members of the telescopic seating system preferably are constructed of thin wall tubing, straight bar stock, right angle bar stock, and plate of suitable materials, for instance, steel, alloy, aluminum, wood or high strength plastics. Components may be joined in any number of conventional manners, such as by welding, gluing or with suitable fasteners. Wheels are preferably of the solid caster type. It will be appreciated that in reference to the wheels, such wheels may be constructed of any device that provides rolling or other relative movement, such as sliding, between respective track surfaces.
[0072] It should be understood that relative positional terms such as “forward,” “aft,” “upper,” “lower,” “above,” “below,” and the like are with reference to the normal operational attitude of the system and should not be considered otherwise limiting.
[0073] The foregoing description is exemplary rather than defined by the limitations within. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention.
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A riser assembly according to an exemplary aspect of the present disclosure includes, among other things, a first skin. A second skin is spaced from the first skin. A core is disposed between the first skin and the second skin. A framework is disposed between the first skin and the second skin. A portion of the framework is positioned laterally outside the core. A method of supporting an accessory relative to a riser assembly is also disclosed.
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FIELD OF THE INVENTION
[0001] The present invention relates to a process for the preparation of LiBF 4 .
BACKGROUND OF THE INVENTION
[0002] LiBF 4 has very useful applications in high voltage lithium primary/secondary cells. LiBF 4 is well known as a battery electrolyte. This compound was earlier prepared by procedures, which were cumbersome and the yield was poor. The purity of the sample prepared was poor and needed recrystallization.
[0003] U.S. Pat. No. 5,079,109 discloses the use of LiBF 4 as a non-aqueous electrolyte for a lithium battery.
[0004] While several methods are known for the preparation of LiBF 4 in the prior art such methods suffer from the following disadvantages:
[0005] 1. The purity of the product is low
[0006] 2. The yield of the product is low
[0007] 3. Ambient temperature reaction for the product yield
[0008] 4. Side reactions occur
[0009] 5. Multiplicity of steps are required.
OBJECTS OF THE INVENTION
[0010] The main object of this invention is to prepare LiBF 4 by a simple chemical reaction.
[0011] Another object of the invention is to obtain LiBF 4 with high yield.
[0012] A further object of the invention is to obtain LiBF 4 by an efficient process.
[0013] The process of the invention overcomes the disadvantages of the prior art enumerated above.
SUMMARY OF THE INVENTION
[0014] Accordingly the present invention relates to a process for the preparation of LiBF 4 reacting LiBO 2 compound with 10 to 48% HF solution in aqueous solution at ambient temperature, concentrating the product and recrystallising to obtain high purity LiBF 4 .
[0015] In one embodiment of the invention, LiBO 2 is suspended in aqueous media/nonaqueous media and reacted with HF.
[0016] In a further embodiment of the invention, a paste of LiBO 2 is added in HF.
[0017] In another embodiment of the invention, LiBO 2 is pasted with water and reacted with HF.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In the present invention LiBF 4 is prepared by treating suspended particles of LiBO 2 /Li 2 N 2 O 4 in aqueous solution or a paste of LiBO 2 in water with HF. The quantity of LiBO 2 and HF are calculated for the reaction separately. After the cessation of the reaction the product was concentrated and crystallized. The product formed was examined and confirmed by x-ray and the purity of the sample was examined.
[0019] A calculated quantity of HF was carefully added to a known weighed quantity of LiBO2 in aqueous solution. The reaction was allowed to proceed. When the reaction ceased, the product was concentrated and recrystallized to get very high purity of the sample. The product was examined for its purity and identified by x-ray. FIG. 1 indicates the x-ray analysis which matches with available literature (Table 1).
TABLE 1 LIBF 4 In- 350985 2θ d value intensity OBS tensity Error 1 18.618 4.762 70 18.797 4.717 36 2 2 26.722 3.333 100 26.903 3.311 87 2 3 27.903 3.195 100 28.176 3.165 100 3 4 34.872 2.571 30 5 37.565 2.392 100 37.845 2.375 55 3 6 37.938 2.370 30 37.845 2.375 55 −1 7 39.623 2.273 30 8 44.541 2.033 100 44.732 2.024 75 2 9 48.093 1.890 10 10 50.326 1.812 30 50.521 1.805 17 2 11 52.875 1.730 30 52.875 1.730 12 0 12 54.557 1.681 30 13 57.960 1.590 30 57.960 1.590 13 0 14 63.693 1.460 10 64.005 1.453 7 3 15 65.153 1.431 20 16 68.965 1.361 10 17 71.991 1.311 10 18 73.968 1.280 20 74.078 1.279 8 1 19 78.227 1.221 20 78.227 1.221 10 0
EXAMPLE 1
Preparation of LiBO 2
[0020] Li 2 CO 3 (2.96 gm) and B 2 O 3 (2.8 gm) are mixed with heating up to 600° C. to obtain LiBO 2 with yield of more than 98%. The colour of the product was white and it was obtained in single phase. The single electrode potential of LiBO 2 with respect to Li in 1M LiClO 4 in propylene carbonate was 2.99 V.
EXAMPLE 2
Preparation of LiBO 2
[0021] Li 2 OH (1.68 gm) and B 2 O 3 (2.8 gm) are mixed with heating up to 600° C. to obtain LiBO 2 with yield of more than 98%. The colour of the product was white and it was obtained in single phase. The single electrode potential of LiBO 2 with respect to Li in 1M LiClO 4 in propylene carbonate was 2.99 V.
[0022] The LiBO 2 obtained by the processes of both examples 1 and 2 was high and no side reactions occur.
EXAMPLE 3
Preparation of LiBF 4
[0023] LiBO 2 and HF were mixed in a mole ratio of 1:4 by taking HF in water in a Teflon container, keeping the temperature at −4° C., slowly adding LiBO 2 . When the reaction ceases, the mixture is slowly heated upto dryness at about 100° C. to obtain dry LiBF 4 with a yield of about 95%. The colour of the product was white and the product was obtained in single phase. The single electrode potential of LiBO 4 with respect to Li in 1M LiClO 4 in propylene carbonate was 2.99 v.
EXAMPLE 4
Preparation of LiBF 4
[0024] LiBO 2 and HF were mixed in a mole ratio of 1:4 by taking HF in alcoholic solvent in a Teflon container, keeping the temperature at −4° C., slowly adding LiBO 2 . When the reaction ceases, the mixture is slowly heated upto dryness at about 100° C. to obtain dry LiBF 4 with a yield of about 95%. The colour of the product was white and the product was obtained in single phase. The equivalent conductance of LiBF 4 in 1 molar PC at 30° C. was 34.0 ohm −1 cm 2 mole −1 .
[0025] In the present invention the following advantages are claimed for the synthesis of LiBF 4 :
[0026] 1. No side reactions occur
[0027] 2. A one step procedure is sufficient to prepare this compound
[0028] 3. Required quantity of the product can be prepared by reacting the calculated quantity of reactants.
[0029] 4. The product obtained is of high purity
[0030] 5. The product yield becomes 100% if the temperature is kept at −4° C.
[0031] 6. Wetting of LiBO 2 prevents evaporation of BF 4 formed during the reaction.
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The present invention describes a process for the preparation of LiBF 4 by reacting LiBO 2 with 10 to 48% HF solution in aqueous solution at ambient temperature, concentrating the product and recrystallizing to obtain high purity LiBF 4 .
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 520,807, filed Aug. 5, 1983, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to web handling machines such as plotters, recorders and sign makers wherein a web is fed longitudinally of itself by a pair of sprockets cooperating with holes in the two longitudinal side edge portions of the web, and deals more particularly with a web loading and feeding system for such a machine, including a related web construction and a method and apparatus for making the web, facilitating by way of visual aids the proper loading of a web onto the machine.
The present invention may be used with any one of various types of machines wherein a web is moved by a pair of sprocket wheels having pins, or teeth-like members, on their peripheries cooperating with rows of feed holes in the web's two side edge portions. In such machines it is usually essential to error free operation that the web be properly loaded in the machine so that the sprocket pins engage the correct web holes. This means that two corresponding pins of the two sprockets located in a common plane passing through the sprocket drive axis should engage two corresponding feed holes of the web located on a common line extending perpendicular to the edges of the web. Often, particularly when the web is very wide, it is difficult to determine by eye which sprocket pins correspond with one another and which holes on the opposite sides of the web correspond with one another, and as a result web loading errors can easily occur. Moreover, sometimes when a web loading error is made the web thereafter nevertheless appears to feed in an apparently normal manner so that errors introduced by the web loading may be ascribed to other causes and not quickly traced back to the faulty loading.
A general object of the invention is therefore to provide a visual means to enable a machine operator to easily visually determine the proper placement of a web when loading it onto the feed sprockets of a machine. Although, as mentioned above, this invention may be used with various different types of web handling devices it is particularly well suited for machines such as the sign making machine as shown in copending patent application Ser. No. 401,722, filed July 26, 1982, wherein the web is relatively wide and wherein in the course of a day's operation many different webs may be loaded onto the machine.
The invention also has as an object the provision of a web construction usable with a web handling machine to facilitate proper loading of it into the machine and has as a related object the provision of a method and apparatus for efficiently making such a web.
Other objects and advantages of the invention will be apparent from the following detailed description of the preferred embodiments and from the accompanying drawings.
SUMMARY OF THE INVENTION
The invention resides in a web loading and feeding system for a web handling machine with such system including two drive sprockets each having a series of radially outwardly extending pins uniformly spaced from one another circumferentially of the sprocket with two corresponding pins on the two sprockets--that is, two pins located at least approximately in the same plane containing the axis of sprocket rotation--being visually distinguished from the remaining pins, the web having similarly uniformly spaced feed holes located in rows extending along each of the side edge portions of the web with corresponding holes--that is, two feed holes on opposite sides of the web located in substantially the same line extending perpendicular to the side edges of the web--at intervals along the length of the web being visually distinguished from the remaining feed holes by means of extra indicator holes, so that the visually distinguished web feed holes may be placed on the visually distinguished sprocket pins to assure proper web loading. The distinguished pair of sprocket pins may be so distinguished by means of extra pins engaging the extra holes of the web, or other visual means such as color differences may be used to provide the distinguishing features.
The invention also resides in the construction of the web by itself whereby in addition to a row of first feed holes extending along one side edge portion of the web and a row of second feed holes extending along the other side edge portion of the web the first side edge portion includes third holes and the other side edge portion of the web includes fourth holes which third and fourth holes serve feed to visually distinguish corresponding pairs of first and second feed holes to aid in properly locating the web onto a handling machine.
The invention still further resides in a method and apparatus for making the web construction whereby the holes in the side edge portions of the web are made by a simple punch, step motor drive and control apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a sign making machine having a web loading and feeding system embodying the present invention with various portions of the machine and of the web being broken away to reveal additional features.
FIG. 2 is a fragmentary perspective view showing the relationship between the drive sprockets and the web during the loading of the web onto the machine of FIG. 1.
FIG. 3 is a side elevational view of one of the web drive sprockets of FIG. 1.
FIG. 4 is a reduced scale plan view of a portion of the web of FIG. 1.
FIG. 5 is an enlarged scale, fragmentary sectional view through the web taken on the line 5--5 of FIG. 4.
FIG. 6 is an enlarged scale, fragmentary plan view of the web of FIG. 4.
FIG. 7 is a view similar to FIG. 2 but showing a different construction of the sprockets.
FIG. 8 is a side elevational view of one of the sprocket of FIG. 7.
FIG. 9 is a schematic view showing an apparatus for making the web of FIG. 1.
FIG. 10 is a fragmentary perspective view showing another embodiment of the web.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the invention is there illustrated as embodied in a sign making machine 10 which is or may be generally similar to the one shown and described in more detail in copending application Ser. No. 401,722, filed July 26, 1982. The machine 10 handles and works on an associated web 12. The web is moved longitudinally of itself, in the illustrated X-coordinate direction, by a pair of drive sprockets 14, 16 forming part of the machine 10 and spaced from one another along and supported for driven rotation in unison about a common drive axis 18. As explained in more detail hereinafter, pins or teeth on the two sprockets 14, 16 engage feed holes in the two side edge portions of the web 12 to drive it in the X-coordinate direction. A platen or roller 17 located between the two sprockets 14 and 16, and similar to that of a typewriter, supports that transverse portion of the web 12 aligned with the sprockets 14, 16.
When the machine 10 is operating two web holddown bails, one for each sprocket 14 and 16, carried by a transverse rod 20 normally hold the web in engagement with the sprockets. In FIG. 1 only the one holddown bail 22 associated with the sprocket 14 is shown and this bail along with its supporting rod 20 is shown in its raised position to give a clearer view of the sprockets.
The machine 10 also includes a tool head 24 suitably supported and driven in the illustrated Y-coordinate direction relative to the web 12.
In a normal sign making mode of operation, the tool head 24 is equipped with a knife-type cutter 26 and the web 12 is an elongated piece of sign making stock consisting of an upper layer of adhesive-backed plastic material, such as vinyl, supported by a bottom layer of release material on which the upper plastic layer is supported with its adhesive-backed face in engagement with the release material. For example, in this case the basic material from which the web 12 is made may be a laminated sheet material made and sold under the name "SCOTCHCAL" by 3M Corporation. This "SCOTCHCAL" has an upper vinyl layer, usually three to five mils thick, made in various different colors, with a pressure-sensitive adhesive on its lower surface, such vinyl upper layer being in turn carried by a lower release layer in the form of a ninety-pound paper coated with silicone. With the web 12 made of such sign making stock and with the tool head 24 equipped with a knife-type cutting tool 26 the web 12 and the tool 26 may be moved relative to one another simultaneously in the X- and Y-coordinate directions, through the operation of the machine 10, to cut alphanumeric characters or other indicia from the upper vinyl layer of the stock which characters or indicia can subsequently be transferred, as described in the aforesaid pending patent application, to another carrier to form a finished sign.
Also, in addition to the aforedescribed cutting or sign making mode of operation of the machine 10 it may also be operated in a plotting mode during which a pencil or other plotting tool is placed in the work head 24 in place of the cutting tool 26 and the web 12 is comprised of a sheet of paper or the like. In both the sign making mode and the plotting mode the machine 10 operates automatically to cause the tool carried by the head 24 to automatically trace characters or other indicia desired for a sign. The purpose of the plotting mode is to allow a proposed sign to be first plotted on paper to check the results of the information entered into the machine before the more expensive sign making stock is cut.
Proper operation of the machine 10 requires that the web 12 be loaded into it--that is, onto the sprockets 14 and 16--so that as the web is moved longitudinally of itself by rotation of the sprockets lines extending transversely of the web perpendicular to its side edges are parallel to the sprocket axis 18. Typically, the web 12 may be relatively wide--say fifteen inches wide--and the feed holes formed in each side edge portion of the web may be relatively closely spaced to one another--say on one-half inch centers. With such large width of the web and small spacing of the feed holes it is difficult to visually properly align the web with the sprocket pins when loading a web onto the machine. That is, assuming the holes on one side edge of the web are properly located relative to the pins of its associated sprocket the holes along the other side edge of the web may be placed on the wrong pins of the associated sprocket, and such error in the loading of the web may not be readily detected in the subsequent operation of the machine even though it introduces errors in the cutting or plotting function.
In accordance with the invention, the machine 10 and web 12 of FIG. 1 are constructed to provide a web loading and feeding system whereby web loading errors of the type described above can be reduced or eliminated through the use of visual means facilitating proper web loading.
Referring to FIG. 2, in the web loading and system of the invention the two sprockets 14 and 16 are both fixed to a common drive shaft 28 for rotation about the common axis 18. The sprocket 14 has a series of radially outwardly extending pins 30, 30 located in a common plane perpendicular to the axis 18 and uniformly spaced from one another circumferentially of the sprocket. The sprocket 16 in turn has a similar series of radially outwardly extending pins 32, 32 located in a common plane perpendicular to the axis 18 and uniformly spaced from one another circumferentially of the sprocket 16 in a manner identical to the spacing of the pins 30, 30 of the sprocket 14. The number of pins 30, 30 on the sprocket 14 is therefore equal to the number of pins 32, 32 on the sprocket 16. This number of pins may vary from application to application, but in the illustrated case the sprocket 14 has fourteen pins 30, 30 and the sprocket 16 likewise has fourteen pins 32, 32. Further, the pins 30, 30 of the sprocket 14 and the pins 32, 32 of the sprocket 16 are so relatively arranged that each pin 30 on the sprocket 14 has a corresponding pin 32 on the sprocket 16 which two pins are located in, or at least substantially in, a common plane passing through the axis 18. For example, in FIG. 2 one such common plane is shown at ABCD and contains a pair of corresponding pins 30 and 32 indicated at a and b.
In keeping with the invention means are provided for visually distinguishing at least one pair of corresponding pins 30 and 32 from the remaining pins 30, 30 and 32, 32 of the sprockets 14 and 16. Such visual distinguishing means may take various different forms and in FIG. 2 consists of an extra, or third, pin 34 on the sprocket 14 and an extra, or fourth, pin 36 on the sprocket 16. The pin 34 on the sprocket 14 is located between two of the pins 30, 30 and likewise the pin 36 on the sprocket 16 is located between two of the pins 32, 32 on the sprocket 16 with the pins 34 and 36 being located in a common plane, such as the plane indicated at AEFD, containing the axis 18. The two extra pins 34 and 36 therefore visually distinguish from the remaining pins 30, 30 and 32, 32 at least one corresponding pair of pins 30 and 32. In FIG. 2 such visually distinguished pair of pins 30 and 32 may be taken to be the pins a and b located clockwise from the pins 34 and 36. However, the distinguished pair of corresponding pins could also be taken to be the pins c and d located counterclockwise from the pins 34 and 36. In FIG. 2 the pin 34 is located midway between two of the pins 30, 30 on the sprocket 14 and the pin 36 is located midway between two of the pins 32, 32 on the sprocket 16. Such middle spacing of the pins 34 and 36 is not, however, necessary and if desired the pin 34 may be located closer to one of the two pins 30 between which it is placed than it is to the other of such two pins and likewise the pin 36 may be located similarly closer to one of the two pins 32 between which it is located than it is to the other of such two pins.
The web 12, as shown in FIGS. 2, 4 and 6 comprises an elongated piece of sheet-like material having parallel side edges 40 and 42. In the side edge portion of the web 12 adjacent the side edge 40 is a row of first feed holes 44, 44 all located on a first line 46 spaced slightly inwardly from the edge 40 and uniformly spaced from one another by a spacing equal to the spacing between the pins 30, 30 of the sprocket 14. Likewise, in the marginal edge portion adjacent the edge 42 is another row of second feed holes 48, 48 all located on a line 50 spaced slightly inwardly from the edge 42 and uniformly spaced from one another by a spacing equal to that of the spacing of the first holes 44, 44. Furthermore, the first holes 44, 44 are so placed relative to the second holes 48, 48 that each first hole 44 has a corresponding second hole 48 located directly opposite from it on the other side of the web. That is, as indicated by the one line 52 indicated in FIG. 4 which extends perpendicular to the side edges 40 and 42, each first hole 44 has a corresponding second hole 48 with such two corresponding first and second holes being located on a common line extending perpendicular to the web side edges and perpendicular to the lines 46 and 50 containing the rows of holes. Also, as seen in FIG. 4, the web between the row of first holes 44, 44 and the row of second holes 48, 48 has a work portion which is completely uniform along its entire length. That is, it has no fold lines, lines of perforations, or markings dividing it into pages or sections. Therefore, a sign of any indefinite length, up to the total length of the web, may be generated on the web by the machine 10.
As part of the invention, the web 12 in addition to the first feed holes 44, 44 and second feed holes 48, 48 includes additional indicator holes serving to visually distinguish corresponding pairs of first and second feed holes at intervals along the length of the web. In FIGS. 2, 4 and 6 these additional indicator holes comprise a row of third holes 54, 54 located on the same line 46 as the first holes 44, 44 and a row of fourth holes 56, 56 located on the same line 50 as the second holes 48, 48. Each third hole 54 is located between two adjacent first holes 44, 44 and each fourth hole 56 is located between two adjacent second holes 48, 48. Further, the placement of each third hole 54 with respect to the two first holes 44, 44 between which it is received conforms to the placement of the third pin 34 of the sprocket 14 between the two pins 30, 30 between which it is received. Similarly, the placement of each fourth hole 56 with respect to the two second holes 48, 48 between which it is received conforms to the placement of the fourth pin 36 of the sprocket 16 with respect to the two pins 32, 32 between which it is received.
Also, still referring to FIGS. 2 and 4, each third hole 54 has a corresponding fourth hole 56 located directly opposite from it along a common line extending perpendicular to the side edges 40, 42 of the web and to the lines 46 and 50, one such common line being shown for example at 58 in FIG. 4. It will therefore be evident from FIGS. 2 and 4 that each pair of corresponding third and fourth indicator holes 54 and 56 serve to visually distinguish at least one corresponding pair of first and second feed holes 44 and 48. For example, in FIG. 2 the illustrated corresponding third and fourth holes 54 and 56 visually distinguish one pair of first and second holes indicated at e and f. They also serve to visually distinguish another pair of first and second holes indicated at g and h. Since in the construction shown the third hole 54 as seen in FIG. 2 is placed equidistantly between the holes e and g and the fourth hole 56 is placed equidistantly between the holes f and h the corresponding pair of first and second holes made up of the holes e and f are visually distinguished from the remaining first and second holes to the same extent as are the corresponding pair made up of the holes g and h. Therefore, the three holes e, g and 54 of FIG. 2 may be taken to be a cluster of holes which cluster is itself visually distinguished from the remaining holes 44, 44 and is placed over the corresponding cluster of pins on the sprocket 14 made up of the pin 34 and the two pins a and c on opposite sides of it when loading the web onto the sprocket 14, and likewise the holes h, f and 56 may be taken to be a similar visually distinguished cluster of holes which is placed on the visually distinguished cluster of pins on the sprocket 16 made up of the pin 36 and the two pins b and d on opposite sides of it. However, if desired the hole 54 may be placed closer to the hole e and the hole 56 closer to the hole f than shown in FIG. 2 to give distinctive prominence to the corresponding first and second holes e and f and in such case the pins 34 and 36 would of course also be located closer to the corresponding pins a and b.
As is obvious from what has already been said, the corresponding pairs of third and fourth indicator holes 54 and 56 distinguish corresponding pairs of first and second feed holes on the web which visually aids in properly loading the web onto the sprockets 14 and 16. That is, in a loading procedure such as illustrated in FIG. 2, the sprockets are turned to bring the third and fourth pins 34, 36 to a web loading position at which the pins 34 and 36 extend generally upwardly. The web 12 is then moved over the sprockets until a corresponding pair of third and fourth holes 54, 56 are located generally above the sprocket pins 34, 36 and then the web is moved downwardly onto the sprockets bringing the holes 54, 56 onto the pins 34 and 36 and bringing the visually distinguished corresponding pair of first and second holes e and f onto the visually distinguished corresponding pair of pins a and b and the visually distinguished corresponding pair of holes g and h onto the visually distinguished corresponding pair of pins c and d, and accordingly proper movement of the web from that point on is assured.
With reference to FIG. 4, the third holes 54, 54 are spaced uniformly from one another along the length of the web by a distance S which distance S is equal to Nd, where d is the spacing between the first holes 40, 40 and is the spacing between the second holes 48, 48, and where N is the number of first pins 30, 30 on the sprocket 14 the number of second pins 32, 32 on the sprocket 16. In the illustrated case the number of pins 30, 30 and 32, 32 is fourteen and therefore S equals 14d--that is, a third hole 54 occurs after every fourteenth hole 44 and likewise a fourth hole 56 occurs after every fourteenth hole 48. As a result of this each time the sprockets 14 and 16 undergo one revolution the third and fourth pins 34 and 36 will enter a new pair of third and fourth holes 54 and 56.
As indicated previously the web 12 may take various different forms depending on the type of machine with which the invention is used, and in the illustrated case may be either a length of sign making stock from which signs are cut or may be a length of paper or the like on which a sign is drawn as a test or checking procedure prior to its being cut from sign making stock material. In FIG. 5 the web 12 is shown to comprise a piece of sign making stock such as the "SCOTCHCAL" material previously mentioned. As such it consists of an upper layer 60 made of a thermoplastic material such as vinyl on the order of three to five mil thickness and having an adhesive backing or coating 62. This upper layer is supported on a release layer 64, to which it is releasably held by the adhesive backing 62, which release layer may consist for example of a ninety-pound paper coated or impregnated with silicone to give it its release property.
FIG. 10 illustrates another embodiment of the web 12 which is similar to the embodiment of FIG. 2, but includes a row of fifth indicator holes 90 located along the same line 46 as the first holes 44 and a row of sixth indicator holes 92 located along the same line 50 as the second holes 48. Each pair of holes 90, 92 is associated with the same holes 44, 48 as a corresponding pair of holes 54, 56, so that the visually distinguished sets of holes 44, 48 are readily identifiable upon visual observation.
In the embodiment of FIG. 10, however, the holes 54 are not positioned equidistant between the holes 44, but instead, are offset and placed closer to the visually distinguished holes 44 which serve as the keyholes for placing the web on the sprockets. Similarly, the fourth holes 56 are offset and positioned closer to the second holes 48 that are transversely aligned along the perpendicular line 94 with the visually identified holes 44 at the opposite side of the web. The pins on the sprockets engaged by the web, of course, would include visually distinguished pins having the same offset as the holes 54, 56.
With uneven spacing between the holes 54, 56 and the adjacent holes 44, 48, the web 12, in the absence of the holes 90, 92 can only be loaded into the machine 10 with one orientation, that is, the holes 44 must always be engaged with a particular sprocket at one end of the drive shaft 28 and the holes 48 must be engaged with the sprocket at the opposite end of the drive shaft. Any reversal of the holes 44, 48 and the sprockets would result in the offset pins on the sprockets engaging the locations of the web on the side of the perpendicular line 94 opposite from the holes 54, 56. The rows of fifth holes 90 and sixth holes 92 are provided for this reason.
It should be understood that the set of fifth holes 90 and the set of sixth holes 92 need not be transversely aligned with one another provided that the holes 54, 56 have the same misalignment. The fifth holes 90 must be offset from the distinguished hole 44 by the same amount that the fourth hole is offset from the distinguished hole 48, but on the opposite side of the line 94. Correspondingly, the sixth hole 92 must be offset from the second hole 48 by the same amount that the third hole 54 is offset from the visually distinguished hole 44 but on the opposite side of the line 94. With both sets of holes 54, 56 and 90, 92 the web 12 may be loaded into the machine without regard to its orientation or association of the holes at one longitudinal edge of the web with one or the other of the drive sprockets.
Referring to FIGS. 7 and 8, these figures show another embodiment of the invention in which the sprockets 14' and 16' do not include any extra pins and wherein other means are provided for visually distinguishing a pair of first and second pins from the remaining ones of such pins. In particular, the sprocket 14' includes a series of uniformly spaced first pins 66, 66 and the sprocket 16' similarly includes a corresponding series of uniformly spaced second pins 68, 68. On the sprocket 14' one of the first pins 66, 66 is visually distinguished from the others by having an appearance different from that of the others, such visually distinguished pin being indicated at G. Similarly on the sprocket 16' one of the second pins 68, 68, as indicated at H, has a visual appearance distinguishing it from the others. This difference in visual appearance of the pins G and H from that of the other pins 66, 66 and 68, 68 may be achieved in various ways, but preferably and as illustrated, it is accomplished by making the pins G and H of a color distinctly different from the color of the pins 66, 66 and of the pins 68, 68. Such a color difference may be achieved for example by painting the pins G and H and the pins 66, 66 and 68, 68 different colors or by making them of differently colored materials.
The web 12 used with the sprockets 14' and 16' of FIGS. 7 and 8 may be identical to that described above in connection with FIGS. 2 to 6 and is so illustrated in FIG. 7.
Again, as illustrated in FIG. 7, each pair of third and fourth indicator holes 54, 56 of the web serve to visually distinguish two corresponding pairs of first and second feed holes from the remaining ones of such first and second holes of the web. One such pair of distinguished feed holes is the pair indicated at e and f and the other such pair is the pair indicated at g and h. Therefore, to achieve proper loading of the web onto the sprockets either one of such visually distinguished pair of feed holes--that is, the pair e and f or the pair g and h--may be placed onto the visually distinguished pins G and H and thereafter the web will be driven properly by the sprockets as the machine operates.
In the embodiment of FIG. 7 the indicator holes 54, 54 do not receive any corresponding pins of the sprockets 14' and 16' and therefore it is not essential that the spacing of the third holes 54, 54 from one another along the length of the web, or the corresponding spacing of the fourth holes 56, 56 from one another along the length of the web be related to the number of teeth on the sprockets. That is, in the equation S=Nd given above, for the embodiment of FIG. 7 it is not necessary that N be equal to the number of first or second pins on the sprockets but instead it is sufficient that N be some integer other than one.
In accordance with the broader aspects of the invention it is not essential that the first holes 44, 44 of the web all be located exactly on a common line such as the line 46 or that the second holes 48, 48 be located on a common line such as the line 50. Instead, for example, alternate ones of the first holes 44, 44 could be located on opposite sides of the line 46 and alternate ones of the second holes 48, 48 could be located on opposite sides of the line 50, and in conformity with this the first pins 30, 30 of the sprocket 15 could be alternately located on opposite sides of a plane perpendicular to the axis 18 and alternate ones of the second pins 32, 32 could be located on opposite sides of another plane perpendicular to the axis 18 to cause the pattern of the pins 30, 30 and of the pines 32, 32 to match the pattern of the holes 44, 44 and of the holes 48, 48. However, to locate the holes on common lines such as the line 46 and the line 50 does have certain advantages and among other things allows a web 12 to be made from a previously unperforated length of sheet material by a simple punching method and appartaus.
The simple punching method and apparatus referred to in the preceding paragraph is illustrated by FIG. 9. As shown in this figure, the apparatus comprises a supply roll 70 for supplying a quantity of unperforated web material 72, and a take-up roll 74 for rerolling such material after it is punched. Between the supply roll 70 and the take-up roll 74 are two punches 76 and 78 located directly opposite from one another along opposite edges of the web 72 for punching the holes in the opposite side edge portions of the web. Each punch 76 and 78 is of a type which punches one hole in the web 72 during each cycle of operation. Between the punches 76, 78 and the take-up roll 74 are a pair of sprockets 80 and 82, driven in unison by a step motor 84 which engage the holes 44, 44 and 48, 48 formed in the web 72 by the punches to move the web past the punches 76 and 78. The operation of the stepping motor 84 and of the punches 76 and 78 is controlled by a controller 86. In operation the controller 86 commands the stepping motor 84 to move the web a proper distance for the punching of the next pair of corresponding holes by the punches 76 and 78. The motor is then stopped and the punches 76, 78 are then commanded to operate simultaneously to punch two corresponding holes in the opposite sides of the web, and the same cycle is then repeated. The distance the stepping motor moves the web between each punching operation is readily controlled by the controller 86, through preprogramming of it, to achieve proper spacing of the holes 44, 44 and 54, 54 along the one side edge of the web and correspondingly similar spacing of the holes 48, 48 and 56, 56 along the other side edge of the web.
In the claims which follow the work area or portion of the web located between the side edge portions containing the feed and indicator holes is described as being "uniform". By this term "uniform" it is meant that the work area or portion is of a continuous, undifferentiated and uninterrupted nature along the full length of the web so as to contain no perforations, holes, lines of weakening, severings, fold lines or other local features interfering with the generation of a graphic along any selected portion, or entire length, of said web.
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In a machine, such as a plotter or sign maker, wherein the web is fed longitudinally of itself by a pair of feed sprockets two corresponding pins of the two sprockets are visually distinguished from the other pins and at intervals along the length of the web corresponding holes on opposite sides of the web are visually distinguished from the other holes to enable a pair of such distinguished web holes to be loaded onto the pair of distinguished sprocket pins, thereby assuring proper loading of the web onto the machine and eliminating the possibility of subsequent faulty operation of the machine due to web misloading. The distinguished pairs of web holes are so distinguished by extra holes in the web and the distinguished pair of pins of the two sprockets are so distinguished by extra pins on the sprockets or by causing the two distinguished pins to have a color or other visual characteristic different from that of the other pins.
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FIELD OF THE INVENTION
The present invention relates to a method for producing a panel stretched over a frame, this panel being manufactured from a flexible and heat-shrinkable textile material, and it relates to a panel obtained according to said method.
BACKGROUND OF THE INVENTION
Different methods for production of flat panels are known, particularly for production of false ceilings in the construction field.
A first solution consists of using widths of PVC, fused and factory pre-assembled in order to form a sheet. This sheet is then secured along its edges to a frame formed, for example, by means of profiled fastening sections. In order to obtain a suitably taut panel, placement of the sheet must be entrusted to an expert, and requires specific equipment.
A second solution, easier to implement, consists of using sheets produced from non-woven materials. These materials can be painted and can have decorative patterns. Easy to install, they make possible frequent changes in decor, but they need to be taut in order to avoid any folding or buckling phenomena. This tightening is generally difficult, and does not enable one to obtain homogeneous tension in all directions of the sheet.
A third solution, particularly described in the publication FR-A-2 552 473, consists of using a heat-stretchable sheet. Before attachment to the frame, the sheet is subjected to a large temperature increase in order to stretch it. In its stretched state, it is attached along its edges in a frame formed by retaining profiled sections. The source of heat is then eliminated so that the sheet contracts by cooling and tightens on the frame. Before it is placed, this sheet must be cut precisely to dimensions that are compatible with those of the frame, anticipating its percentage of stretching and contraction. Cutting to dimensions which are too small will not allow this sheet to be stretched enough to secure it to the frame. Cutting to dimensions which are too large will generate waste and therefore extra material cost. Moreover, in order to enable stretching the sheet, and to obtain, after attachment, a homogeneous tension over its whole surface, the sheet must be heated entirely in one pass to a temperature of approximately 50–60° C. In order to obtain this homogeneous temperature rise, the whole room in which the sheet is going to be placed must be heated to this temperature. Consequently, this method is difficult to use in large rooms and by non-specialized persons. It generates high costs of implementation, as well as difficult work conditions for the placement personnel. Moreover, this heating can cause deterioration of other elements present in the room (furniture, floor covering, . . . ).
A fourth solution, particularly described in the publication FR-A-2 619 531, consists of using a heat-shrinkable cloth secured on the frame; the cloth is attached, not tightly, to the frame and is then subjected to a large temperature increase allowing it to contract and tighten on the frame. This cloth is, for example, produced from PVC. This method thus makes it possible to produce a panel simply, and without requiring the involvement of experts. Nevertheless, this method does not allow one to obtain an optimal result, since the panel is not homogeneously taut in all directions.
Therefore, there is no solution providing a satisfactory response to the problem that is posed.
SUMMARY OF THE INVENTION
The present invention therefore aims to remedy this problem by proposing a method for producing panel, making it possible to obtain simply, economically, under good work conditions, and without influence on the environment, a panel, even of large dimensions, that is homogeneously taut in all of its directions. The invention also proposes a panel which is produced in the form of a single piece with no sewing or fusing, which can have large dimensions, and which allows one to tension it homogeneously in all directions and in a way that is currently unequalled.
For this purpose, the invention relates to a method for producing a panel of the type indicated in the preamble, characterized by the fact that it comprises the steps of:
manufacture of a strip of a flexible textile material from synthetic textile threads according to a knitting method in order to form meshes that can be deformed in all directions,
coating the flexible textile material on at least one of its sides by means of a coating mixture containing at least one polymer with elastomeric characteristics in the polymerized state, and a covering coloring substance,
polymerization of the polymer contained in the coating mixture,
cutting a sheet from the flexible textile material whose dimensions are slightly greater than those of the frame,
attaching the frame to a partition or ceiling, this frame being made up of retaining profiled sections forming a closed frame,
engaging the peripheral edges of the sheet in said retaining profiled sections and,
local heating at least one zone of the sheet in order to bring about the heat shrinking of the textile material.
The edges of the sheet extending past the retaining profiled sections are preferably cut off flush with said retaining profiled sections and/or the excess is fitted into said profiled sections by means of a spatula.
According to an advantageous characteristic, the synthetic textile threads constituting the basis of the flexible textile material include heat-shrinkable polyester threads.
According to another advantageous characteristic, the coating mixture moreover contains a flame retardant substance.
According to a preferred embodiment, the coating mixture consists of a paste which is deposited in the form of at least one extruded rope over at least a part of the width of the flexible textile material and which is made to penetrate into the meshes of the textile material before polymerization of the polymer contained in the coating mixture is effected.
The polymer contained in the coating mixture preferably contains polyurethane.
The covering coloring substance advantageously further contains titanium oxide and/or colored pigments and/or decorative elements present at least in a form chosen from the group comprising at least powders, flakes, granules, films of mineral and/or synthetic substances, and/or a mixture of these elements.
According to an advantageous embodiment, the sheet is printed according to a digital printing method.
The frame is preferably formed with retaining profiled sections having two opposite clamping jaws.
The invention also relates to a panel stretched on a frame attached to a support, this frame consisting of retaining profiled sections forming a closed frame, characterized by the fact that it is produced from a sheet whose dimensions are slightly greater than those of the frame which is to be produced, this sheet being cut from a textile strip produced from synthetic textile threads according to a knitting method in order to form meshes that can be deformed in all directions, this textile strip being coated on at least one of its sides by means of a coating mixture containing at least one polymer having elastomeric characteristics in the polymerized state and a covering coloring substance, the polymer contained in the mixture being polymerized, the peripheral edges of the sheet being engaged in the retaining profiled sections constituting the frame, the edges of the sheet extending past the profiled sections being cut flush with the retaining profiled sections after local heating of the sheet arranged so as to bring about heat shrinking and tightening of it.
According to a particularly advantageous embodiment, the panel has, at least on a part of one of its sides, at least one digitally printed image, chosen, for example, from the group that comprises at least a decorative image, an advertising representation, a drawing, an inscription.
According to another embodiment, the panel advantageously has a surface treatment obtained by at least one method chosen from the group which comprises at least ultraviolet binding, molecular grafting.
This surface treatment is preferably arranged so as to give the panel properties chosen from the group which comprises at least antiseptic, insecticidal, antistatic, disinfectant properties.
BRIEF DESCRIPTION OF THE DRAWING
The present invention and its advantages will appear more clearly in the following description of an embodiment example, with reference to the FIGURE representing a panel obtained by the method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the FIGURE, the method for producing a panel 1 stretched on frame 2 comprises the successive steps described hereafter.
In a first step, a strip of flexible textile material is manufactured from synthetic textile threads, for example, by means of a knitting method, this flexible textile material having meshes 5 which can be deformed in all directions. The threads are in particular heat-shrinkable textile threads of polyester or any other equivalent textile material.
In a second step, one or both sides of the strip is (are) coated with a coating mixture containing a polymer which is elastomeric in the polymerized state. This polymer contains, for example, polyurethane or any other equivalent material. The polyurethane coating in particular gives the textile material a smooth and uniform aesthetic appearance. The coated flexible textile material moreover has the advantage that it is impermeable to dust, is washable, and can be painted with any commercially available paint or can be printed.
The coating mixture can contain a flame retardant substance allowing the panel 1 that is produced to be protected from flames and to be classified as fireproof class M1.
The coating mixture can also contain a covering coloring substance making it possible to obtain a panel 1 whose appearance is even more uniform over its whole surface in a given color. It is possible to use, for example, a coloring substance moreover containing titanium oxide. This coloring substance can also contain colored pigments and/or decorative elements such as, for example, powders, flakes, granules, films of mineral and/or synthetic substances and/or a mixture of these elements.
The coating mixture consists, for example, of a paste which is deposited over the whole width of the flexible textile material and on both sides of this flexible textile material in the form of extruded ropes, for example, one rope per side. The strip of flexible textile material is present, for example, in the form of a spool and is unwound longitudinally under a depositing nozzle which is given an alternating transverse movement, for example, making possible the deposition of extruded ropes over the whole width of the flexible textile material. This paste is forced on both sides to penetrate inside the meshes of the flexible textile material, for example, between two pressing rollers which also allow the deposit to be evened out over the whole surface of the strip. It is completely possible to envisage depositing only a single extruded rope on one side of the strip. In that case, the paste will be made to penetrate in such a way that it passes through the flexible textile material and emerges on the non-coated side so that it can be distributed over the whole surface of the flexible textile material. Suitable distribution of the paste can also be obtained by using scrapers replacing or supplementing the use of the rollers. Coating of both sides of the flexible textile material can be done in a single operation, or in two successive operations between which the flexible textile material is turned over. The paste deposited in the form of an extruded rope can be made fluid, for example, by means of heating with ultrasound, which facilitates its penetration into the flexible textile material.
In a third step, the polymer contained in the coating mixture is polymerized in order to give the flexible textile material the elastomeric characteristics belonging to the polymer that is used, in particular its heat shrinking characteristic. One thus obtains a heat shrinkable flexible textile material that can, for example, be put in the form of a roll and unwound as needed. During this polymerization step, the lateral edges of the flexible textile material are preferably held, for example, by means of a spiked chain, in order to prevent the flexible textile material from undergoing excessive heat shrinking effects.
In a fourth step, a sheet is cut from the flexible textile material thus obtained that is intended to form panel 1 . This sheet is cut such that its dimensions are slightly greater than those of frame 2 . As explained in the rest of the description, this cutting does not have to be done with special precision. During this cutting, heat shrinking of the sheet will of course be anticipated. In a non-limiting manner, the percentage of contraction of this type of textile material is on the order of 5 to 10%.
In a fifth step, frame 2 is attached to support 3 in the form of a partition or ceiling. This frame 2 consists of retaining profiled sections 2 ′, for example, four of them, each having, for example, two opposite clamping jaws (not represented). These retaining profiled sections 2 ′ are arranged so as to form a closed frame. Retaining profiled sections 2 ′ can also be attached to different supports 3 in order to produce a panel 1 between two walls or a panel 1 installed vertically on the floor.
In a sixth step, the peripheral edges of the sheet are engaged between the clamping jaws of retaining profiled sections 2 ′. The sheet secured along its peripheral edges is pre-stretched when it is placed on frame 2 .
In a seventh step, the sheet is heated locally at the places having folds or lack of tension in order to bring about heat shrinking of the flexible textile material. To do this, the heating end of a heat gun, mounted, for example, on a mobile carriage, is positioned at distance of approximately 20 to 30 cm from the sheet facing the predetermined zone of the sheet that is to be tightened. The heat gun is possibly moved to a second zone. Preferably, the heat gun is moved, for example, according to a straight line trajectory shifted from one line to another for the purpose of sweeping the whole surface of the sheet. The use of a localized heat source in the form of a heat gun heated to approximately 200° C. makes it possible to obtain a rapid contraction of each heated zone of the sheet without the need to heat the whole room, which remains at room temperature. It is thus possible to produce panel 1 stretched from a single piece in large rooms, in a rapid, simplified manner without risk of deterioration of the surface coverings or furniture present in the room. The step of placement of panel 1 therefore takes place in a room-temperature environment, and does not generate work conditions that are difficult for the placement personnel.
Depending on the dimensions of the sheet, it is possible to cut the edges of the sheet which extend past retaining profiled sections 2 ′ flush with these retaining profiled sections 2 ′.
Thus, no part of the sheet surrounding panel 1 remains. This step makes it possible, on the one hand, not to have to cut the sheet with special precision, and moreover to obtain a suitable finishing level for panel 1 . In order to obtain a similar result, it is also possible to insert the projecting edges of the sheet, into profiled fastening sections 2 ′. This cutting and/or insertion can take place before or after the heat shrinking step. Before attachment of the sheet, it is possible to provide for it be printed, for example, by means of a digital printing method.
This type of process allows the production of a panel 1 stretched on frame 2 in order to form a partition, ceiling 3 , or an advertising panel. This panel 1 has a mechanical strength up to fifteen times greater than that of conventional surface coverings, for example, made of PVC. Moreover, this panel 1 can have, at different locations of its covering surface, cutouts 4 forming decorative patterns, or holes provided for integrating spotlights.
It is easy to modify the aesthetic appearance of panel 1 by integrating decorative elements, [or] pigments in the coating mixture that is used, during the production method; or after placement of panel 1 , by printing an image, by painting, or by any other equivalent means. Panel 1 can also be reversible and have a different décor on each side. The image 6 can be a decorative image, an advertising representation, a drawing, an inscription, or any other type of image.
According to an embodiment variant of particular interest, panel 1 has a surface treatment which is obtained, for example, by ultraviolet binding, molecular grafting, or any other equivalent method. This surface treatment makes it possible to give panel 1 antiseptic, insecticidal, antistatic, disinfectant, or any other suitable property.
INDUSTRIAL APPLICATION POSSIBILITIES
Panel 1 and its method of production can of course be used to produce any type of panel 1 , for example, a wall covering for the purpose of carrying out wall decoration as well as taut suspended ceilings. Profiled fastening sections 2 ′ used in this method for installing suspended ceilings can be of different types.
This description clearly demonstrates that the invention allows all the objectives to be attained, and particularly makes it possible to obtain a homogeneous tension of panel 1 in all directions while allowing simple, rapid, and economical production. The present invention is not limited to the embodiment example that has been described, but extends to any modification and variant obvious to the expert in the field, while remaining within the scope of the protection defined in the appended claims.
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The invention concerns a method for producing a panel substantially stretched on a frame stretched homogeneously in all directions. The panel ( 1 ) is obtained from a sheet cut out in web of soft textile material produced from knitted synthetic textile yams forming deformable stitches in all directions. The textile web is coated with a coating mixture comprising an elastomeric polymerized polymer and a covering coloring substance. The peripheral edges of the sheet are engaged in retaining profiled sections ( 2 ) forming a closed frame ( 2 ) fixed on a support ( 3 ). Said sheet is stretched by local heating in at least a zone causing it to be heat-shrunk and stretched on the frame ( 2 ). The invention is applicable to false ceilings, advertising boards, and all types of wall decorations.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to firearm accessories and more specifically to a firearm handgrip with a bipod.
BACKGROUND OF THE INVENTION
[0002] Shooting firearms, specifically during combat requires maintaining a steady and stable position to insure accuracy of aim. Stabilizing the firearm manually, simply by holding it tight is usually impractical due to the size and weight of the firearm. Therefore, peripheral support devices have been developed during the years for use in conjunction with firearms as a means for stabilizing and improving accuracy.
[0003] Early stabilizing means were large stationary objects such as rocks and tree branches to forked sticks, shooting slings, bipods and tripods. In more recent times, compact collapsible bipod supports have been developed. These collapsible bipods are relatively lightweight and are mountable to the forearm stock of a firearm. Most conventional bipod supports include a pair of legs that can be pivoted from an up position adjacent the firearm stock, to a down position engaging a support surface.
[0004] Tracking moving targets requires several different motions of the firearm in the hand of the shooter. The first motion is horizontal or lateral rotation, also referred to as “panning”. Another motion is sometimes required when the shooter places the bipod on an uneven support surface. In this case, the firearm has to be rotated around the axis of the bore. This motion is also referred to as “canting.”
[0005] Several attempts have been made in designing compact, ergonomic bipods that are both collapsible and concealable within a handgrip of a firearm. Some references focus on the quick deployment of the bipods whereas other references focus on lock mechanisms that lock the bipod upon deployment.
[0006] U.S. Pat. No. 7,111,424, which is incorporated by reference in its entirety herein, discloses a fore grip or a gun handle with a concealable and collapsible bipod that requires only one action to deploy and lock the bipod. Specifically, locking the bipod prevents the abovementioned motions (panning, tilting canting) and therefore the suggested bipod is limited to shooting activities where these motions are not required.
[0007] U.S. Patent Application No. 2005/0241206, which is incorporated by reference in its entirety herein, discloses a hollow grip handle with a bipod for quick deployment. When the legs are extended, and placed on a support surface, the weight of the weapon causes the feet to pivot against the bias springs to align the feet with the support surface. In addition, stop members allow a desired degree of horizontal rotation of the leg assembly relative to the housing. The relative rotation permits the weapon to be horizontally pivoted to engage the target without the need to move or shift the feet relative to the underlying support surface.
[0008] Sometimes during combat it is required to perform panning of a target (horizontal tracking) for a while prior to shooting. In the case that the angle of rotation is substantial, the accuracy of the shooting is decreased. It would be advantageous therefore to have a quick deployment bipod that tracks the horizontal rotation angle of the firearm and enables a quick realignment of the bipod, for an accurate shooting.
SUMMARY OF THE INVENTION
[0009] The present invention discloses a firearm handgrip with a collapsible and concealable bipod positioned within the handgrip. The bipod enables tracking of the horizontal angle of the firearm. Specifically, the bipod is quickly deployable by pressing a button that activates a highly reliable release mechanism. Upon bipod deployment, the shooter is free to place the bipod on any surface, including uneven surfaces wherein the bipod legs are positioned on different heights so that the bipod maintains stability. The bipod enables panning (horizontal rotation) and canting (right-left) of the firearm. Additionally, after panning the firearm and subsequently lifting the bipod from the surface it lies on, the bipod's legs automatically realign to a plane perpendicular to the firearm, thus tracking and adjusting to the new horizontal angle of the firearm.
[0010] The handgrip comprises four main elements: The first element is a hollow housing that may be mountable to a firearm. The housing may be composed of aluminum, hardened polymer, composite material and the like. The second element is a bipod that enables panning and canting and further enables tracking a horizontal angle for quick realignment of the bipod legs. The third element is a compression spring for forcing deployment of the bipod and the third element is a release mechanism for releasing the spring and deploying the bipod.
[0011] The steps of the method according to the present invention are: (a) releasing the bipod from the handgrip resulting in bipod deployment upon a support surface; (b) horizontally rotating the firearm in accordance with a moving target and finally (c) lifting the bipod from the support surface, causing the legs of the bipod to realign so that the plane of the legs becomes substantially perpendicular to the firearm.
BRIEF DESCRIPTION OF DRAWINGS
[0012] The subject matter regarded as the invention will become more clearly understood in light of the ensuing description of embodiments herein, given by way of example and for purposes of illustrative discussion of the present invention only, with reference to the accompanying drawings (Figures, or simply “FIGS.”), wherein:
[0013] FIG. 1 is an elevational view of an embodiment of the invention showing the firearm handgrip with the bipod in a deployment position;
[0014] FIG. 2 is an exploded view of an embodiment of the invention showing the firearm handgrip;
[0015] FIG. 3 is a cross-sectional view of an embodiment of the invention showing the firearm handgrip with the bipod in a deployment position; and
[0016] FIG. 4A and FIG. 4B are cross-sectional views of an embodiment of the invention showing the firearm handgrip with the bipod in a stored and deploy positions respectively;
[0017] Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.
DETAILED DESCRIPTION OF THE INVENTION
[0018] FIG. 1 shows an elevational view of an embodiment of the invention showing the firearm handgrip 100 with the bipod in after deployment 101 . The handgrip 100 enables the shooter to practice all the motions required in combat. Specifically, the handgrip 100 may be horizontally rotated around its axis in a panning motion l 102 . Finally, the handgrip 100 may be canted to the right 103 B and to the left 103 A in order to fit the bipod to an uneven support surface.
[0019] FIG. 2 shows an exploded view of an embodiment of the invention showing the firearm handgrip 100 . The handgrip 100 comprises a hollow housing 210 mountable to a firearm. The housing 210 has a top end with a horizontal channel and an open bottom end. The handgrip 100 further comprises a bipod comprising a vertically sliding piston 220 located within the housing 210 . The piston 220 has a top end and a bottom end. The handgrip 100 further comprises two legs 252 A, 252 B hingedly connected to the bottom end of said piston 220 , wherein a first torsion spring 253 positioned between the legs 252 A, 252 B causes the legs 252 A, 252 B to expand outwardly whenever the legs 252 A, 252 B are released from the housing 210 . The bipod further comprises a tracking mechanism comprising a horizontally positioned second torsion spring 221 having a first end and a second end, wherein the first end is connected to the legs 252 A, 252 B and the second end is connected to the bottom end of the piston 220 . The deployment of the bipod is achieved by a first compression spring 231 ) positioned within the housing 210 between the top end of the housing 210 and the top end of the piston 220 . At the top end of the housing a release mechanism for releasing the first compression spring 230 and pushing the piston 220 down causing the deployment of the bipod.
[0020] Upon the deployment of the bipod and stabilizing the bipod on a support surface, the handgrip 100 enables panning the firearm horizontally. The tracking mechanism is configure so that upon lifting the firearm from the support surface, the legs 252 A, 252 B track the new horizontal angle of the firearm and the plane including the legs 252 A, 252 B aligns substantially perpendicularly to the firearm.
[0021] FIG. 3 shows a cross-sectional view of an embodiment of the invention showing the firearm handgrip with the bipod in a deployment position. The horizontal tracking mechanism is depicted in details. The piston 220 is positioned at the bottom end of the housing 210 . The horizontal torsion spring 320 is connected to the bottom end of the piston 220 in one end and to the legs 252 A, 252 B on the other end. The inner side of the bottom end of the housing may be threaded, 310 A, 310 B so that it may serve as outline for panning movements.
[0022] FIG. 4A and FIG. 4A show cross-sectional views of an embodiment of the invention showing the firearm handgrip with the bipod in a stored and deploy positions respectively; These figures illustrates the operation of the release mechanism: Whenever the bipod is in the stored positioned, the first compression spring 440 A is compressed between the piston and the bottom side of you bottom. The ram 410 A is fitted within the channel and both magnet pieces 420 A and 450 A are aligned so that they attract each other. The magnetic attraction power is selected so that it overcomes the expansion power of the first compression spring 440 A. Then, pushing the ram 430 B inside realigns the magnets so that the magnetic attraction force decreases and so the compression spring 440 B is release, pushing down the piston and the legs. The magnetic release mechanism is more reliable than mechanical mechanism, as there is practically no contact between the first compression spring and the ram.
[0023] According to some embodiments of the invention, the invention may also be practices as a method. The method is a method for tracking the horizontal angle of a firearm using a handgrip with a deployable bipod. The steps of the method are: (a) releasing the bipod from the handgrip resulting in bipod deployment upon a support surface; (b) horizontally rotating the firearm in accordance with a moving target and finally (c) lifting the bipod from the support surface, causing the legs of the bipod to realign so that the plane of the legs becomes substantially perpendicular to the firearm.
[0024] According to other embodiments of the invention, lifting the bipod from the support surface is followed by repositioning the bipod on said support surface and finally shooting the target.
[0025] According to other embodiments of the invention, the method enables canting of the firearm as well as horizontally rotating the firearm in accordance with a moving target.
[0026] In the above description an embodiment is an example or implementation of the inventions. The various appearances of “one embodiment,” “an embodiment” or “some embodiments” do not necessarily all refer to the same embodiments.
[0027] Although various features of the invention may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the invention may be described herein in the context of separate embodiments for clarity, the invention may also be implemented in a single embodiment.
[0028] Reference in the specification to “some embodiments”, “an embodiment”, “one embodiment” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the inventions.
[0029] It is understood that the phraseology and terminology employed herein is not to be construed as limiting and are for descriptive purpose only.
[0030] The principles and uses of the teachings of the present invention may be better understood with reference to the accompanying description, figures and examples.
[0031] It is to be understood that the details set forth herein do not construe a limitation to an application of the invention.
[0032] Furthermore, it is to be understood that the invention can be carried out or practiced in various ways and that the invention can he implemented in embodiments other than the ones outlined in the description below.
[0033] It is to be understood that the terms “including”, “comprising”, “consisting” and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers or groups thereof and that the terms are to be construed as specifying components, features, steps or integers.
[0034] If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element.
[0035] It is to be understood that where the claims or specification refer to “a” or “an” element, such reference is not be construed that there is only one of that element.
[0036] It is to be understood that where the specification states that a component, feature, structure, or characteristic “may”, “might” “can” or “could” be included, that particular component, feature, structure, or characteristic is not required to he included.
[0037] Where applicable, although state diagrams, flow diagrams or both may be used to describe embodiments, the invention is not limited to those diagrams or to the corresponding descriptions. For example, flow need not move through each illustrated box or state, or in exactly the same order as illustrated and described.
[0038] Methods of the present invention may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks.
[0039] The term “method” may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belongs.
[0040] The descriptions, examples, methods and materials presented in the claims and the specification are not to be construed as limiting but rather as illustrative only.
[0041] Meanings of technical and scientific terms used herein are to be commonly understood as by one of ordinary skill in the art to which the invention belongs, unless otherwise defined.
[0042] The present invention can be implemented in the testing or practice with methods and materials equivalent or similar to those described herein.
[0043] Any publications, including patents, patent applications and articles, referenced or mentioned in this specification are herein incorporated in their entirety into the specification, to the same extent as if each individual publication was specifically and individually indicated to he incorporated herein. In addition, citation or identification of any reference in the description of some embodiments of the invention shall not be construed as an admission that such reference is available as prior art to the present invention.
[0044] While the invention has been described with respect to a limited number of embodiments, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of some of the embodiments. Those skilled in the art will envision other possible variations, modifications, and applications that are also within the scope of the invention. Accordingly, the scope of the invention should not he limited by what has thus far been described, but by the appended claims and their legal equivalents. Therefore, it is to be understood that alternatives, modifications, and variations of the present invention are to be construed as being within the scope and spirit of the appended claims.
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A firearm handgrip with a collapsible and concealable bipod positioned within the handgrip. The bipod enables tracking of the horizontal angle of the firearm. Specifically, the bipod is quickly deployable by pressing a button that activates a highly reliable release mechanism. Upon bipod deployment, the shooter is free to place the bipod on any surface, including uneven surfaces wherein the bipod legs are positioned on different heights so that the bipod maintains stability. The bipod enables panning (horizontal rotation), tilting (up-down) and canting (right-left) of the firearm. Additionally, after panning the firearm and subsequently lifting the bipod from the surface it lies on, the bipod's legs automatically realign to a plane perpendicular to the firearm, thus tracking and adjusting to the new horizontal angle of the firearm.
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CROSS REFERENCES TO RELATED APPLICATIONS
This present application is a divisional application which claims the benefit of the filing date of U.S. patent application Ser. No. 10/871,799, filed Jun. 18, 2004, the disclosure of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
Electronic devices such as flat screen monitors or other electronic equipment are supported for use by a variety of known adjustable stands and/or extension arms. For example, there is known from U.S. Pat. No. 6,609,691 an adjustable extension arm for mounting a monitor to a supporting surface, the disclosure of which is incorporated herein by reference. The extension arm is constructed from a pair of nested channel members which form an adjustable parallelogram that permits the electronic device coupled thereto to be raised and lowered to a desired height. Such extension arms are useful when it is desired to elevate the monitor off a desk or other surface, in order that the device meets eye level or some other desired height. U.S. Pat. No. 6,499,704, the disclosure of which is incorporated herein by reference, discloses a pole stand having a base, a pole attached to the base, and a collar, which is positonable on the pole. The collar is provided with a support mount that can receive various coupling components, which may in turn be attached to an electronic device such as a monitor.
Despite these known adjustable stands and extension arms, there is the desire for further improvements in an adjustable support for an electronic device and mounting brackets for use therewith.
SUMMARY OF THE INVENTION
In accordance with an embodiment of the present invention, there is described a mounting apparatus for an electronic device, the mounting apparatus comprising an elongated beam having a longitudinal axis; and at least one bracket adapted to be coupled to an electronic device, the bracket including a body having a bore adapted to receive the beam therethrough, and a pair of spaced apart ribs extending from the body into said bore, the ribs adapted for engagement with the beam when the beam is received within the bore.
In accordance with a further embodiment of the present invention, there is described a mounting apparatus for an electronic device, the mounting apparatus comprising an elongated beam having a longitudinal axis, the beam having a bracket engagement portion; and at least one bracket adapted to be coupled to an electronic device, the bracket including an upper bracket member pivotably attached to a lower bracket member forming a bore therebetween, one of the upper and lower bracket members including a beam engagement portion accessible within the bore, the beam engagement portion coacting with the bracket engagement portion when the beam is received within the bore to prevent the bracket from twisting about the beam.
In accordance with a further embodiment of the present invention, there is described a mounting bracket adapted for coupling an electronic device to an elongated beam, the bracket comprising a body having a bore adapted to receive the beam therethrough, and a pair of spaced apart ribs extending from the aid body into the bore, the ribs adapted for engagement with the beam when the beam is received within the bore.
In accordance with a further embodiment of the present invention, there is described a mounting bracket adapted for coupling an electronic device to an elongated beam, the bracket comprising an upper bracket member pivotably attached to a lower bracket member forming a bore therebetween, one of the upper and lower bracket members including a beam engagement portion accessible within the bore, the beam engagement portion adapted for coacting with a portion of the beam when the beam is received within the bore to prevent the bracket from twisting about the beam.
In accordance with a further embodiment of the present invention, there is described a mounting bracket adapted for coupling an electronic device to an elongated beam, the bracket comprising a body having a bore adapted to receive the beam therethrough; means for preventing twisting of the body about the beam when the beam is received within the bore; and means for engaging a surface of the beam at spaced apart locations when the beam is received within the bore.
In accordance with a further embodiment of the present invention, there is described a mounting bracket adapted for coupling an electronic device to a curved elongated beam, the bracket comprising an upper bracket member pivotably attached to a lower bracket member between an open and closed position, the upper and lower bracket members forming a through bore therebetween when in the closed position, the bore having first and second spaced apart ends, first and second ribs extending from the upper and lower bracket members into the bore, the first rib arranged adjacent the first end and the second rib arranged adjacent the second end, each of the ribs having a curved inner surface adapted for engagement with a surface of the beam when received within the bore, and a beam engagement portion accessible within the bore adapted for coacting with a portion of the beam when received within the bore to prevent twisting of the bracket about the beam.
In accordance with a further embodiment of the present invention, there is described a mounting apparatus for an electronic device, the mounting apparatus comprising an elongated beam; and a mounting bracket adapted for coupling an electronic device to the elongated beam, the bracket comprising a body having a bore adapted to receive the beam therethrough, means for preventing twisting of the body about the beam when the beam is received within the bore, and means for engaging a surface of the beam at spaced apart locations when the beam is received within the bore.
In accordance with a further embodiment of the present invention, there is described a mounting apparatus for an electronic device, the apparatus comprising a curved elongated beam having a longitudinal axis, the beam having a bracket engagement portion extending along the axis; and at least one mounting bracket adapted for coupling an electronic device to the beam, the bracket comprising an upper bracket member pivotably attached to a lower bracket member between an open and closed position, the upper and lower bracket members forming a through bore therebetween when in the closed position, the bore having first and second spaced apart ends, first and second ribs extending from the upper and lower bracket members into the bore, the first rib arranged adjacent the first end and the second rib arranged adjacent the second end, each of the ribs having a curved inner surface adapted for engagement with a surface of the beam when received within the bore, and a beam engagement portion accessible within the bore adapted for coacting with the bracket engagement portion of the beam when received within the bore to prevent twisting of the bracket about the beam.
In accordance with a further embodiment of the present invention, there is described a mounting apparatus for adjusting the elevation of an electronic device coupled thereto, the mounting apparatus comprising an elongated beam having a longitudinal axis; and at least one bracket adapted to be coupled to an electronic device, the bracket including a body having a bore adapted to receive the beam therethrough, and means for adjusting the elevation of an electronic device when coupled thereto relative to the body.
In accordance with a further embodiment of the present invention, there is described a mounting apparatus for adjusting the elevation of an electronic device coupled thereto, the mounting apparatus comprising an elongated beam having a longitudinal axis; and at least one bracket adapted to be coupled to an electronic device, the bracket including a body having a threaded opening and a bore adapted to receive the beam therethrough, and an externally threaded bushing having an opening at one end thereof, the bushing threadingly received within the threaded opening within the body; and a coupling device received within the opening of the bushing for coupling an electronic device to the bracket, whereby the elevation of the electronic device can be adjusted by advancing the bushing through the body by rotation of the bushing.
In accordance with a further embodiment of the present invention, there is described a mounting bracket for adjusting the elevation of an electronic device coupled thereto, the bracket comprising a body adapted for coupling an electronic device thereto, and means for adjusting the elevation of an electronic device when coupled thereto relative to the body.
In accordance with a further embodiment of the present invention, there is described a mounting bracket for adjusting the elevation of an electronic device coupled thereto, the bracket comprising a body having a threaded opening, and an externally threaded bushing having an opening at one end thereof, the bushing threadingly received within said threaded opening within the body; and a coupling device received within the opening of the bushing for coupling an electronic device to the body, whereby the elevation of the electronic device can be adjusted by advancing the bushing through the body by rotation of the bushing.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with features, objects, and advantages thereof may best be understood by reference to the following detailed description when read with the accompanying drawings in which:
FIG. 1 is a front elevational view of a mounting apparatus constructed in accordance with one embodiment of the present invention;
FIG. 2 is a perspective view of an elongated beam adapted for use in the mounting apparatus in accordance with one embodiment of the present invention;
FIG. 3 is a perspective view of a mounting bracket constructed in accordance with one embodiment of the present invention;
FIG. 4 is a perspective view, looking from above, of the upper bracket member of the mounting bracket shown in FIG. 3 ;
FIG. 5 is a perspective view, looking from below, of the upper bracket member of the mounting bracket shown in FIG. 3 ;
FIG. 6 is a front elevational view of the lower bracket member of the mounting bracket shown in FIG. 3 ;
FIG. 7 is a top plan view illustrating a plurality of electronic devices mounted to a curved elongated beam using a mounting bracket constructed in accordance with one embodiment of the present invention;
FIG. 8 is a diagrammatical illustration showing the relationship of a mounting bracket coupled to a curved elongated beam in accordance with one embodiment of the present invention;
FIG. 9 is a front elevational view of a mounting bracket constructed in accordance with another embodiment of the present invention;
FIG. 10 is a perspective view of a mounting bracket constructed in accordance with another embodiment of the present invention;
FIG. 11 is a perspective view of the projection shown in the mounting bracket shown in FIG. 10 ;
FIG. 12 is a front elevational view of a mounting bracket constructed in accordance with another embodiment of the present invention; and
FIG. 13 is a perspective view of a mounting bracket constructed in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing the preferred embodiments of the invention illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
Referring now to the drawings, wherein like reference numerals represent like elements, there is shown in FIG. 1 a mounting apparatus generally designated by reference numeral 100 . The mounting apparatus 100 includes an elongated beam 102 and at least one mounting bracket for use therewith. In the embodiment shown in FIG. 1 , the mounting apparatus 100 includes a plurality of mounting brackets 104 , 106 , 108 , whose construction will be described hereinafter. An electronic device such as a flat screen monitor 110 is coupled to each of the mounting brackets by means of, for example, a tilter device 112 such as known from U.S. Pat. No. 6,505,988, the disclosure of which is incorporated herein by reference. The beam 102 is supported in a horizontal orientation overlying floor 114 by means of a stand 116 . As to be described hereinafter, the beam 102 may be also be supported from the ceiling, vertical wall or office furniture as may be desired.
Referring to FIG. 2 , there is illustrated one embodiment of a beam 102 adapted for supporting an electronic device via a mounting bracket. The beam 102 is constructed as an elongated member having a circular cross-section and a predetermined radius of curvature. The beam 102 , as shown, is constructed as a solid beam from a lightweight metal such as aluminum and the like. It is contemplated that the beam 102 may be constructed from other materials such as plastics and reinforced plastics, as well as a hollow tubular member or a hollow tubular member that is filled with a secondary material such as a metal or plastic filler.
In the preferred embodiment, the beam 102 has a circular cross-sectional shape. This facilitates bending of the beam 102 to the desired radius of curvature. However, it is contemplated that the beam 102 may have other geometric shapes, for example, polygonal, square, oval and the like. Although the beam 102 has a predetermined radius of curvature in accordance with the preferred embodiment, it is to be understood that the beam may also be linear without a radius of curvature if so desired.
The beam 102 is provided with a bracket engagement portion in the nature of an elongated slot 118 . The cross-sectional shape of the slot 118 may have various forms, for example, rectangular, keyhole, polygonal and the like. The slot 118 is provided extending along the longitudinal axis 119 of the beam generally arranged at its mid-point, for example, in alignment with the diameter of the beam 102 . As shown, the slot 118 is formed on the side of the beam 102 having the larger radius of curvature, i.e., outwardly of the beam. However, it is contemplated that the slot 118 may also be provided on the surface of the beam having the smaller radius of curvature, i.e., facing inwardly. Although the slot 118 has been shown as a continuous slot form one end of the beam 102 to the other, it is contemplated that the slot may be formed as segments which are discontinuous.
Referring now to FIGS. 3 through 6 , there will be described a mounting bracket constructed in accordance with one embodiment of the present invention. The mounting brackets 106 , 108 are adapted to be slid along the beam 102 for securing at a predetermined location. On the other hand, the mounting bracket 104 is intended to have a fixed location along the beam 102 . The construction of the mounting bracket 104 will be described hereinafter. As best shown in FIG. 3 , the mounting brackets 106 , 108 are constructed from a body 120 which includes an upper bracket member 122 and a lower bracket member 124 , and optionally, a bushing 126 .
The upper bracket member 122 includes a boss 128 having an upper surface 130 and a lower surface 132 . A threaded opening 134 extends through the boss 128 between the upper and lower surfaces 130 , 132 . A pair of spaced apart ribs 136 having an aligned through bore 138 are provided extending away from the lower surface 132 adjacent one end of the boss 128 .
An arcuate shaped member 140 extends away from the boss 128 having an inner curved surface 142 . The curved surface 142 is formed by a radius generally corresponding to the radius of the cylindrical beam 102 . In this regard, the shape of the inner surface 142 conforms to the shape of the beam 102 . In an embodiment where the beam 102 is polygonal in cross-sectional shape, the inner surface 142 of the upper bracket 142 will have a corresponding polygonal shape.
A projection 146 extends inwardly from the forward edge 148 of the arcuate shaped member 140 . The projection 146 is an elongated body having a cross-sectional shape generally conforming to the cross-sectional shape of the slot 118 formed in beam 102 . In this regard, the projection 146 is adapted to extend into the slot 118 , whereby the mounting bracket may slide longitudinally along the beam 102 while the projection is engaged within the slot. Thus, it is not a requirement that the projection 146 have the same corresponding shape as the slot 118 . Although the projection 146 has been shown as a single elongated body, it is contemplated that the projection may be formed from spaced apart segments, or a single projection whose length is shorter than the length of the arcuate shaped member 140 . The projection 146 extends inwardly into the opening formed by the inner curved surface 142 of the arcuate shaped member 140 .
The arcuate shaped member 140 includes a boss 150 formed outwardly thereof proximate the forward edge 148 . The boss 150 includes an opening 152 which may be threaded or non-threaded. As will be described hereinafter, the boss 150 is part of a locking assembly operative for securing the upper and lower bracket members 122 , 124 in assembled relationship about the beam 102 .
As thus far described, the arcuate shaped member 140 has an inner curved surface 142 which is generally planar between its spaced apart edges 154 , 156 . An elongated curved rib 158 extends projecting inwardly from the inner curved surface 142 of the arcuate shaped member 140 adjacent each edge 154 , 156 . The ribs 158 generally have a radius of curvature center corresponding to the radius of curvature center of the inner curved surface 142 of the arcuate shaped member 140 . As such, the outer edge of the ribs 158 generally lie in a circular plane parallel to the circular plane concentric with the inner curved surface 142 . Although the ribs 158 have been illustrated as continuous ribs substantially co-extensive with the edges 154 , 156 of the inner curved surface 142 , it is contemplated that the ribs may be formed as spaced apart segments. Although the ribs generally have a rectangular cross-sectional shape, they may have other shapes such as polygonal, triangular, trapezoidal or the like.
The lower bracket member 124 will now be described with reference to FIG. 6 . The lower bracket member 124 includes an arcuate shaped member 160 having an inner curved surface 162 . The inner curved surface 162 is defined by a radius of curvature generally corresponding to the radius of curvature of the inner curved surface 142 of the arcuate shaped member 140 . The inner curved surface 162 is generally of similar shape to inner curved surface 142 so as to conform with the cross-sectional shape of the beam 102 . In this regard, the upper and lower bracket members 122 , 124 when in their assembled closed relationship as shown in FIG. 3 define a through bore 164 having the general cross-sectional shape as the beam 102 . In the preferred embodiment, the bore 164 has a circular shape, although other shapes are contemplated as previously described, and wherein the longitudinal axis of the bore is arranged transverse to the longitudinal axis of the threaded opening 134 in boss 128 .
A rib 166 is formed extending outwardly from a central portion of one end 168 of the lower bracket member 124 . The rib 166 is adapted to be rotationally received within the opening 170 formed between the spaced apart ribs 136 on the upper bracket member 122 as best shown in FIG. 5 . Rib 166 includes a through bore 172 which aligns with bore 138 within ribs 136 so as to receive an axle 174 for pivotably attaching the upper and lower bracket members 122 , 124 together.
A boss 176 is provided extending outwardly from the other end 178 of the arcuate shaped member 160 . The boss 176 has a through opening 180 which may be threaded or unthreaded. In assembled relationship, the openings 152 , 180 are aligned with each other so as to accommodate a bolt, screw or other attachment means for securing the upper and lower bracket members 122 , 124 together in fixed assembled relationship. It is to be understood that other locking assemblies may be used such as clamps, hooks or other fasteners, both threaded and non-threaded, for securing the upper and lower bracket members 122 , 124 together.
An elongated curved rib 182 similar in construction to rib 158 is provided projecting inwardly from the inner curved surface 162 of the arcuate shaped member 160 adjacent its side edges 184 , 186 . The ribs 158 , 182 of the corresponding upper and lower bracket members 122 , 124 cooperate with each other to define the radial limits of the bore 164 formed thereby.
The projection 146 has been described as being formed extending inwardly from the upper bracket member 122 . It is to be understood that the projection 146 may be formed, in the alternative, extending inwardly from the lower bracket member 124 . It is further contemplated that a secondary projection 146 may be formed extending from the lower bracket member 124 to cooperate with the projection of the upper bracket member 124 so as to both be received within the slot 118 of the beam 102 .
The mounting brackets 106 , 108 are shown in assembled relationship in FIG. 3 . As previously described, the lower bracket member 124 is pivotably coupled to the upper bracket member 122 by an axle 174 extending through the aligned bores 138 , 172 of the nested ribs 136 , 166 . This permits the mounting brackets 106 , 178 to be positioned about the beam 102 with the projection 146 extending into the slot 118 . The upper and lower bracket members 122 , 124 are secured together, by, for example, a bolt or screw extending through the aligned openings 152 , 180 of the overlying bosses 150 , 176 , or other such clamping assembly.
The bushing 126 , as best shown in FIG. 3 , is constructed as a generally hollow tubular body having external threads at least about an upper portion of the bushing. The bushing 126 is adapted to be threadingly engaged within the threaded opening 134 within the upper bracket member 122 . The lower end of the bushing 126 is provided with an enlarged knob 188 . The knob 188 facilitates rotation of the bushing 126 , by hand, so as to advance and retract the bushing within the upper bracket member 122 . The bushing 126 is operative for supporting an electronic device by coupling same via, for example, a coupling device such as a tilter device 112 , forearm extension, extension arm or other such coupling device. The tilter device 112 is partially shown in FIG. 3 having a downwardly depending shaft (not shown) received within the upper opening provided within the bushing 126 . The adjustability of the bushing 126 is operative for raising and lowering the height or elevation of the electronic device which is coupled to the mounting bracket 106 , 108 . This is useful to align each of the electronic devices at the same elevation.
Referring to FIG. 7 , there is illustrated the mounting brackets 106 , 108 coupled to a beam 102 . In this regard, the upper and lower bracket members 122 , 124 are pivotably opened to receive the beam 102 . The upper bracket member 122 is positioned about the top half of the beam 102 with the projection 146 captured within the slot 118 . The projection 146 temporarily attaches the upper bracket member 122 to the beam 102 while the lower bracket member 124 is pivoted into a closed position encircling the beam. A threaded bolt received within the aligned bosses 150 , 176 brings the upper and lower bracket members 122 , 124 together in a clamping action about the beam 102 . Prior to final clamping, the brackets 106 , 108 can be slid along the beam 102 with projection 146 extending within the slot 118 to position the bracket at the desired location. Once positioned, the mounting brackets 106 , 108 are firmly secured to the beam by tightening the bolt or other clamping assembly as previously described.
A flat screen monitor 110 is coupled to each of the mounting brackets 106 , 108 via, for example, a tilter device 112 . However, other coupling devices such as an extension arm, forearm extension or other suitable assembly may be used as disclosed in U.S. Pat. No. 6,609,691. As shown in FIG. 1 , the bushing 126 is used to raise or lower each of the monitors 110 so that they are arranged at the desired elevation. In the preferred embodiment, each of the monitors 110 are arranged in a common horizontal plane with their upper and lower edges in alignment with one another. The height adjustment of each of the monitors 110 is achieved by rotating the bushing 126 via knob 188 . Any number of mounting brackets 106 , 108 may be coupled to the beam 102 , depending upon its length, to accommodate a plurality of monitors 110 or other electronic device.
Referring to FIG. 8 , the upper and lower bracket members 122 , 124 have planar inner curved surfaces 142 , 162 forming a cylindrical shape. As the beam 102 has a radius of curvature, the outer surface of the beam engages the inner curved surfaces 142 , 162 of the upper and lower bracket members 122 , 124 generally at a single midpoint identified by reference numeral 190 . The ribs 158 , 182 by extending from the side edges of the inner curved surfaces 142 , 162 engage the outer surface of the beam 102 at two spaced apart circumscribing locations. The engagement of the ribs 158 , 182 with the beam 102 provides enhanced mechanical coupling of the mounting brackets to the beam via the compressive force exerted thereon by the upper and lower bracket members 122 , 124 . This simplifies the construction of the mounting brackets. In an alternative embodiment, the curved inner surfaces 142 , 162 could be in the nature of a compound curve to accommodate both the cross-sectional shape of the beam 102 , as well as its radius of curvature.
Referring to FIG. 9 , there will now be described the construction of a mounting bracket 104 in accordance with another embodiment of the present invention. As previously described, the mounting brackets 106 , 108 are adapted to slide along the beam 102 for positioning at a desired location. The mounting bracket 104 , on the other hand, is adapted to be positioned at a fixed predetermined location along the beam 102 . To this end, the mounting bracket 104 is provided with a depending projection 192 extending away from the inner curved surface 142 of the upper bracket member 122 . The projection 192 may have a shape conforming to the shape of a corresponding opening (not shown) provided within the beam 102 . For example, projection 192 has a circular shape to be received within a circular opening within the beam 102 . However, it is noted that a circular projection 192 will fit within a square or polygonal shaped opening within the beam 102 . The opening within the beam 102 is formed at one or more predetermined locations for coupling the mounting bracket 104 thereat. It is also contemplated that the projection 192 can be provided extending from the lower bracket member 124 if desired. The construction of the mounting bracket 104 to include projection 192 typically obviates the need for providing a projection 146 as described with respect to mounting brackets 106 , 108 which is adapted to be received within the slot 118 of the beam 102 . Although only one projection 192 is illustrated, it is to be understood that spaced apart projections can also be incorporated into the mounting bracket 104 . A downwardly depending shaft 194 extends outwardly from the lower bracket member 124 . The shaft 194 is adapted to be received within a stand 116 for supporting the beam 102 in a horizontal orientation as shown in FIG. 1 . Generally, in all other respects, mounting bracket 104 is similar in construction to mounting brackets 106 , 108 .
Mounting bracket 104 , in one embodiment, is positioned centrally along the beam 102 at its mid point to support the beam via a stand 116 supported on the floor 114 , or attached to the ceiling, or a vertical wall. It is also contemplated that the beam 102 can be supported from a desk or other structure as may be desired. It is contemplated that the beam 102 may be supported by the use of a plurality of mounting brackets 104 arranged at spaced apart locations, each coupled to a stand 114 or other support structure, with or without the use of the slideable mounting brackets 106 , 108 . Accordingly, the mounting brackets 104 , 106 and 108 may be used in combination with each other for supporting an electronic device such as a flat screen monitor 110 and the like at various locations along the beam 102 .
Referring to FIG. 10 , there is illustrated another embodiment of a mounting bracket 196 . The mounting bracket 196 is of similar construction to mounting bracket 106 , 108 as previously described. The mounting bracket 196 is constructed to include a removable projection 198 which is shown in greater detail in FIG. 11 . The projection 198 is formed as a flat body having a u-shape by virtue of a pair of spaced apart legs 200 , 202 . The legs 200 , 202 are sized and shaped to be received within the slot 118 of the beam 102 .
The projection 198 is located between the free ends of the upper and lower bracket members 122 , 124 whereby the legs 200 , 202 extend inwardly into the bore 168 formed by the upper and lower bracket members. The main body of the projection 198 is attached to either an upper or lower boss 204 , 206 of the mounting bracket 196 having openings 208 in alignment with corresponding openings 210 within the projection 198 . A screw, bolt or other fastening member may be inserted through the aligned openings for securing the projection 198 to either the upper bracket member 122 or lower bracket member 124 . Generally, in all other respects, the construction of the mounting bracket 196 is similar to the mounting brackets 106 , 108 . Although the projection 198 has been disclosed as having U-shaped, the projection may also be constructed as a rectangular body simulating projection 146 .
A mounting bracket 212 in accordance with another embodiment of the present invention is shown in FIG. 12 . The mounting bracket 212 is constructed to accommodate a beam 102 provided with an outwardly projecting longitudinally extending rib 214 , as opposed to a slot 118 . In this regard, the inner curved surface 142 , 162 of either of the upper or lower mounting bracket members 122 , 124 is provided with a corresponding elongated opening 216 . Generally, in all other respects, the mounting bracket 212 is similar in construction to the aforementioned mounting brackets.
Referring to FIG. 13 , there is illustrated another embodiment of a mounting bracket 218 . Unlike the previously described mounting brackets, mounting bracket 218 is not intended to couple an electronic device thereto, but rather, to couple the beam 102 to, for example, stand 116 or other supporting structure or device. The mounting bracket 218 includes an upper bracket member 220 and a lower bracket member 124 . The construction of the lower bracket member 124 has been previously described with respect to FIG. 6 . As shown in FIG. 13 , the lower bracket member 124 includes a projection 146 and a downwardly depending shaft 194 as described with respect to the mounting bracket shown in FIG. 9 . The upper bracket member 220 is similar in construction to the upper bracket member 122 as described with respect to FIGS. 4 and 5 , but for the projection 146 and threaded opening 134 . However, as previously described, the projection 146 may be incorporated in either the upper or lower bracket members. The upper bracket member 220 is devoid of threaded opening 134 , as the mounting bracket is not intended to be coupled to an electronic device. The upper bracket 220 member is constructed to be pivotably attached to the lower bracket member 124 in lieu of the upper bracket member 122 having the threaded opening 134 . This minimizes the number of components required to be inventory when assembling a mounting bracket. As such, the lower bracket member 124 may be coupled to either of the upper bracket members depending upon the application of the mounting bracket.
Mounting bracket 218 allows for the independent mounting of electronic devices to the beam 102 , separate and apart from the mounting brackets used for mounting the beam to a support. This facilitates the adjustment of the electronic devices relative to each other along the beam 102 . That is, manipulation of the mounting bracket to adjust an electronic device does not affect the position or attachment of the mounting bracket used to attach the beam 102 to a support.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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A mounting apparatus includes a horizontally supportable beam and one or more mounting brackets for coupling an electronic device thereto. The beam is supportable from any number of support surfaces. The mounting brackets are provided with a projection to prevent twisting of the bracket during installation on the beam. One or more circular ribs within the bracket accommodate the use of curved beams. The mounting brackets enable positioning of the electronic device longitudinally along the beam at predetermined positions.
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CROSS-REFERENCE TO SIMULTANEOUSLY FILED RELATED APPLICATION
"Measurement of Oil Saturation And Properties In Aprotic Extracts by NMR Spectroscopy", Vinegar et al, Ser. No. 115,022.
BACKGROUND OF THE INVENTION
This invention relates to NMR spectroscopy and, more specifically, NMR spectroscopy of fluids contained in porous materials.
Coring of an earth formation is a routine procedure in oil production operations. A core is obtained in order to retrieve a small section of the reservoir formation that may be used to measure rock properties and determine insitu oil saturation.
Unfortunately, the coring process subjects the core to high fluid velocities and high pressures that disturb the core and any insitu fluids within the core. Solid particles such as barite in the drilling mud often invade deeply into the core. In addition, drilling fluids from either a water-based mud or an oil-based mud can invade the core and flush out some of the insitu oil saturation.
The standard analysis technique used in the oil industry for determining oil saturation in cores to be cut small 1" outside diameter plugs every foot of the core and extract the plugs using the Dean-Stark extraction technique. This is a laborious and expensive procedure. Moreover, this procedure will often sample those parts of the core that have been seriously flushed by mud filtrate and have had their oil saturations reduced. Thus, the oil saturations for core plugs are typically understood to be the minimum possible oil saturation in the reservoir, while the true unflushed oil saturation in the reservoir is often significantly higher.
Sponge coring is an attractive alternative to the blowdown losses of conventional coring, without the expense and low recovery associated with pressure core. A sponge core barrel traps the oil expelled from the core in an oil-wet, high porosity polyurethane sponge surrounding the core. At the surface, cored sections are stored in completion brine or frozen and then transported to the laboratory to determine the quantity of oil trapped in the sponge.
The present method of determining the fluid saturations in the sponge is by solvent extraction. Typically two days are required for the extraction process on each one foot section of sponge. The solvent must then be separated from the extracted oil and water volumes. Finally, the oil volume must be corrected for non-reacted components of the polyurethane which are removed along with the oil in the extraction.
These and other limitations and disadvantages are overcome by the present invention, however, and methods are provided for obtaining insitu oil saturations from core.
SUMMARY OF THE INVENTION
In a preferred embodiment of the invention, methods are provided for more accurately determining in-situ oil and brine saturation in porous samples using NMR. Additional characteristics of the oil and/or brine in the samples may also be determined. The samples may be either an earthen core sample and/or the polyurethane liner of a sponge core, or drill cuttings.
As an alternative to solvent extraction, the present invention provides methods for the use of Nuclear Magnetic Resonance (NMR) for rapid non-destructive analysis of sponge core. The advantages of NMR are high accuracy, since chemical extraction is not required, and high speed, since an NMR spectra of each foot of sponge core can be obtained in seconds. In addition, NMR information about oil composition and viscosity can be obtained simultaneously.
NMR spectroscopy is a rapid, nondestructive method for measuring oil/water saturations and porosity on carbonates and clean sandstones. This results in core analysis costs about 1/5 that of standard Dean-Stark extraction. NMR spectroscopy can also be more accurate than Dean-Stark extraction when the extraction is incomplete or when dewatering occurs of gypsum or other temperature sensitive minerals in the core.
It is an object of the present invention to provide methods for measuring in-situ oil and brine saturations in a porous sample.
It is an object of the present invention to provide methods for measuring chemical and physical properties of oil and brine in a porous sample.
These and other objects and advantages of the present invention will become apparent from the following detailed description wherein reference is made to the figures in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows measured and computer proton densities for various oils.
FIGS. 2A-B show 1 H NMR spectrum of the dry sponge, with FIG. 2A shown on the same scale as the spectra in FIGS. 3 and 4, and with FIG. 2B shown expanded by a factor of 100.
FIG. 3 shows 1 H NMR spectrum of water-saturated sponge.
FIG. 4 shows 1 H NMR spectrum of Soltrol-saturated sponge.
FIG. 5 shows 1 NMR spectrum from two sponges with one sponge saturated with water and the other sponge saturated with Soltrol.
FIG. 6 shows 1 H NMR spectrum of a sponge saturated with both water and Soltrol and the resonance at 12 ppm is due to the TFAA internal standard.
FIG. 7 shows 1 H NMR spectrum of sponge saturated with an actual crude oil and water.
FIG. 8 shows 1 H NMR spectrum of sponge saturated with an actual crude oil and the resonances at 7.2 ppm and 1.2 ppm correspond to aromatic and aliphatic protons, respectively.
FIGS. 9A-G show 1 H NMR spectra of sponge saturated with water and SOLTROL obtained using an inversion recovery sequence with the corresponding τ delays between the 180° and 90° pulses.
FIGS. 10A-C show the proton NMR spectra of core plugs with A corresponding to S o =0.00, B corresponding to S o =0.03, and C corresponding to S o =0.45, with the spectra normalized to the largest peak height.
FIG. 11 shows a log of oil saturation in core measured by NMR vs. depth.
FIG. 12 shows the NMR spectra of one foot of whole core showing well-resolved oil and water resonances.
FIG. 13 shows the NMR log of oil saturation in the whole core versus depth.
FIG. 14 shows NMR detection limits for S o .
FIG. 15 shows a log of fluid-filled porosity in core measured by NMR vs. depth.
FIG. 16 shows 13 C NMR spectroscopy of a water saturated dolomite core plug.
FIG. 17 shows 13 C NMR spectroscopy of a soltrol saturated dolomite core plug.
DETAILED DESCRIPTION
NMR spectroscopy of saturated sponge is based on the chemical shift differences between oil and water protons. Chemical shifts are the differences in the magnetic field strength at which resonances are obtained for nuclei of the same kind (such as protons) but located in different molecular environments (such as aliphatic vs aromatic structures). They are typically expressed in parts per million (ppm) of the main magnetic field: for example, --CH 2 -- resonance of aliphatic protons are at 1.2 ppm while the OH resonance of water protons are at 5.3 ppm, relative to a standard material, tetramethylsilane (TMS).
A General Electric CSI-2T pulsed NMR spectrometer was used for these measurements. The CSI-2T has a superconducting magnet with 310 mm bore and an RF coil which can obtain spectra from a sample volume 4.5 in. o.d. by 8 in. long. The large magnet bore means that about 50 cu in. of sponge can be measured simultaneously in the central region of the RF coil shimmed for best magnetic field homogeneity.
Other spectrometers may also be employed in the practice of the methods of the present invention. Such NMR spectrometers should be high resolution spectrometers with a resolution of about 1 ppm (although a resolution of at least 0.1 ppm is preferred) and have a high magnetic field to provide faster data acquisition and higher frequency Larmor frequencies for improved signal-to-noise ratios.
The aliphatic proton density of oils (including isoalkane, N-alkane, and cyclo-alkane types of oils) averages 0.113 moles/cc at 20° C., with very little variation from crude oil to crude oil so that a sample of the particular crude oil being tested is not required. The aromatic proton density of oils averages 0.068 moles/cc at 20° C., again with little variation from oil to oil. Further, a weighted average of aliphatic and aromatic proton densities may be employed for the particular oil being tested. This weighted average may be constructed from the fractions of aliphatics and aromatics found in the 1 H NMR spectra of the oil. The weights or fractions are determined from the area under the respective portions of the 1 H NMR spectra. Thus, the proton density, D o , (in moles/cc) in the oil may be determined from
D.sub.o =F.sub.al D.sub.al +F.sub.ar D.sub.ar' (1)
where F al and F ar are the aliphatic and aromatic fractions as determined by 1 H NMR spectroscopy and D al =0.113 moles/cc (the aliphatic proton density) and D ar =0.068 moles/cc (the aromatic proton density). For example, for a 5% aromatic fraction (i.e., where the area under the aromatic portion of the 1 H NMR spectra is 5% of the total area under both the aliphatic and aromatic portions of the 1 H NMR spectra)
D.sub.o =(0.95) (0.113)+(0.05) (0.068)=0.111.
Once the proton density D o is determined, or an average value, such as 0.111, is assumed, the intensity of the oil spectra, I o , as determined by the total area under the oil spectra, may be combined with similar information for a known volume of a reference fluid to obtain the volume of the oil, V o . More particularly, the volume of the reference or standard, V R , is known, as is the proton density, D R , of the reference or standard. The intensity, I R , of the reference or standard is the total area under the NMR spectra of the reference or standard. That is, V o may be obtained from the following equation, ##EQU1##
The oil saturation in the core may then be computed from the volume of oil in the extract divided by the pore volume, V p , of the core. The pore volume, V p , may be determined by conventional hydrostatic weighing of the core in toluene. The oil saturation, S o is thus determined from, ##EQU2## where V o is the oil volume from NMR spectroscopy. If V w is the volume of brine or water determined by NMR spectroscopy then its saturation, S w , may be determined from, ##EQU3## Further, the gas saturation, S g , may be determined by ##EQU4## However, it is also possible to determine the pore volume, V p , from NMR. NMR may be used to determine pore volume if the pores are all filled with fluid or fluids capable of providing NMR signals. More specifically, a core sample may be scanned before extraction (if the core volume is fully filled by brine and/or oil) and the total signal is representative of the total porosity.
The integrated area under each proton resonance is proportional to the proton concentration of that chemical species. Since oil and water have nearly identical proton concentration per unit volume (i.e. 0.111 moles/cc), the integrated areas under those resonances are proportional to the bulk volume of oil and water in the sample. FIG. 1 compares the proton density of equal volumes of several oils and water with measurements of the integrated intensity under their NMR resonances. An internal NMR reference standard can be used for absolute calibration. For oil/water spectroscopy, trifluoroacetic acid (TFAA) at 12 ppm is a better standard than TMS at 0 ppm since TMS overlaps partially with the aliphatic oil resonance. A vial containing a measured amount of TFAA can be placed inside the RF coil together with the sponge as an internal reference standard. A series of NMR spectra were obtained on various sections of sponge core. Dry sections of sponge, 4"×1"×1", were removed from the aluminum core barrel and saturated in different fluids under a vacuum.
FIG. 2a shows the NMR spectrum of the dry sponge with identical acquisition parameters to those used in FIGS. 3 and 4. At this level the dry sponge contributes no detectable signal. FIG. 2b shows the dry sponge signal expanded by a factor of 100, showing a broad resonance of about 10 ppm full width half maximum (FWHM) detectable at 2:1 above system noise. For practical purposes the NMR contribution from the dry sponge may be ignored.
FIG. 4 shows the NMR spectrum of a sponge fully saturated with SOLTROL. The spectrum represents four pulsed acquisitions of three seconds each. A single peak from SOLTROL is evident at a chemical shift of 1.2 ppm with a linewidth of 1.5 ppm FWHM.
FIG. 3 shows the NMR spectrum of a water-saturated sponge. The water resonance is at 5.3 ppm and the linewidth is also 1.5 ppm FWHM.
FIG. 5 shows the NMR spectrum of the SOLTROL-saturated and water-saturated sponges measured in the spectrometer at the same time. The oil and water lines are well-resolved in the spectrum despite the 1.5 ppm broadening due to the sponge.
FIG. 6 shows the NMR spectrum of a single sponge saturated with equal parts SOLTROL and water. Since the oil and water lines are nearly baseline resolved, the determination of separate water and oil bulk volumes is simplified. There is little difference between the spectra obtained with water and oil in the same sponge (FIG. 6) and in different sponges (FIG. 5), which demonstrates the ability to analyze multiple samples at the same time.
FIG. 7 shows the NMR spectrum of a sponge containing an actual crude oil and water. The separate resonances are still baseline resolved. An expanded portion of the crude oil spectrum obtained from a sponge containing only crude oil is shown in FIG. 8. The separation between the aliphatic components at 1.2 ppm and the aromatic components at 7.2 ppm is evident. Integration of the aliphatic and aromatic portions of the spectrum shows the crude contains 3% aromatic protons. Fortunately, the aromatic resonance in 7.2 ppm does not overlap significantly with the 5.3 ppm water resonance. The aliphatic/aromatic analysis could be useful in measuring changes in oil composition and origin in long cored intervals.
In FIG. 9 an inversion recovery pulse sequence is used to measure the T 1 relaxation time of all components of the NMR spectrum from a sponge containing SOLTROL and water in order to measure the viscosity of the oil. The measured relaxation times are 1.1 sec for SOLTROL and 2.1 seconds for water. Using T 1 correlations such as those in the hereinbefore cited cross-reference application, it is possible to obtain an estimate of the crude oil viscosity. For specific crudes a particular correlation may be determined, for example for the actual crude tested the product of T 1 and viscosity is approximately equal to 1.6 cp-seconds. The SOLTROL viscosity is estimated to be 1.45 cp, in good agreement with the actual value of 1.3 cp.
Practical implementation of NMR spectroscopy for sponge core analysis requires procedures for removing the frozen sponge from the aluminum core barrel and allowing the sponge to thaw without evaporation of light ends. A jig has been constructed to push 6" sections of frozen sponge out of the aluminum barrel by applying vertical pressure from a press to the sponge sections while the aluminum barrel is supported at its base. The frozen sponges can then be placed inside sealed polyethylene bags and allowed to thaw before NMR spectroscopy.
Alternatively, the sponge core barrel may be constructed from fiberglass or other non-metallic, non-magnetic materials, which will not scatter the radiofrequency magnetic field as aluminum does. This eliminates the step of removing the frozen sponge from the aluminum core barrel.
Although it was generally believed that 1 H NMR spectroscopy on cores would result in linewidths too broad to resolve oil and water resonances, much of the broadening has been found to be due to sample shape-dependent magnetic susceptibility broadening which can be compensated with magnetic field shimming. Thus, 1 H NMR linewidths have been obtained in carbonates and clean sandstones of about 1.5-2 ppm, which is sufficient for spectrally-resolving oil and water resonances (oil-water frequency separation=5 ppm). This opens up all the capabilities of 1 H NMR spectroscopy for nondestructive core analysis.
In the first set of experiments, the core samples were frozen 1" o.d.×1.5" long plugs cut every foot from a carbonate core and allowed to thaw inside TEFLON capped glass vials. NMR spectroscopy was performed on the core plugs while inside the vials, so that any liquid evaporated from the plugs would also be measured. The vials were placed inside a special TEFLON positioner for accurate repositioning inside the RF coil in the magnet.
NMR spectroscopy was performed with the General Electric CSI-2T spectrometer discussed hereinbefore, using a 3" i.d. RF coil. A standard 90 degree pulse-and-acquire sequence was used with 32 acquisitions.
Ten minutes per plug was required for sample positioning, data acquisition, and deconvolving the NMR spectra into separate oil and water resonances. Thus, forty core plugs were analyzed per day at about 1/5 the cost of standard Dean-Stark extraction.
FIGS. 10A-C are examples of the NMR spectra for core plugs with S o =0, S o =0.03 and S o =0.45, respectively, where S o is the oil saturation. The NMR linewidths of approximately 2 ppm are sufficiently narrow compared to the 5 ppm separation of oil and water peaks to allow good spectral resolution. The spectrum with S o =0.03 is approximately at the deconvolution limit where the oil resonance cannot be detected above the much larger water resonance.
FIG. 11 shows a log of NMR determined oil saturation in the core versus depth. As in many carbonates, the oil saturation appears to be highly variable on the plug-to-plug basis. This suggests that whole core spectroscopy would give more representative sampling. The whole core (33/4" o.d.) was measured in one foot sections by 1 H NMR spectroscopy in the CSI 2T spectrometer, using a 41/2" i.d. R.F. coil. FIG. 12 shows the NMR spectra of one foot of whole core showing well-resolved oil and water resonances. FIG. 13 shows the NMR log of oil saturation in the whole core versus depth.
The accuracy of NMR spectroscopy for quantifying oil-water saturation within the core plugs is within 5%. The primary error sources are (1) deconvolving the NMR spectra into separate oil and water resonances, and (2) variations in proton density among different crudes. Experimental data from various fields show variations of 0-5% for the crude oil aliphatic proton density relative to the proton density of water at 25° C. The latter source of error can be reduced further if a representative sample of the crude is available for calibration. This may be obtained by centrifuging a small sample of core and separating the crude oil from fluids discharged during centrifuging.
The limits of NMR detection of oil saturation in core plugs depend on both the oil volume detection limit and the spectrum deconvolution limit. The oil volume detection limit was determined by measuring successively smaller volumes of oil until the signal peak height was about twice the background response from coil, sample holder, and empty vial. The spectrum deconvolution limit of S o =3% was estimated from synthetic spectra using the linewidths observed for the actual samples from this field. Since NMR detects fluid volumes, the lowest oil saturation detectable will depend on both the porosity and size of the sample, as shown in FIG. 14. For 1"×1.5" plugs, the oil volume detection limit of 0.03 cc implies a detectable oil saturation limit greater than the 3% deconvolution limit for sample porosities below 5%. For larger plugs and higher porosity samples, the oil saturation detection limit is determined by the 3% spectrum deconvolution limit.
NMR spectroscopy was also used to measure the fluid-filled porosity of the core plugs from this oil field as shown in FIG. 15. The porosity was computed from the total proton signal (oil and water) converted to fluid volume and divided by the bulk volume of the core. FIG. 15 shows the fluid-filled porosity measured on a one foot section of the whole core.
The fluid-filled porosity of a core may be less than the total porosity if gas is present due to reservoir gas saturation, blowdown losses, core expansion at the surface, fluid evaporation, etc. The field's crude oil however, was not believed to be gassy, and the tightness of the core should reduce blowdown losses. In order to check for gas in the core, NMR measurements were made on a plug before and after vacuum immersion overnight in SOLTROL. The measured fluid content increased from 0.38 cc to 0.40 cc, a 5% change.
Further, 13 C NMR spectroscopy may be employed to measure oil saturation, particularly in shaly sands where the 1 H NMR resonance is too broad to resolve oil protons from water protons. With 13 C NMR spectroscopy only the carbon nuclei in the oil will be detected, since water contains no carbon atoms. Moreover, the carbon nuclei in solid minerals such as carbonates will not be measured because of very short relaxation times and wide NMR linewidths. FIG. 16 and FIG. 17 show the 13 C spectra of two samples of Bakers dolomite, one saturated with water and the other with SOLTROL, respectively. The SOLTROL has no aromatic constituents and thus no aromatic spectra. These spectra were obtained in ten minutes of signal averaging on a General Electric QE 300 spectrometer. No 13 C signal is detected in the water saturated dolomite showing that the carbon atoms of solid carbonate minerals are not detected.
As described hereinbefore for 1 H NMR spectroscopy, 13 C NMR spectroscopy may also be employed to determine the quantity or volume of liquid hydrocarbons in the sample. The aliphatic carbon density of oils average 0.052 moles/cc at 20° C., and the aromatic carbon density in oil averages 0.091 moles/cc at 20° C. From these carbon densities and associated fractions of aromatic and aliphatic carbons, the weighted carbon density of the oil may be determined, as described hereinbefore for proton densities. Once the carbon density of the oil is known, or assumed, it is then possible to determine the volume of the oil in the sample in the same manner as described hereinbefore for proton density and determination of oil volume therefrom. Further, the 13 C NMR spectra of the crude oil may be characterized and correlated, i.e. "finger-printed", to determine if the oil from different parts of a reservoir are the same, which would demonstrate continuity of a geologic unit. However, the low 13 C sensitivity results in much longer analysis time than 1 H NMR spectroscopy.
Once the 13 C spectra and 1 H spectra for an oil or oil product have been determined, it is then possible to determine chemical properties, such as the carbon to hydrogen ratio, carbon aromatic to aliphatic ratio, and proton aromatic to aliphatic ratio, which may be used to determine the maturity of the source rock for oil.
Further, it is possible to perform various so-called "2D" NMR techniques, such as heteronuclear correlated "2D" NMR spectroscopy. The heteronuclear correlated "2D" technique cross-plots the 1 H and 13 C connectivities and yields detailed structural information about the oil or oil product.
NMR spectroscopy also provides estimates of oil viscosity and surface wettability from the proton T 1 relaxation times of oil and water resonances. As determined by NMR, the oil viscosity in the plugs was between 1 and 3 cp at room temperature, which agreed with the viscosity of the oil extracted from one sample using pressurized solvent and with the viscosity from T 1 measurements on solvent extracts of the plugs. In addition, successive NMR T 1 measurements on the oil remaining in the plugs showed an increase in the viscosity of the oil after each stage of extraction.
API gravity may be determined from viscosity using a determined equation for a particular type of crude oil. Alternatively, API gravity may be determined from viscosity using relationships such as those disclosed by various references. (See for example, Beal, C., "The Viscosity of Air, Water, Natural Gas, Crude Oil And Its Associated Gases at Oil Field Temperatures And Pressures", Trans. AIME Vol. 165, (1946) p. 94.)
The field's core was determined to be water wet. This follows because (a) the field's oil and water had similar viscosity, and (b) the water relaxation time in the cores was substantially shorter than bulk water, whereas the oil relaxation time was the same in the cores as in the bulk crude.
Thus, it is clear that the methods of the present invention measure the physical and chemical properties of oil or oil products using 1 H and/or 13 C NMR spectroscopy. Further, the methods may also determine the saturation of such oil or oil products in porous samples.
Many other variations and modifications may be made in the apparatus and techniques hereinbefore described by those having experience in this technology, without departing from the concept of the present invention. Accordingly, it should be clearly understood that apparatus and methods depicted in the accompanying drawings and referred to in the foregoing description are illustrative only and are not intended as limitations on the scope of the invention.
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Methods are provided for using Nuclear Magnetic Resonance (NMR) spectroscopy to measure the bulk volume of oil and water in the polyurethane liner of sponge core. The method is accurate, rapid, and non-destructive. It provides information simultaneously in oil composition and viscosity.
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This is a continuation of Ser. No. 821,128 filed Aug. 2, 1977, now abandoned.
FIELD OF THE INVENTION
This invention relates to flavorants, flavoring compositions, foodstuffs and tobaccos containing the same.
SUMMARY OF THE INVENTION
The flavoring compositions provided by the present invention contain a compound of the general formula ##STR1## wherein R 1 and R 2 each represent a C 1-3 -alkyl group, A represents an alkylene group which may be branched and R represents a hydrogen atom or the methyl, ethyl, formyl, acetyl or propionyl group or a group of the formula ##STR2##
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The C 1-3 -alkyl group in the formula I compounds is the methyl, ethyl, propyl or isopropyl group. The methyl group is the preferred C 1-3 -alkyl group. The symbol A represents a straight or branched chain alkylene group such as the methylene, ethylene, propylene or butylene group. The ethylene and propylene groups are the preferred alkylene groups. One or more of the hydrogen atoms of the alkylene chain can be substituted, in particular by methyl. R preferably represents a hydrogen atom or the methyl group.
Although a large number of the compounds of formula I are known, there is no disclosure in the corresponding literature sources that any of said compounds have any organoleptic properties.
It has now surprisingly been found in accordance with the present invention that the compounds of formula I possess particular flavouring properties and are, accordingly, very well suited as flavour-imparting ingredients in flavouring compositions The flavouring spectrum is very broad. The compounds of formula I possess fruity, spicy (e.g. mustard-like), vegetable-like (e.g. leek, celery, cauliflower, chive, onion, garlic, asparagus, rhubarb, tomato etc) and mushroom-like notes as well as cheese and meat notes. Of particular interest are the roast, meat and fish notes; for example, the notes of roast meat, poultry and fish, in particular tuna fish, sardines and anchovies. However, interesting egg and potato notes are also present.
The compounds of formula I can accordingly be used, for example, for the aromatisation of products such as foodstuffs, luxury goods and drinks, said compounds preferably not being used alone but rather in the form of compositions containing other flavouring substances.
The present invention is based on the finding mentioned earlier and is concerned in one aspect with a flavouring composition which contains as an essential flavour-imparting ingredient a compound of formula I hereinbefore in virtually pure form or in the form of mixtures (with the exception of mixtures which contain compounds of formula I and which originate from natural sources).
The invention is also concerned in another aspect with a process for the manufacture of the flavouring compositions aforesaid, which process comprises adding a compound of formula I in virtually pure form or in the form of mixtures (with the exception of mixtures which contain compounds of formula I and which originate from natural sources) to known flavouring compositions or mixing a compound of formula I in virtually pure form or in the form of mixtures (with the exception of mixtures which contain compounds of formula I and which originate from natural sources) with natural or synthetic compounds or mixtures thereof suitable as constituents of flavouring compositions.
In yet another aspect, the invention is concerned with a method of imparting a flavour to materials, which method comprises applying to said materials or incorporating therein a flavour-imparting amount of a compound of formula I in virtually pure form or in the form of mixtures (with the exception of mixtures which contain compounds of formula I and which originate from natural sources) or of a flavouring composition as hereinbefore defined.
As already mentioned, the flavouring compositions provided by the present invention should contain the compounds of formula I in virtually pure form or in the form of mixtures, with the exception of mixtures which contain compounds of formula I and which originate from any natural sources.
The expression "virtually pure" is used herein to mean, in particular, that the compounds of formula I are free from the impurities which are present in addition to the compounds of formula I in mixtures originating from any natural sources. As virtually pure compounds I in the scope of the present invention, there are to be understood, in particular, those compounds which are synthetically prepared.
The compounds of formula I can be used as flavouring substances, for example, for the production of improvement, intensification, enhancement or modification of fruit, meat, vegetable, cheese, mushroom-like, spicy or roast notes in foodstuffs (e.g. meat, fish, seafood products, meat-substitute products, sauces, broths, soups such as dry soups, vegetables such as various type of cabbage, legumes, leeks and onions, spicing agents such as mustard, ketchup and soya sauce, flavour strengtheners, snack food, roasted products such as nut products, coffee or cocoa, dairy products such as cheese, quark and yoghurt etc), in luxury goods (e.g. tobacco, chocolate; crackers etc) and drinks (e.g. lemonades etc). The term "foodstuffs" in the claims includes all of the foregoing except tobacco.
The pronounced flavour qualities of the compounds of formula I enable them to be used in low concentrations. A suitable range is ca 0.001 ppm-100 ppm, preferably ca 0.1 ppm-10 ppm, in the finished product (i.e. the flavoured foodstuff, luxury goods or drink).
The compounds of formula I can be mixed with the constituent used for flavouring compositions, preferably together with other flavour-imparting ingredients and/or adsorption and carrier substances and/or diluents, enveloping (encapsulating) substances, emulsifiers, stabilising agents etc, or added to such flavours in the customary manner. Among the flavours contemplated according to the present invention there are to be understood flavouring compositions which can be diluted or dispersed in edible materials in a manner known per se. They can be converted into the customary forms of use such as solutions, pastes or powders, according to methods known per se. The products can be spray-dried, vacuum dried or lyophilised. The formulation of these synthetic flavours and the flavouring of the products can also be carried out in a manner known per se [see J. Merory; Food flavourings, composition, manufacture and use; Avi Publ. Co. Inc. Westport (1968), or A. M. Burger; die naturlichen and kunstlichen Aromen; A. Huthig, Verlag Heidelberg 1968].
Examples of suitable carriers, thickeners, flavour-improvers, spices, auxiliary ingredients and the like which can be used in the production of such customary forms of use are:
Exudates, guar gum, tara gum, pectin, xanthane, modified starches and celluloses, gum arabic, tragacanth, salts or brewers' yeast, alginates, carrageens or similar absorbants; flavour-imparting ingredients, maltol, spice oil resins, smoke flavours; cloves, meat extract, Maillard products, sodium citrate; monosodium glutamate, disodium inosine-5'-monophosphate (IMP), disodium guanosine-5-phosphate (GMP); milk and cheese powder; special flavour substances, diluents such as water, ethanol, propyleneglycol, glycerine, benzyl alcohol, citric acid esters, fatty acid esters, olive oil; stabilising agents such as antioxidants (e.g. butylated hydroxytoluene, butylated hydroxyanisole etc, buffer substances such as, for example, phosphates, citrates etc.
The concentration of the compounds of formula I in the flavour compositions can vary within a wide range (e.g. between about 1 ppm and 100.permill.). A preferred range is between 10 ppm and 10.permill..
The following Table illustrates suitable concentrations of flavour substances in various forms of application:
TABLE______________________________________Form of use General Preferred______________________________________Compositions in liquid forme.g.Solutions [in water, alcohols(ethanol, glycerine,benzyl alcohol,propyleneglycoletc.),esters (e.g. citric acidesters, fatty acid esters)] 1 ppm-10 .permill. 10 ppm-10 .permill.Pastes 10 ppm-50 .permill. 100 ppm-10 .permill.Spray-dried powders 50 ppm-100 .permill. 300 ppm-30 .permill.Lyophilised vacuum driedpowders 50 ppm-100 .permill. 300 ppm-30 .permill.Adsorbed powders 50 ppm-100 .permill. 300 ppm-30 .permill.(adsorbates)Diluting agent for foodstuffs 50 ppb-100 ppm 300 ppb-30 ppmStructured proteins for meatsubstitutes 50 ppb-100 ppm 300 ppb-30 ppmDip sauces 50 ppb-100 ppm 300 ppb-30 ppmCocktail sauces 50 ppb-100 ppm 300 ppb-30 ppmMeat sauces 100 ppb-100 ppm 200 ppb-20 ppmPotato stock 50 ppb-100 ppm 300 ppb-30 ppmSoups 10 ppb-50 ppm 100 ppb-10 ppmMeat preserves 10 ppb-50 ppm 100 ppb-10 ppmReady-made dishes (e.g.meat dishes) 10 ppb-50 ppm 100 ppb-10 ppmMeat extracts and Maillardproducts 10 ppm-50 .permill. 100 ppm-10 .permill.Spice agent 10 ppm-50 .permill. 100 ppm-10 .permill.Cheese powder and cheeseextender 50 ppb-100 ppm 300 ppb-30 ppmVegetable powder and 50 ppb-100 ppm 300 ppb-30 ppmextender______________________________________
In special cases, the compounds of formula I can also be added alone to the products to be flavoured. In this case particular care must be taken during the addition to achieve a uniform dispersion of such a compound in the product being aromatised.
The following Table lists compounds of formula I which are of particular interest having regard their aroma properties:
TABLE______________________________________Compound Aroma______________________________________(CH.sub.3).sub.2 N(CH.sub.2).sub.3 SH after sardines, tuna fish(CH.sub.3).sub.2 N(CH.sub.2).sub.3 SCH.sub.3 potato-like, fatty(CH.sub.3).sub.2 N(CH.sub.2).sub.3 SCOCH.sub.3 meat-like, tuna fish, roast note in particular(CH.sub.3).sub.2 N(CH.sub.2).sub.2 SH meat-like, slight fish note, penetrating(CH.sub.3).sub.2 N(CH.sub.2).sub.2 SCH.sub.3 after green tomatoes, potatoes(C.sub.2 H.sub.5).sub.2 N(CH.sub.2).sub.2 SH meat-like, potato-like, interesting roast note, spicy(i-Prop).sub.2 N(CH.sub.2).sub.2 SH after meat pastry(i-Prop).sub.2 N(CH.sub.2).sub.2 SCOCH.sub.3 meat-like, after sardines(CH.sub.3).sub.2 N(CH.sub.2).sub.2 SS(CH.sub.2).sub.2 N(CH.sub.3).sub.2 after vegetables, cabbage(CH.sub.3).sub.2 N(CH.sub.2).sub.3 S(CH.sub.2).sub.3 N(CH.sub.3).sub.2 fatty, interesting roast note, after roast meat(CH.sub.3).sub.2 N(CH.sub.2).sub.3 SS(CH.sub.2).sub.3 N(CH.sub.3).sub.2 after potatoes, fish, amine-like(CH.sub.3).sub.2 NCH(CH.sub.3)CH.sub.2 SH after beef, interesting roast note(CH.sub.3).sub.2 NCH(CH.sub.3)CH.sub.2 SCOCH.sub.3 after roast meat, roast note(C.sub.2 H.sub.5).sub.2 N(CH.sub.2).sub.4 SH after fried fish(CH.sub.3).sub.2 NCH.sub.2 CH(CH.sub.3)SCH.sub.3 after cheese, strong(CH.sub.3).sub.2 NCH(CH.sub.3)CH.sub.2 SCH.sub.3 after sauerkraut, cabbage.______________________________________
The following Examples illustrate the present invention:
EXAMPLE 1
A dip mix for sauce can be prepared as follows:
40.0 g of a mixture consisting of
______________________________________ Parts by weight______________________________________*Sour cream, spray dried (e.g.SAA-creme-H) 89.4Sodium glutamate 7.29Hydrolysed vegetable protein (e.g.HPP, Type RF-B, oil-coated) 1.66Citric acid 0.17Pepper aroma 0.17Marjoram aroma 0.03Thyme aroma 0.03Curcuma aroma 0.26Salt 0.66Mustard powder 0.33 100.00______________________________________ *spray-dried sour cream base with vegetable fat.
are mixed and dissolved with 50 ml of water while stirring.
The flavour of this dip sauce is weak and uncharacteristic. By adding 3-5 ppm of 2-diisopropylaminoethylmercaptan, the resulting dip sauce is given a pleasant, meat-like note which harmonises well with the existing spice note.
EXAMPLE 2
A cocktail sauce aroma can have the composition A or B:
______________________________________ Parts by weight A B______________________________________Levulinic acid 10 10Raspberry ketone 10 10(p-hydroxyphenylbutone)Dimethyl disulphide (1% inpropyleneglycol) 1 1Dimethyl sulphide (1% inpropyleneglycol) 2 2Piperidine 5 5Thiolactic acid 5 53-Acetylpyridine 10 10Terpinen-4-ol 3 3Trimethylamine (25% inpropyleneglycol) 40 40Propyleneglycol 914 913.5S-Acetyl-2-diisopropylamino-ethylmercaptan (1% in propylene-glycol) 0.5 1000 1000______________________________________
At an amount of 200 g/100 liters of cocktail sauce, the odour and flavour of composition A are insipid.
By adding S-acetyl-2-diisopropylaminoethylmercaptan, the flavour is greatly improved in that a note emerges which is strongly reminiscent of sardines (Composition B).
A similar effect is achieved by using 0.5 parts by weight of a 1% propyleneglycol solution of 4-diethylaminobutylmercaptan in place of S-acetyl-2-diisopropylaminoethylmercaptan.
EXAMPLE 3
A cocktail sauce aroma can have the composition A or B:
______________________________________ Parts by weight A B______________________________________Levulinic acid 10 10Raspberry ketone 10 10Dimethyl disulphide (1% inpropyleneglycol) 1 1Dimethyl sulphide (1% inpropyleneglycol) 2 2Piperidine 5 5Thiolactic acid 5 53-Acetylpyridine 10 10Terpinen-4-ol 3 3Trimethylamine (25% inpropyleneglycol) 40 40Propyleneglycol 914 913.52 Diemthylaminoethylmercaptan(1% in propyleneglycol) 0.5 1000 1000______________________________________
At an amount of 200 g/100 liters of cocktail sauce, the odour and flavour of composition A are insipid.
By adding 2-dimethylaminoethylmercaptan the flavour is greatly improved, the note which now emerges being reminiscent of anchovies (Composition B).
EXAMPLE 4
A cocktail sauce aroma can have the composition A or B:
______________________________________ Parts by weight A B______________________________________Levulinic acid 10 10Raspberry ketone 10 10Dimethyl disulphide (1% inpropyleneglycol) 1 1Dimethyl sulphide (1% inpropyleneglycol) 2 2Piperidine 5 5Thiolactic acid 5 53-Acetylpyridine 10 10Terpinen-4-ol 3 3Trimethylamine (25% inpropyleneglycol) 40 40Propyleneglycol 914 913.52 Diemthylaminoethylmercaptan(1% in propyleneglycol) 0.5 1000 1000______________________________________
At an amount of 200 g/100 liters of cocktail sauce, the odour and flavour of the composition are insipid.
By adding 3-dimethylaminopropylmercaptan the flavour is modified in an advantageous manner in that a note now emerges which is reminiscent of sardines and tuna fish (Composition B).
3-Dimethylaminopropyldisulphide can be used in the foregoing flavour in place of 3-dimethylaminopropylmercaptan.
EXAMPLE 5
A brown meat sauce can be prepared as follows:
20 g of a mixture consisting of
______________________________________ Parts by weight______________________________________Dry meat extract, finely ground 18Vegetable fat 15Roast onion flavour 0.4Salt 5.6Sodium glutamate 16Hydrolysed vegetable protein 20Caramel powder 1Coriander powder 0.3Marjoram flavour 0.1Bay leaf flavour 0.12Citric acid 0.28Modified potato starch 23.20 100.00______________________________________
are stirred in 1 liter of cold water and boiled while stirring continuously. After boiling for 3 minutes, the odour and flavour of this sauce are weak and uncharacteristic.
After adding 3-5 ppm of S-acetyl-3-dimethylaminopropylmercaptan, an excellent roast meat note is observed.
EXAMPLE 6
A potato flavour composition can have the composition A or B:
______________________________________ Parts by weight A B______________________________________Valerianic acid 0.3 0.3Vanillin 1.2 1.2Ethyl butyrate 2.5 2.5Lactic acid 2.5 2.5Butyric acid 2.5 2.5Diacetyl 3.0 3.0Methional 60.0 40.0(3-Dimethylaminopropyl)-methylsulphide 20.0Ethyl alcohol 928.0 928.0 1000.0 1000.0______________________________________
A comparison of A and B shows that composition A is greatly inferior.
By partly replacing methional by (3-dimethylaminopropyl)-methyl sulphide an improvement in flavour emerges. Composition B has a pronounced potato note which is reminiscent of potato chips.
EXAMPLE 7
A cheese aroma can have a composition A or B:
______________________________________ Parts by weight A B______________________________________Lactic acid 10 10Ethyl butyrate 30 30Ammonium isovalerate 30 30i-Valerianic acid 50 50Caproic acid 60 60Butyric acid 120 120(2-Dimethylaminoethyl)-methylsulphide 5Propyleneglycol 700 695 1000 1000______________________________________
A comparison of A and B shows that the customary composition A is greatly inferior.
By adding (2-dimethylaminoethyl)-methyl sulphide, the cheese flavour in composition B is strengthened in an advantageous manner, the composition being reminiscent of Cheddar cheese.
EXAMPLE 8
A clear meat soup can be prepared as follows:
20.0 g of a mixture consisting of
______________________________________ Parts by weight______________________________________Salt 50.15Sodium glutamate 20.0Caramel powder 0.2Nutmeg flavour 0.05Clove flavour 0.05Pepper flavour 0.05Hydrolysed vegetable protein 11.5Vegetable fat (melting point 40° C.) 17.0Onion powder 1.0 100.0______________________________________
is placed in 1 liter of hot water.
The flavour of this soup is weak and uncharacteristic. By adding 3-5 ppm of 2-diethylaminoethylmercaptan the meat flavour present is strengthened in an advantageous manner and, in addition, a pleasant roast meat note now emerges which harmonises well with the meat flavour.
EXAMPLE 9
Imitation dry bacon pieces (bits) containing the following ingredients can be prepared:
______________________________________ Parts by weight______________________________________Coloured texturised soya protein 750 gPalm kernel fat (melting point32°-34° C.) 160 gCooking salt 50 gSodium glutamate 10 gVegetable protein hydrolysate 25 gPepper flavour 2.7 gOnion flavour 0.2 gGarlic flavour 0.1 gSmoke flavour 2 g 1000 g______________________________________
The ingredients, with the exception of the soya protein, are mixed well in a mixer with the molten palm kernel fat and dried, together with the soya protein, in a tumble drier at 35°.
The granular mass solidifies upon cooling. This product can be used as an adjunct to, or replacement for, bacon in omelettes, with beans, in soups and sauces, in sandwiches and salads etc.
The product shows, however, a somewhat insipid and unspecific flavour. By adding 2-5 ppm of 2-diethylaminoethylmercaptan and/or 2-5 ppm of 2-diisopropylaminoethylmercaptan to the fat suspension, the imitation dry bacon pieces prepared therefrom have a meaty, smoky bacon-like pleasant character.
EXAMPLE 10
An all-purpose seasoning powder containing the following ingredients can be prepared:
______________________________________ Parts by weight______________________________________Cooking salt 354 gSodium glutamate 200 gVegetable protein hydrolysate 200 gMaize starch 100 gPalm kernel fat (melting point32°-34° C.) 50 gOnion powder 50 gYeast autolysate 25 gTurmeric powder 13 g2-Dimethylaminopropylmercaptan (1%in propyleneglycol) 8 g 1000 g______________________________________
The turmeric powder is emulsified in the palm kernel fat and then blended with the remaining ingredients. The resulting powder is suitable for the seasoning of foodstuffs not only during cooking but also at the table.
By omitting the 2-dimethylaminopropylmercaptan there is obtained an uncharacteristic seasoning powder which lacks the desired meaty note.
EXAMPLE 11
An extended (stretched) cheese powder containing the following ingredients can be prepared:
______________________________________ Parts by weight______________________________________Cheese powder 500 gPre-cooked maize starch 50 gButtermilk powder 150 gMaltodextrin 285 gCooking salt 4.9 gCitric acid 5 gSodium citrate 5 g(2-Dimethylaminopropyl)-methyl-sulphide (1% in propyleneglycol) 0.1 g 1000 g______________________________________
The ingredients are mixed well to give a cheese-like product which is suitable for the seasoning of spaghetti, pizzas, soups, pastries, dip sauces etc.
When the (2-dimethylaminopropyl)-methylsulphide is not added, the product has a bland and insipid flavour.
EXAMPLE 12
A ready seasoned partial hamburger premix (i.e. a meat extender containing soya protein can be prepared as follows:
______________________________________ Parts by weight______________________________________Textured soya protein (texturedsoya) (Miratex 210) 700 gandPalm kernel fat (melting point32°-34° C.) 70 gare mixed in a mixer-drier at 35° C. andtreated with:Cooking salt 30 gSodium glutamate 10 gVegetable protein hydrolysate 16 gPepper flavour 2.3 gOnion flavour 0.5 gGarlic flavour 0.2 g3-Dimethylaminopropylsulphide (1%in propyleneglycol) 1 g.By admixture ofEgg powder 70 gandDried onion flakes 100 gthere is obtained 1000 gof a stable powder which is mixed withMinced beef 2400 gandWater 1600 g______________________________________
and fried in portions to give hamburgers with a pleasant rost meat odour.
If the 3-dimethylaminopropylsulphide is not added, then the hamburger tastes weak and insipid. On the other hand, if the 3-dimethylaminopropylsulphide is replaced by a similar amount of 5-acetyl-3-dimethylaminopropylmercaptan, then an excellent roast meat note is realized.
Unless they are described in the literature, the compounds of formula I can be prepared in a manner known per se. A summary of the preparative methods is given in the following Table:
TABLE__________________________________________________________________________ TemperatureMethod (*) Products (Formula I) Educts Solvent (e.g.) range (e.g.)__________________________________________________________________________B N,N-Dialkylamino- S-Acyl-dialkyl- (Educt brought Methanol, ethanol, 0°-100° C., alkyl-mercaptan amino-alkyl- into contact propanol, water especially mercaptan (2) with the 20°-65° C. solvent, e.g. for a few minutes to several days)C N,N-Dialkylamine- Dialkylamino- Alkylmercaptan Base Organic 0 -100° C., alkyl sulphide alkyl halide solvent, especially especially (1) two-phase system 20°-60° C., NaOH benzene, KOH/ benzene or NaOH/ ether, KOH/etherA S-Acyl-dialkylamino- Dialkylamino- Thio-alkane- Organic, especially 0°-100° C., alkylmercaptan alkyl halide carboxylic aprotic solvent, especially (1) acid or salt e.g. chloroform, 20°-60° C. (e.g. alkali water metal salt)E N,N-Dialkylamino- Dialkylamino- Oxidising NaOH/ether, as C -80° C. to alkyl-disulphide alkylmercaptan. agent, e.g. 100° C., I.sub.2, O.sub.2, H.sub.2 O.sub.2 especially or organic or 10°-30° C. inorganic peroxideD N,N-Dialkylamino- Dialkylamino- Alkali metal NaOH/Benzene, as C 0°-100° C., alkyl sulphide alkyl halide hydrogen especially (1) sulphide 20°-60°__________________________________________________________________________ C. (*) See the following Examples. (1) Chloride, bromide, iodine. (2) Conveniently containing a readily cleavable acyl group such as formyl acetyl, propionyl, benzoyl.
EXAMPLE 1 (Method A)
100 g of 3-dimethylamino-1-propyl chloride hydrochloride are dissolved in 1.2 liters of chloroform and 192 g of triethylamine are added. 54 ml of thioacetic acid are added dropwise and the mixture is kept at the reflux temperature for 18 hours. The cooled solution is washed three times with 500 ml of 1-N sodium hydroxide and once with 500 ml of water. The aqueous phases are extracted with chloroform and the combined chloroform phases are dried, concentrated and distilled at 86°-89° C./10 mmHg. In this manner, 91.3 g (89.5%) of pure S-acetyl-3-dimethylaminopropylmercaptan are obtained.
The following compounds are obtained according to the same method:
______________________________________S-acetyl-3-dimethylamino-propylmercaptan: 38°-44° C./0.04 mmHg;S-acetyl-2-diisopropyl-aminoethylmercaptan: 102°-108° C./10 mmHg; andS-acetyl-2-dimethylamino-propylmercaptan: 84°-87° C./11 mmHg.______________________________________
EXAMPLE 2 (Method B)
86.4 g of S-acetyl-3-dimethylaminopropylmercaptan are held at the reflux temperature for 15 hours in 900 ml of methanol. The methanol is then distilled off and the residue distilled at 150°-155° C. under normal pressure. In this manner, 44.2 g (69% yield) of pure 3-dimethylaminopropylmercaptan are obtained; boiling point 42° C./10 mmHg.
The following compounds are obtained according to the same method:
______________________________________2-Diisopropylaminoethylmercaptan: 72°-74°/10 mmHg;2-dimethylaminopropylmercaptan: 125°-145° C.;2-dimethylaminoethylmercaptan: 124°-128° C.; and2-diethylaminoethylmercaptan: 160° C.______________________________________
EXAMPLE 3 (Method C)
10 g of 1-dimethylaminopropyl-2-chloride hydrochloride, 100 ml of 2-N aqueous sodium hydroxide solution, 100 ml of benzene and 0.8 g of benzyl-triethylammonium chloride are introduced into a flask and ca 20 g of methylmercaptan are introduced for 40 minutes at room temperature while stirring. The mixture is then held at the reflux temperature for 4 hours. The benzene phase is concentrated and distilled, and gives, at 165°-168° C, 2.4 g (29% yield) of a mixture of [1-dimethylaminopropyl(2)]-methyl sulphide (a) and 2-dimethylaminopropylmethyl sulphide (b) in the ratio of 15 to 85. The two products can be separated by preparative gas chromatography or column chromatography.
Identifying properties
compound a:
gas chromatography, Carbowax 100° C., retention time 21/2 min.;
NMR (CDCl 3 ) δ=1,25 ppm/D 3H (>CH--CH 3 )
compound b:
gas chromatography, Carbowax 100° C., retention time 4 min.;
NMR (CDCl 3 ) δ=1,17 ppm/D 3H (>CH--CH 3 )
The following compounds are obtained according to the same method:
______________________________________3-Dimethylaminopropylmethyl sulphide: 90°-100° C./25 mmHg;and 2-dimethylaminoethylmethyl sulphide: 130°-133° C.______________________________________
EXAMPLE 4 (Method D)
10 g of 3-dimethylaminopropyl chloride hydrochloride, 100 ml of 2-N sodium hydroxide solution, 100 ml of benzene, 0.5 g of benzyl-triethylammonium chloride hydrochloride and 6.7 g of NaHS.H 2 O (70%) are held at the reflux temperature in a flask for 24 hours. The aqueous phase is then extracted three times with 50 ml of ether each time, the combined organic phases are washed with water, concentrated and fractionally distilled at 75°-85° C./0.025 mmHg. 1.35 g (21%) of 3-dimethylaminopropyl sulphide (are obtained in the form of a clear colourless liquid.
EXAMPLE 5 (Method E)
Iodine is added portionwise to a mixture of 4 g of 3-dimethylaminopropylmercaptan in 60 ml of ether and 30 ml of 2-N sodium hydroxide solution until the solution is no longer decolorised each time (ca 4.2 g of iodine). After stirring for 1 hour, the ether phase is dried over magnesium sulphate, concentrated and fractionally distilled at 95°-100° C./0.025 mmHg. 2.7 g (68%) of 3-dimethylaminopropyl disulphide are obtained in the form of a clear colourless liquid.
The following compound is obtained according to the same method:
2-Dimethylaminoethyl disulphide: 130°-132° C./10 mmHg.
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Dialkylamino-alkylene mercaptans and sulfides, useful for preparing flavoring compositions and foodstuffs and tobaccos, and process for preparing said compositions, foodstuffs and tobaccos.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 60/666,226 filed Mar. 29, 2005.
FIELD OF THE INVENTION
[0002] The present invention pertains to a method and apparatus for pre-drying thickened lime mud in a pneumatic dryer so that the predried mud can then be fed directly to a lime reburning kiln.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to methods and apparatus in the field of reburning lime sludge in which lime sludge, largely CaCO 3 , is regenerated to form active lime, CaO. In the pulp and paper industry, pulp is prepared by cooking wood under either the sulphate or soda method. The cooking process results in the dissolution of the major portion of the lignin components of the wood leaving a pulp fraction that is purified in a washing step. The washed pulp may be thereafter screened and bleached and is then fed to a dryer or directly to a paper mill.
[0004] The spent liquor from the washing step contains dissolved wood and the chemicals used during the cooking process. So that these chemicals can be recovered and reused, the spent liquor is normally concentrated via evaporation to remove most of the water content, and is burnt in a recovery boiler where the cooking chemical charge is recovered in the form of Na 2 CO 3 in a green liquor.
[0005] So that the cooking chemicals can be recovered, the Na 2 CO 3 present in the green liquor must be converted to NaOH. This is usually achieved by treatment of the green liquor with burnt lime CaO in the causticizing process to form a “white liquor” containing lime sludge. The reaction is as follows:
[0000] Na 2 CO 3 +CaO+H 2 →2NaOH+CaCO 3
[0000] The calcium carbonate, CaCO 3 , also known as lime sludge, is then converted into burnt lime, CaO, by the lime sludge reburning process which uses a rotary, lime sludge reburning kiln that typically operates at temperatures of about 1700-2100° F. In the rotary kiln, the lime sludge is subjected to the countercurrent flow of hot gas so that CaO is regenerated via the reaction
[0000] CaCO 3 +heat→CaO+CO 2 ↑
[0006] Traditional lime reburning kilns have been large devices wherein the lime sludge entered at an upstream kiln end and was subjected to the action of rotary chains, baffles or the like to dry the lime mud as it proceeding through the kiln, with countercurrently flowing hot gases heating and calcining the sludge.
[0007] Recently, in order to minimize capital expenditures, lime reburning kilns have been made smaller with the lime mud subjected to a thickening step and subsequent preheating or drying step in a pneumatic dryer prior to feed into the lime reburning kiln. In the typical pneumatic dryer designs, hot flue gas from the lime reburning kiln was used as the heating and transport medium for the lime sludge with the thickened lime sludge and flue gas directed into a vertically disposed pneumatic dryer or conduit located proximate the flue gas exit from the kiln. The lime sludge heated in the pneumatic dryer was then separated from the flue gas in a cyclone or the like followed by feed of the separated, pre-dried lime sludge into the lime feed inlet end of the reburning kiln. Lime mud drying systems have been incorporated into the designs of new kilns to minimize capital expenditures. However, in the case of retrofits they are usually incorporated as a means to increase production and/or to reduce fuel cost.
[0008] One problem associated with such systems arose when the latent heat in the kiln flue gas was not great enough to evaporate the moisture content of the lime sludge fed to the pneumatic dryer. In these cases, clogging of the flue gas duct work and downstream separator could occur. Accordingly, there is a need in the art to minimize problems associated with convention lime mud reburning systems in which pneumatic dryers are employed to preheat lime mud prior to entry of the preheated or predried mud into the lime burning kiln.
SUMMARY OF THE INVENTION
[0009] In accordance with the invention, a method for heat treating lime mud utilizing a pneumatic dryer and a reburning kiln is disclosed. The method comprises feeding lime mud to a thickener at a predetermined flow rate and thickening the lime mud in the thickener. The thickened lime mud is dried and preheated in a pneumatic dryer utilizing flue gases that are exhausted from the kiln. The thickened dried lime mud and flue gases are separated in a cyclone or the like. The temperature of the separated dried lime mud is determined either by direct measurement thereof in the cyclone or in proximity to the cyclone or by indirect measurement in which the temperature of the effluent flue gas from the separator is assessed. Then, the feed rate or amount of thickened lime mud fed to the pneumatic dryer is controlled so as to ensure that the latent heat in the dryer is sufficient to adequately dry the thickened lime mud therein. Such control can be made by adjustably regulating the feed rate of the lime mud fed to the lime mud thickener or by control of the operation of the lime mud thickener itself so that the amount of thickened lime mud exiting the thickener for transport to the pneumatic dryer is adjusted. This process control is correlated to and actuated by the measured temperature of the separated dried lime mud. The separated, dried lime mud is directed from the separator to the lime reburning kiln.
[0010] The apparatus disclosed is utilized to heat treat lime mud and includes a lime mud filter for thickening lime mud, a lime reburning kiln which includes a flue gas discharge, and a pneumatic drying conduit operatively connected to the lime reburning kiln for pneumatically preheating and drying thickened lime mud therein with the flue gas emanating from the flue gas discharge of the lime reburning kiln.
[0011] A separator, such as a cyclone separator, is connected to the pneumatic drying conduit to separate the preheated dried lime from the flue gas. The separated, predried lime mud is then fed to the upstream, lime mud entry end of the rotary, lime reburning kiln. A process loop controller is provided to control the feed rate of lime sludge ultimately fed to the pneumatic dryer in response to the temperature of the separated lime.
DRAWING
[0012] The invention will be further described in conjunction with the following appended drawing in which FIG. 1 is a diagrammatic drawing of the apparatus used for carrying out the method of the invention.
DETAILED DESCRIPTION
[0013] Turning to the figure, there is shown a storage tank 2 with mixing vanes therein which is utilized to store and mix the lime sludge. A pump 4 pulls the lime sludge through the lime mud feed line 12 into the vat 42 of the lime sludge thickener (lime mud precoat filter) shown at 16 .
[0014] A density sensor and control unit 6 , such as a PLC (or a Distributive Control System (DCS), is operatively connected to an adjustable valve member such as a solenoid valve 8 so that make up water can, if desired, be fed to line 12 to control the density of the lime mud that is fed to the lime sludge thickener. A controllable valve 10 is shown in operative association with flow rate controller 14 so that the flow rate of lime mud fed to the lime sludge thickener 16 may be adjustably controlled.
[0015] As shown, the lime sludge thickener is of the type generally utilized throughout the industry as can be seen, for example, in U.S. Pat. No. 5,149,448. The entire disclosure of this patent is incorporated by reference. The lime sludge thickener is of the normal type in which a doctor or the like 18 scrapes thickened lime sludge from the rotating filter drum so that it drops via a gravity conveyor or the like 100 to a belt conveyor 44 disposed beneath the thickener.
[0016] The thickener is of the type in which a vacuum is drawn through manifold 90 via the action of the vacuum pump 30 acting through the vacuum receiver/separator 28 . The vacuum acts to draw sludge from the vat 42 onto the drum where it will be thickened and subsequently removed from the drum via the action of doctor 18 . The rotary drum thickener type 16 is the most common means of dewatering lime mud, but the skilled artisan will also appreciate that a disc type thickener can also be used in the process of dewatering lime mud for this application.
[0017] The vacuum pump 30 provides the force to the pull the slurry of lime mud, which is mostly CaCO 3 onto the drum where the dewatered lime mud is removed via the action of the doctor 18 . The air that is pulled through the lime mud on the drum along with the water and soluble sodium compounds associated with the feed slurry are pulled through the manifold 90 and then into the receiver/separator 28 . The receiver/separator 28 separates the liquid from the gas. The liquid drains by gravity to the filtrate pump 26 , where it is pumped back into the recausticizing process. The gas that exits through the top of the receiver/separator 28 is pulled to the vacuum pump 30 . As shown, the vacuum pump is a liquid ring type design and therefore requires water in order to generate its design vacuum pressure and flow rate. Water is fed to the vacuum pump via the water line 32 . The water enters the pump and mixes with the gas (air) pulled through the lime mud filter. The combination of water and gas exits the vacuum pump 30 through line 34 into the discharge separator/silencer 36 . The seal water and gas are separated in the separator/silencer 36 . The water drains from the silencer from the line 38 . The gas exits the silencer through exhaust pipe 40 .
[0018] Water nozzles 20 , 22 are provided and actuated via control valve 24 so as to apply a water jet to the circumference of the rotating mud on the drum. The nozzles function to wash soluble sodium compounds from the lime mud via displacement washing. These compounds if not reduced to an acceptable level in the dewatered lime discharged into the lime reburning kiln can cause excessive pollution emission and/or difficulty in lime kiln operation.
[0019] A screw conveyor 46 is located at the downstream end of belt conveyor 44 to convey thickened lime mud from the lime sludge thickener to a vertically disposed pneumatic drying conduit 48 . The conduit 48 is provided in communication with the flue gas exit end of the lime reburning kiln 58 . As can be seen in the drawing, flue gas exiting from the upstream end of the reburning kiln is shown at 92 and flows into the pneumatic drying conduit 48 to provide latent heat sufficient to evaporate the water content from the thickened lime sludge as same exits from the screw conveyor 46 into the pneumatic conduit 48 . Typically, the lime sludge is thickened in the thickening device 16 so that it will contain from about 65-85% solids. Rotary vanes or other mixing baffles (not shown) may be disposed in the conduit 48 to increase the mixing turbulence and hence the heat transfer properties of the conduit.
[0020] The predried lime mud and flue gas travel upwardly through the conduit and are separated from each other in a cyclone 50 with the flue gas exiting via the gas duct 52 via the action of Induced Draft (ID) Fan 60 . The predried, thickened and separated lime mud is passed through a rotary air lock 54 and is then gravity fed through conduit 56 to the lime reburning kiln 58 . The purpose of the rotary air lock is to isolate the conduit 56 from the negative pressure at the point of the cyclone. As the pressure in the cyclone is more negative than at the back of the lime reburning kiln 58 , without the rotary air lock 54 the dry lime dust separated in the cyclone would not flow down the conduit 56 and the cyclone would fill up with dried lime mud. As is conventional in the art, the lime mud will proceed downstream (toward the left hand direction shown in the figure) with the hot flue gases flowing in countercurrent fashion from left to right so as to calcine the lime mud in the reburning kiln and so that the flue gases exit as shown at 92 into the vertically disposed pneumatic drying conduit 48 .
[0021] Effluent gas temperature monitor 62 is provided in operative association with effluent gas conduit 52 and communicates via process control line 64 with the feed control means 14 which controls the flow rate of the line mud from the storage tank 2 into the lime sludge thickener. The feed control means 14 is preferably a control valve in combination with a fixed speed pump or a variable speed pump without a control valve where the speed of the pump is varied in order to obtain the desired flow set point but the artisan will appreciate that a host of other controllers could be operatively associated with the effluent gas temperature monitor 62 and feed control means 14 to adjustably control the flow rate of lime mud from the storage vat 2 into the thickener 16 . According to one aspect of the invention, when the temperature as sensed by monitor 62 falls below a first set point, for example about 300° F., then the feed rate of lime mud to the thickener 16 is decreased until the first set point temperature is achieved.
[0022] The effluent gas monitor 62 also is operatively connected with a proportioning controller 102 that can operate to selectively shut off vacuum pump motor 27 . If the pump motor 27 is shut off, a vacuum will not be drawn through the manifold 90 so that the rotating drum will not be able to pick up any sludge from the vat 42 . In effect, this will result in the cessation of the feed of thickened mud onto conveyor 44 . This ultimately will result in an increase in the temperature of the gas measured at 62 and commensurate increase of temperature in the conduit 42 . A second set point temperature of about 220° F. may be determined. If the temperature measured by monitor 62 falls below this second set point, communication with a controller operatively associated with pump 27 is made via control line 120 , and the controller is actuated to turn off the pump. The cessation of the thickened mud into the dryer 48 can also be accomplished by the stopping the drive motor (not shown) for the rotary drum filter 16 . There are several means to accomplish the cessation of the feed of the thickened mud into the dryer 48 , however the elimination or reduction of the vacuum or in the case of a disc filter the positive pressure, is usually considered the least mechanically disruptive. It is also plausible and probable that by reversing the belt conveyor 44 that the cessation of thickened mud to the drying conduit can be accomplished.
[0023] It is noted that all of the equipment downstream of the thickener has a maximum operating temperature of about 750° F. In order for this temperature not to be exceeded, the system will also sense a third set point temperature at 62 and convey this information through process line 66 to adjustable spray nozzles 68 , 70 to control the flow of water through the nozzles 68 , 70 into the pneumatic drying conduit 48 . When the monitor 62 assesses temperature at above 700° F., only one of the nozzles will be opened and produce an optimal spray flow pattern so as to slightly cool the pneumatic conduit. During conditions where the line mud feed is lost, which is a normal occurrence, such as when the lime mud filter is re-precoated, there is no mud feed to the pneumatic dryer. Since the back end temperature of the lime kiln will usually be about 1000-1400° F., this temperature will carry on through the ducting within a few seconds. In order to prevent damage to the downstream equipment the second nozzle system will open. A fourth set point of about 750° F. will be used to control the second nozzle. When this fourth set point is exceeded, maximum spray flow will be injected into the conduit to prevent damage to the system. A fifth set point of, for example, 800 F will be used to shut-off the fuel supply to the main burner of the rotary lime kiln 58 . This is shown schematically in the drawing as process control line 110 that is in operative association with fuel supply valve 112 . This interlock is the final means of preventing excessive temperature from damaging the drying system, cyclone, ID fan and electrostatic precipitator.
[0024] In another embodiment, process line 130 operatively connects proportioning controller 102 with pump motor 27 so as to vary the amount of vacuum impressed upon the lime sludge thickener 16 . In this embodiment, a sixth temperature set point, for example, 680° F., could be set. If the temperature measured by monitor 62 exceeds this sixth set point, then the vacuum drawn on the filter could be reduced, ultimately resulting in a reduction of the cyclone exit temperature so that it does not exceed this set point. In this embodiment, it should be noted that the overall amount of lime mud fed to the thickener 16 should not applicably decrease.
[0025] One benefit to variable control of the vacuum drawn in filter 16 is the potential decrease in power consumption of the vacuum pump motor 27 . The actual power consumption of this motor 27 is a function of its rotation rate and, if its maximum rotation rate is not required for the predetermined set lime mud feed rate to the thickener, then the power is wasted.
[0026] As the artisan will envision, this variable control loop may also be configured in such a way that its operation is independent from the cyclone exit temperature. In this regard, the loop 130 operatively connecting the proportioning device 102 to the pump motor 27 could be associated with a vacuum level detector or the like. A vacuum set point, for example, 20 inches Hg vacuum could be used as this set point, and the speed of the motor controlled to maintain this desired vacuum set point.
[0027] Upon review, it is seen that the temperature of the separated lime mud in the separator 50 is sensed, in the embodiment shown, by an indirect measurement of effluent gas through line 52 . In turn, this temperature measurement controls the feed rate of the lime mud as it is fed to the lime mud thickener. A first set point, normally about 300° F. will be utilized for this control. That is, when the cyclone exit temperature drops below this first set point, the feed flow to the lime mud precoat filter will be decreased until this set point temperature. A second set point of about 220° F. will also be monitored. When the cyclone exit temperature drops below this second set point, the vacuum pump motor to the thickener will be stopped to eliminate all mud flow to the conduit 42 . This will result in the temperature exiting the cyclone to increase above this set point. Again there are several means of stopping the flow of thickened lime mud to the drying conduit 48 and therefore any and all means of eliminating the flow of mud into the conduit 48 , are included in this design. Eliminating the source of the motive force that allows the thickened lime mud to be drawn from the vat 42 is only one of these means.
[0028] Also, the temperature of the effluent flue gas flowing through line 52 is utilized to adjustably control the amount of spray emanating from the nozzles 68 , 70 into the pneumatic drying conduit 48 . As stated above, a third set point temperature is monitored and, when this third set point is exceeded controls flow through one of the nozzles. If a fourth set point is exceeded, both nozzles are opened providing maximum flow of cooling water into the pneumatic drying conduit 48 . For example, one nozzle can be controlled so as to spray cooling water at a flow rate of about 0-15 gpm with a second nozzle being controlled to spray at a rate of from 15-50 gpm.
[0029] Although this invention has been described with respect to certain preferred embodiments, it will be appreciated that a wide variety of equivalents may be substituted for these specific elements shown and described herein, all without departing from the spirit and scope of the invention as defined in the appended claims.
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Method and apparatus for pneumatically drying thickened lime mud and feeding the dried thickened lime mud to a lime reburning kiln. The thickened mud is pneumatically dried via the action of flue gas emanating from the lime reburning kiln. The dried, thickened lime is separated from the flue gas in a cyclone separator. A process loop controller determines the temperature of the separated lime and, in response, controls the feed rate of lime fed to the pneumatic dryer to ensure that the dryer possesses the requisite latent heat needed to dry thickened lime therein. In one embodiment, the feed rate of lime fed to the thickener is adjustably controlled which, in turn, adjustably varies the flow rate of the thickened mud to the dryer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/419,853, which claims priority to International Application No. PCT/US2013/063177, filed on Oct. 3, 2013, which claims priority to U.S. Provisional Patent Application No. 61/744,822, filed on Oct. 4, 2012.
TECHNICAL FIELD
[0002] The invention relates generally to electrical power systems, including generating capacity of a gas turbine, and more specifically to pressurized air injection that is useful for providing additional electrical power during periods of peak electrical power demand from a gas turbine system power plant, as well as to inlet heating to allow increased engine turn down during periods of reduced electrical demand.
BACKGROUND OF THE INVENTION
[0003] Currently marginal energy is produced mainly by gas turbine, either in simple cycle or combined cycle configurations. As a result of load demand profile, the gas turbine base systems are cycled up during periods of high demand and cycled down or turned off during periods of low demand. This cycling is typically driven by the Grid operator under a program called active grid control, or AGC. Also, in many electrical markets, peak power demands occur when it is hottest outside. Gas turbines naturally loose power and efficiency at elevated ambient temperatures which further increases the number of gas turbines that must be run during peak periods. Unfortunately, because industrial gas turbines, which represent the majority of installed base, were designed primarily for base load operation, when they are cycled, a severe penalty is associated with the maintenance cost of that particular unit. For example, a gas turbine that is running base load could go through a normal maintenance once every three years, or 24,000 hours at a cost in the 2-3 million U.S. dollar range. That same cost could be incurred in one year for a plant that is forced to start up and shut down every day.
[0004] Currently these gas turbine plants can turn down to approximately 50% of their rated capacity. They do this by closing the inlet guide vanes of the compressor, which reduces the air flow to the gas turbine, also driving down fuel flow as a constant fuel air ratio is desired in the combustion process. Maintaining safe compressor operation, and compliance with emissions requirements, typically limit the level of turn down that can be practically achieved.
[0005] The safe compressor lower operating limit is improved in current gas turbines by introducing warm air to the inlet of the gas turbine, typically from a mid stage bleed extraction from the compressor. Sometimes, this warm air is also introduced into the inlet to prevent icing. In either case, when this is done, the work that is done to the air by the compressor is sacrificed in the process for the benefit of being able to operate the compressor safely to a lower flow, thus increasing the turn down capability and preventing icing of the inlet. This has a further negative impact on the efficiency of the system as the work performed on the air that is bled off is lost. Additionally, the combustion system also presents a limit to the system.
[0006] The combustion system usually limits the amount that the system can be turned down because as less fuel is added, the flame temperature reduces, increasing the amount of carbon monoxide (CO) emissions that are produced. The relationship between flame temperature and CO emissions is exponential with reducing temperature, consequently, as the gas turbine system gets near the flame temperature limit, the CO emissions spike up, so a healthy margin is kept from this limit. This characteristic limits all gas turbine systems to approximately 50% turn down capability, or, for a 100 MW gas turbine, the minimum power, or maximum turn down, that can be achieved is about 50%, or 50 MW. As the gas turbine mass flow is turned down, the compressor and turbine efficiencies fall off as well, causing an increase in heat rate of the gas turbine. Some operators are faced with this situation every day and as a result, as the load demand falls, their gas turbine plants hit their lower operating limit and they have to turn the gas turbines off, which costs them a tremendous maintenance cost penalty.
[0007] Another characteristic of a typical gas turbine is that as the ambient temperature increases, the power output from the gas turbine system goes down proportionately due to the linear effect of the reduced density as the temperature of air increases. Power output can be down by more than 10% from nameplate output during hot days, typically when peaking gas turbines are called on most to deliver power.
[0008] Another characteristic of typical gas turbines is that air that is compressed and heated in the compressor section of the gas turbine is ducted to different portions of the gas turbine's turbine section where it is used to cool various components. This air is typically called turbine cooling and leakage air (hereinafter “TCLA”), a term that is well known in the art with respect to gas turbines. Although heated from the compression process, TCLA air is still significantly cooler than the turbine temperatures, and thus is effective in cooling those components in the turbine downstream of the compressor. Typically 10% to 15% of the air that comes in the inlet of the compressor bypasses the combustor and is used for this process. Thus, TCLA is a significant penalty to the performance of the gas turbine system.
[0009] Another characteristic of many large frame engines used to generate power is that the RPM is fixed because the shaftline of the gas turbine is fixed to the generator and the generator must spin at a specific speed to generate electricity at a specific frequency, for example 3600 RPM for 60 HZ and 3000 RPM for 50 HZ. The term “shaftline” means the shaft of the gas turbine and the shaft of the generator and including any fixed ratio gearbox attached between those shafts, so that at all operating conditions the ratio of revolutions per minute (RPM) of the gas turbine shaft to the RPM of the generator shaft remains constant. In gas turbines that have free turbines or multiple turbine shafts within, this is not true. Consequently only one shaft of a multi-shaft gas turbine, the one tied to, or on the shaftline with, the generator, has to spin at a constant rpm. This is a significant consideration when injecting air upstream of the combustor.
[0010] On a multi-shaft engine, like the LM6000 for example, when the air is injected upstream of the combustor, the high pressure turbine actually speeds up which drives the high pressure compressor harder, which in turn induces more air flow through the gas turbine's low pressure compressor, and the compressor as a whole. Therefore, the increased airflow that is being injected upstream of the combustor is the injected air plus the additional flow that is induced in the gas turbine engine's core. Since the low pressure compressor is tied to the low pressure turbine (LPT) and generator, it spins at 3600 RPM (for a 60 HZ generator) and additional air flow goes through the LPT because of the reduced pressure between the high pressure compressor (HPC) and LPC. In other words, since the high pressure compressor is working harder and inducing flow through the low pressure compressor, the low pressure compressor does not need to work as hard to compress the air going to the combustor, so more of the energy that drives the low pressure turbine and the power turbine is available to drive the generator (or other load).
SUMMARY
[0011] The present invention relates to improved electrical power systems and methods of using the same, including increasing the capacity of a gas turbine.
[0012] The current invention, which may be referred to herein as TurboPHASE™, provides several options, depending on specific plant needs, to improve the efficiency and power output of power plants using multi-shaft gas turbine engines, at low loads, and to reduce the lower limit of power output capability of such gas turbines while at the same time increasing the upper limit of the power output of the gas turbine, thus increasing the capacity and regulation capability of a new or existing gas turbine system.
[0013] One aspect of the present invention relates to methods and systems that allow running multi-shaft gas turbine systems to provide additional power quickly during periods of peak demand.
[0014] Yet another aspect of the present invention relates to methods and systems that allow gas turbine systems to be more efficiently turned down during periods of lowered demand.
[0015] One embodiment of the invention relates to a system comprising at least one existing gas turbine that comprises a low pressure compressor, a high pressure compressor, a combustor, a high pressure turbine, and a low pressure turbine, wherein a first shaft connects the low pressure compressor and the low pressure turbine, and a second shaft connects the high pressure compressor and the high pressure turbine, and further comprising an auxiliary compressor which is not the same as the low pressure compressor or the high pressure compressor.
[0016] An advantage of preferred embodiments of the present invention is the ability to efficiently increase the turn down capability of the gas turbine system during periods of lower demand and improve the efficiency and output of the gas turbine system during periods of high demand.
[0017] Another advantage of additional preferred embodiments of the present invention is the ability to efficiently increase the turn down capability of the gas turbine system during periods of low demand by using an auxiliary compressor driven by a fueled engine, the operation of which is independent of the electric grid.
[0018] Another advantage of other preferred embodiments of the present invention is the ability to increase the turn down capability of the gas turbine system during periods of low demand by using an auxiliary compressor driven by a fueled engine which produces heat that can be added to compressed air flowing to the gas turbine, from the auxiliary compressor.
[0019] Another advantage of additional preferred embodiments of the present invention is the ability to increase output of the gas turbine system during periods of high demand by using an auxiliary compressor which is not driven by power produced by the gas turbine system.
[0020] Another advantage of the present invention is the ability to incorporate selective portions of the embodiments described herein on existing gas turbines to achieve specific plant objectives.
[0021] Another advantage of another embodiment of the present invention is that because the incremental amount of compressed air can be added at a relatively constant rate over a wide range of ambient temperatures, the power increase achieved by the gas turbine is also relatively constant over a wide range of ambient temperatures.
[0022] Other advantages, features and characteristics of the present invention, as well as the methods of operation and the functions of the related elements of the structure and the combination of parts will become more apparent upon consideration of the following detailed description and appended claims with reference to the accompanying drawings, all of which form a part of this specification.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0023] The present invention is described in detail below with reference to the attached drawing figures, wherein:
[0024] FIG. 1 is a schematic drawing of a first embodiment of the present invention including injection of compressed air from the booster system into the combustor of a multi-shaft gas turbine engine with inlet bleed heating.
[0025] FIG. 2 is a schematic drawing of an additional embodiment of the present invention showing injection of compressed air from the booster system into an inlet of the low pressure compressor of a multi-shaft gas turbine engine to provide inlet heating.
[0026] FIG. 3 is a schematic drawing of yet another alternate embodiment of the present invention showing injection of a first portion of compressed air from the booster system into an inlet of the high pressure compressor of a multi-shaft gas turbine engine, and injection of a second portion of compressed air from the booster system into the combustor of the multi-shaft gas turbine engine.
[0027] FIG. 4 is a chart showing various locations of reference points, or stations, in a typical multi-shaft gas turbine engine.
DETAILED DESCRIPTION
[0028] One aspect of the invention relates to a method of supplementing the power output of a gas turbine system having in series a low pressure compressor, a high pressure compressor, a combustor, a high pressure turbine, and a low pressure turbine, wherein a first shaft connects the low pressure compressor and the low pressure turbine, and a second shaft connects the high pressure compressor and the high pressure turbine, the method comprising: (i) providing a booster system having a fueled engine, and an auxiliary compressor; (ii) operating the fueled engine to drive the auxiliary compressor to produce compressed air from the auxiliary compressor and hot exhaust gas from the fueled engine; (iii) heating the compressed air with heat extracted from the hot exhaust gas, thereby producing hot compressed air; and (iv) injecting the hot compressed air into the gas turbine system downstream of the high pressure compressor of the gas turbine system, thereby increasing the mass flow of air therethrough and augmenting the power output of the gas turbine system.
[0029] According to one embodiment, the auxiliary compressor is a multistage compressor having at least one upstream compression stage and at least one downstream compression stage fluidly downstream of the upstream compression stage, and the step of operating the fueled engine to drive the auxiliary compressor to produce compressed air from the auxiliary compressor includes the step of cooling the compressed air exiting the upstream compression stage before delivering it to the downstream compression stage. Preferably, the step of injecting the hot compressed air into the gas turbine system downstream of the compressor of the gas turbine system includes injecting the hot compressed air into the combustor.
[0030] According to another embodiment, the step of injecting the hot compressed air into the gas turbine system downstream of the compressor of the gas turbine system includes injecting the hot compressed air into the combustor.
[0031] Another aspect of the invention relates to a method of supplementing the power output of a gas turbine system having in series a low pressure compressor, a high pressure compressor, a combustor, a high pressure turbine, and a low pressure turbine, wherein a first shaft connects the low pressure compressor and the low pressure turbine, and a second shaft connects the high pressure compressor and the high pressure turbine, the method comprising: (i) providing a booster system having a fueled engine, and an auxiliary compressor; (ii) operating the fueled engine to drive the auxiliary compressor to produce compressed air from the auxiliary compressor; (iii) injecting a first portion of the compressed air into an inlet of the high pressure compressor of the gas turbine system downstream of the low pressure compressor.
[0032] According to one embodiment, the the step of injecting the first portion of the compressed air into an inlet of the high pressure compressor of the gas turbine system downstream of the low pressure compressor is preceded by the step of cooling the first portion of compressed air. Preferably, the step of operating the fueled engine to drive the auxiliary compressor to produce compressed air from the auxiliary compressor includes the step of producing hot exhaust gas from the fueled engine.
[0033] According to preferred embodiments, the step of producing hot exhaust gas from the fueled engine is followed by the step of heating a second portion of the compressed air with heat extracted from the hot exhaust gas, thereby producing hot compressed air. According to still further preferred embodiments, the method comprises the step of injecting the first portion of the compressed air into an inlet of the high pressure compressor of the gas turbine system downstream of the low pressure compressor and the step of injecting the hot compressed air into the gas turbine system downstream of the high pressure compressor. Preferably, the step of injecting the hot compressed air into the gas turbine system downstream of the high pressure compressor of the gas turbine system includes injecting the hot compressed air into the combustor.
[0034] Yet another aspect of the invention relates to an apparatus for supplementing the power output of a gas turbine system having in series a low pressure compressor, a high pressure compressor, a combustor, a high pressure turbine, and a low pressure turbine, wherein a first shaft connects the low pressure compressor and the low pressure turbine, and a second shaft connects the high pressure compressor and the high pressure turbine, the apparatus comprising: (i) an auxiliary compressor to produce compressed air, the auxiliary compressor having at least one compressed air outlet; (ii) a fueled engine connected to the auxiliary compressor to drive the auxiliary compressor, the fueled engine producing hot exhaust gas and having an exhaust outlet; and (iii) a recuperator having a first recuperator inlet, a second recuperator inlet, a first recuperator outlet, and a second recuperator outlet, the first recuperator inlet fluidly connected to the at least one compressed air outlet, the second recuperator inlet fluidly connected to the exhaust outlet, the first recuperator outlet fluidly connected to the first recuperator inlet and fluidly connected to the gas turbine system downstream of the high pressure compressor of the gas turbine system, and the second recuperator outlet is fluidly connected to the second recuperator inlet; wherein heat from the hot exhaust gas is transferred to the compressed air in the recuperator prior to being injected into the gas turbine system.
[0035] According to one embodiment, the auxiliary compressor is a multistage compressor, and each stage of the multistage compressor has a stage inlet and a stage outlet. Preferably, the apparatus further comprises an intercooler heat exchanger fluidly connected to at least one of the stage inlets and at least one of the stage outlets to cool the compressed air exiting the at least one of the stage outlets prior to delivering the compressed air to the at least one of the stage inlets downstream thereof. According to one preferred embodiment, the first recuperator outlet is fluidly connected to the combustor of the gas turbine system.
[0036] Yet another aspect of the invention relates to an apparatus for providing inlet heating on a gas turbine system having in series a low pressure compressor, a high pressure compressor, a combustor, a high pressure turbine, and a low pressure turbine, wherein a first shaft connects the low pressure compressor and the low pressure turbine, and a second shaft connects the high pressure compressor and the high pressure turbine, the apparatus comprising: (i) an auxiliary compressor to produce compressed air, the auxiliary compressor having at least one compressed air outlet; (ii) a fueled engine connected to the auxiliary compressor to drive the auxiliary compressor, the fueled engine producing hot exhaust gas and having an exhaust outlet; and (iii) a recuperator having a first recuperator inlet, a second recuperator inlet, a first recuperator outlet, and a second recuperator outlet, the first recuperator inlet fluidly connected to the at least one compressed air outlet, the second recuperator inlet fluidly connected to the exhaust outlet, the first recuperator outlet fluidly connected to the first recuperator inlet and fluidly connected to an inlet of the low pressure compressor, and the second recuperator outlet is fluidly connected to the second recuperator inlet; wherein heat from the hot exhaust gas is transferred to the compressed air in the recuperator prior to being injected into the gas turbine system.
[0037] Yet another aspect of the invention relates to an apparatus for supplementing the power output of a gas turbine system having in series a low pressure compressor, a high pressure compressor, a combustor, a high pressure turbine, and a low pressure turbine, wherein a first shaft connects the low pressure compressor and the low pressure turbine, and a second shaft connects the high pressure compressor and the high pressure turbine, the apparatus comprising: (i) an auxiliary compressor to produce compressed air, the auxiliary compressor having at least one compression stage and at least one outlet of the compression stage; (ii) a fueled engine connected to the auxiliary compressor to drive the auxiliary compressor, the fueled engine producing hot exhaust gas and having an exhaust outlet; and (iii) a cooling tower having at least one inlet and at least one outlet, the at least one inlet of the cooling tower fluidly connected to the at least one outlet of the compression stage, and the at least one outlet of the cooling tower fluidly connected to an inlet of the high pressure compressor downstream of the low pressure compressor.
[0038] A still further aspect of the invention relates to an apparatus for supplementing the power output of a gas turbine system having in series a low pressure compressor, a high pressure compressor, a combustor, a high pressure turbine, and a low pressure turbine, wherein a first shaft connects the low pressure compressor and the low pressure turbine, and a second shaft connects the high pressure compressor and the high pressure turbine, the apparatus comprising: (i) an auxiliary compressor to produce compressed air, wherein the auxiliary compressor is a multistage compressor, and each stage of the multistage compressor has a stage inlet and a stage outlet; (ii) a fueled engine connected to the auxiliary compressor to drive the auxiliary compressor, the fueled engine producing hot exhaust gas and having an exhaust outlet; (iii) a cooling tower having a first inlet, a first outlet, and a second outlet, the first inlet of the cooling tower fluidly connected to one of the stage outlets, the first outlet of the cooling tower fluidly connected to one of the stage inlets, and the second outlet of the cooling tower fluidly connected to an inlet of the high pressure compressor downstream of the low pressure compressor; and (iv) a recuperator having a first recuperator inlet, a second recuperator inlet, a first recuperator outlet, and a second recuperator outlet, the first recuperator inlet fluidly connected to one of the stage outlets, the second recuperator inlet fluidly connected to the exhaust outlet, the first recuperator outlet fluidly connected to the first recuperator inlet and fluidly connected to an inlet of the gas turbine system downstream of the high pressure compressor, and the second recuperator outlet is fluidly connected to the second recuperator inlet; wherein heat from the hot exhaust gas is transferred to the compressed air in the recuperator prior to being injected into the gas turbine system.
[0039] Preferably, the first recuperator outlet is fluidly connected to the combustor of the gas turbine system.
[0040] Yet another aspect of the invention relates to a method of providing inlet heating on a gas turbine system having in series a low pressure compressor, a high pressure compressor, a combustor, a high pressure turbine, and a low pressure turbine, wherein a first shaft connects the low pressure compressor and the low pressure turbine, and a second shaft connects the high pressure compressor and the high pressure turbine, the method comprising: (i) providing a booster system having a fueled engine, and an auxiliary compressor; (ii) operating the fueled engine to drive the auxiliary compressor to produce compressed air from the auxiliary compressor and hot exhaust gas from the fueled engine; (iii) heating the compressed air with heat extracted from the hot exhaust gas, thereby producing hot compressed air; and (iv) injecting the hot compressed air into an inlet of the low pressure compressor of the gas turbine system.
[0041] FIG. 1 shows the layout for an air injection system of the present invention, referred to as “TurboPHASE”, into a multi-shaft gas turbine, where the air injection system includes a recuperator 110 , an auxiliary compressor 400 , and a fueled engine 101 (along with a cooling tower 107 that cools the air being compressed by the auxiliary compressor 400 ). As used herein, the term “fueled engine” means a heat engine, such as a piston driven or rotary (e.g. Wankel) internal combustion engine (e.g. gasoline engine, diesel engine, natural gas fired engine, or similar fuels, or a combination of such fuels) or a gas turbine, that produces work by combusting a fuel with air to heat a working fluid which then drives blades or the like. The low pressure compressor 10 (referred to herein as “LPC”) is connected to the low pressure turbine 14 (referred to herein as “LPT”) and the power turbine 15 (referred to herein as “PT”) which is also connected to the load or generator 16 . The high pressure compressor 11 (referred to herein as “HPC”) is connected to the high pressure turbine 13 (referred to herein as “HPT”). The HPC 11 , the HPT 13 , and the shaft 19 that connects them are commonly known as the “HP Core”, and the balance is known as the “LP Section”. The HP Core and the LP Section are fluidly connected both in the compression section (the LPC and the HPC) and in the turbine section (the HPT, LPT and PT). The combustor 12 takes the HPC pressurized air flowing from the HPC exit 17 and adds energy to the pressurized air by burning fuel in it and then returning the pressurized air to the inlet 18 of the HPT. The HP Core shaft 19 is hollow to allow the two shafts to rotate relative to each other.
[0042] The balance of the diagram in FIG. 1 , items 100 to 111 inclusive, produce hot, compressed air through recuperator exit 112 to be injected into the combustor 12 in addition to the pressurized air that the gas turbine is delivering through the HPC exit 17 . This hot compressed air delivered through recuperator exit 112 is generated by an auxiliary compressor 400 that is intercooled, and preferably driven by a reciprocating fueled engine 101 . As shown in FIG. 1 , ambient air enters the fueled engine 101 at the fueled engine intake 100 , and ambient air enters auxiliary compressor 400 at the compressor inlet 111 . The fueled engine 101 mechanically drives the shaft 103 of the auxiliary compressor 400 . Typically there is a coupling—hydraulic, mechanical, or mechanical/hydraulic—(not shown) connected to a gearbox between the fueled engine 101 and the auxiliary compressor 400 to increase the speed of the auxiliary compressor 400 to the correct compressor inlet RPM. The coupling and the gearbox are not shown in FIG. 1 for simplicity, but as those skilled in the art will readily appreciate, would likely be included in most applications.
[0043] As the input shaft 103 is turned, several stages of the auxiliary compressor 400 are turned (or driven). FIG. 1 shows an exemplary two-stage auxiliary compressor 400 , however, more stages may be applicable as pressure requirements vary depending on gas turbine combustor pressures. Regardless of the actual number of stages, each stage of the multistage compressor has a stage inlet (e.g. 108 ) and a stage outlet (e.g. 106 ). The air enters the first stage 104 of the multi-stage auxiliary compressor 400 through air inlet 111 and exits through first stage exit 106 at a higher pressure and subsequently a higher temperature than when it entered the first stage 104 . This hotter, higher pressure compressed air then enters the intercooler, in FIG. 1 shown as a cooling tower 107 , and is cooled to approximately 100 Fahrenheit (° F.). The cooling tower 107 may be a completely separate system, or a part of the existing plant cooling system. After the compressed air is cooled, the compressed air exits the cooling tower 107 through cooling tower exit and enters the inlet 108 of the second stage of the auxiliary compressor 105 where it is further compressed. As those skilled in the art will readily appreciate, the first stage 104 of the multi-stage auxiliary compressor 400 is upstream of the second stage 105 of the multi-stage auxiliary compressor 400 , which is downstream of the first stage 104 . Although only two stages of the auxiliary compressor 400 are shown in FIGS. 1-3 for clarity, it is to be understood that if there are additional stages in the auxiliary compressor 400 , this compression and intercooling process is repeated for each stage of the multistage auxiliary compressor 400 until the desired pressure is achieved. Then the compressed air exits the auxiliary compressor 400 after the last stage of compression through the auxiliary compressor exit 109 , which is connected to the inlet of the first heat transfer circuit of the recuperator 110 , and enters the first heat transfer circuit of the recuperator 110 . In the recuperator 110 , the warm compressed air is further heated using the exhaust of the fueled engine 101 which is fed into the second heat transfer circuit of the recuperator 110 through the fueled engine exhaust path 102 . The fueled engine exhaust path 102 is connected to the inlet of the second heat transfer circuit of the recuperator 110 , so that the exhaust of the fueled engine flows through the second heat transfer circuit of the recuperator 110 , and then exits the second heat transfer circuit of the recuperator 110 and exhausts to the atmosphere, having been cooled as a result of transferring heat to the compressed air in the first heat transfer circuit of the recuperator 110 . The compressed air in the first heat transfer circuit, heated in the recuperator 110 as the result of the transfer of heat from the exhaust in the second circuit of the recuperator 110 , exits the first heat transfer circuit of the recuperator 110 through recuperator exit 112 and flows into an inlet of the combustor 12 upstream of the combustor 12 where it is added to the pressurized air flowing from the exit 17 of the HPC of the gas turbine and is entering the combustor 12 from the main compressor exit 17 .
[0044] When the hot compressed air from the first heat exchange circuit of the recuperator 110 is added to the combustor 12 , more fuel is added to the combustor 12 through fuel line 22 to maintain the same firing temperature as before the hot compressed air from the first heat exchange circuit of the recuperator 110 was added. As those skilled in the art will readily appreciate, the additional compressed air and fuel added to the combustor 12 provides more energy to the inlet 18 of the HPT 13 , and consequently, more power is produced by the gas turbine HPT 13 which in turn spins the HP Core shaft 19 faster. This in turn induces and compresses more flow through the HPC 11 , since all of the additional energy extracted by the HPT 13 is used as work in the HPC 11 because there is no external load or generator 16 attached to the HP Core shaft 19 . Although the additional compressed air added to the combustor 12 from the first heat exchange circuit of the recuperator 110 , and the additional fuel that is added to the combustor 12 to maintain the firing temperature, increases the RPM of the HP Core shaft 19 , the LPC 10 still spins at the same RPM, since its speed is fixed by the generator, but the variable guide vanes in the LPC 10 can be adjusted to allow the LPC 10 to pass more flow.
[0045] Tables 1 and 2 below shows results from a commercial software program called “GasTurb”. In using GasTurb for analysis of the present invention, injection into the combustor 12 of compressed air from the first heat exchange circuit of the recuperator 110 is simulated by adding a negative bleed number for the HPC 11 . The station identifications listed in Tables 1 and 2 are shown in FIG. 4 . (Note: the term “TurboPHASE” as used in these tables refers to the present invention, the elements of which are identified in FIG. 1 by reference the numerals 100 - 112 .)
[0000]
TABLE 1
GasTurb program results for 14.4 lbs/sec injection into an LM6000
Hot Day w/
Design
Hot Day
TurboPHASE
TurboPHASE Flow (lb/s)
—
—
14.4
14.4
TurboPHASE Location
—
—
HPC Exit
Booster
Exit
Power (MW)
51.81
43.45
51.12
44.16
Heat Rate BTU/(kW * h)
8529
8953
8156
8854
Mass flow (lb/s)
306
270
296
273
[0000]
TABLE 2
GasTurb program results for 14.4 lbs/sec injection into an LM6000
Hot Day HPC Exit
Hot Day Booster Exit
Design
Hot Day
TurboPHASE 14.4 lb/s
TurboPHASE 14.4 lb/s
W
T
P
W
T
P
W
T
P
W
T
P
Station
(lb/s)
(R)
(psia)
(lb/s)
(R)
(psia)
(lb/s)
(R)
(psia)
(lb/s)
(R)
(psia)
amb
519
14.7
555
14.7
555
14.7
0
554.67
14.696
1
300.3
519
14.7
265.5
555
14.7
275.9
555
14.7
254.2
555
14.7
2
300.3
519
14.7
265.5
555
14.7
275.9
555
14.7
254.2
555
14.7
24
300.3
696
36.7
265.5
743
36.4
275.9
731
34.7
254.2
754
37.7
25
300.3
696
36.0
265.5
743
35.8
275.9
731
34.1
268.5
754
37.2
3
297.3
1517
458.0
262.8
1549
406.6
273.2
1598
449.1
265.8
1559
411.1
31
243.3
1517
458.0
215.1
1549
406.6
237.9
1598
449.1
217.5
1559
411.1
4
248.9
3050
444.2
220.0
3050
394.2
243.2
3050
434.9
222.5
3050
398.5
41
272.9
2928
444.2
241.3
2931
394.2
265.3
2940
434.9
243.9
2931
398.5
43
272.9
2183
103.5
241.3
2196
92.8
265.3
2192
101.0
243.9
2197
93.8
44
303.0
2121
103.5
267.8
2137
92.8
292.9
2140
101.0
270.8
2139
93.8
45
303.0
2121
102.5
267.8
2137
91.8
292.9
2140
100.0
270.8
2139
92.8
49
303.0
1393
14.8
267.8
1439
14.8
292.9
1417
14.8
270.8
1437
14.8
5
306.0
1391
14.8
270.5
1437
14.8
295.7
1416
14.8
273.5
1436
14.8
6
306.0
1391
14.7
270.5
1437
14.7
295.7
1416
14.7
273.5
1436
14.7
[0046] As shown in Table 1, the power output of the gas turbine increases from 43.45 MW on a 95° F. (approximately 555 degrees Rankine, as shown in Table 2) day to 51.12 MW, an increase of 7.67 MW or 18% with an injection rate of 14.4 lbs/sec or 5.5% of the baseline hot day LPC inlet flow (station 1, 265.5 lbs/sec). Also notice in Tables 1 and 2 that the exhaust flow from the gas turbine has increased from 270 to 295.7 lbs/sec (rounded to 296), or 9.3%. The extra 3.8% is “induced” flow generated by the gas turbine HPC 11 . This is significant as the cost of the TurboPHASE system ( 100 - 112 in FIG. 1 ) is primarily tied to the mass flow rate the system can deliver, and consequently, the effective cost from a “power delivered” standpoint, or $/kW, is improved on a gas turbine that has multiple shafts 19 , 20 as compared to a single, or “fixed”, shaft machine. On an F-class fixed shaft engine, such as the GE frame 7FA gas turbine engine, a TurboPHASE system adding 14.4 lbs/sec of air to the combustor could produce 5.1 additional megawatts. However, because of the induced flow and additional power it creates in a multiple shaft engine, the multiple shaft engine has an effective improvement in output of 50% with very little cost increase. For example, the HP Core shaft 19 speed increases by approximately 1000 RPM as compared to baseline hot day RPM, and only 600 RPM compared to standard day RPM.
[0047] FIG. 2 shows an alternate embodiment of the present invention of FIG. 1 , except that the cooling tower is omitted in this embodiment, and compressed air discharged from the exit 206 of the first stage 104 of the auxiliary compressor 400 is routed to the inlet of the first heat exchange circuit of the recuperator 110 instead of to the cooling tower, and the downstream stages, such as 105 , are either mechanically or aerodynamically disconnected from the shaft 103 of the auxiliary compressor 400 . If the downstream stages are mechanically disconnected, those stages will have zero RPM. On the other hand, if the downstream stages of the auxiliary compressor 400 are aerodynamically disconnected, those stages will maintain speed while being aerodynamically unloaded, and any air that is flowing through those stages will be discharged to the atmosphere 207 . In either case, only the first stage 104 is producing the compressed air that enters the recuperator 110 and gets heated therein, so minimal energy is used to produce the compressed air that enters the first heat exchange circuit of the recuperator 110 . The hot compressed air exiting the first heat exchange circuit discharge 212 of the recuperator 110 enters the inlet of the gas turbine and effectively produces inlet heating much more economically than occurs with typical gas turbine inlet heating systems.
[0048] Normally, in a gas turbine inlet heating system, air is taken, or “bled”, from the compressor discharge 17 at full pressure and temperature. With preferred TurboPHASE systems, inlet heating is accomplished with a fraction of the fuel consumption, producing a significant efficiency benefit. This type of inlet heating can be accomplished on a multi-shaft gas turbine or a single shaft gas turbine. A typical gas turbine can have as much as 6% inlet bleed and almost half of the fuel entering the gas turbine is used by the gas turbine compressor to pressurize and heat the air, therefore 3% of the fuel entering the gas turbine is effectively wasted just to heat the inlet up, resulting in a 3% efficiency penalty. With the proposed system shown in FIG. 2 , only ⅓ of the fuel would be required for the same mass flow of hot air, resulting in an efficiency penalty of approximately 1%, instead of 3%, for a savings of 2%.
[0049] FIG. 3 shows another alternate embodiment of FIG. 1 , however, in FIG. 3 , the first stage 304 of the auxiliary compressor 400 is sized to produce significantly more flow than the downstream compressor stages, such as 105 . A first portion of the compressed air produced by the first stage 304 of the auxiliary compressor is extracted through a discharge line 301 after it is cooled in the cooling tower 107 , and is injected into the HPC 11 downstream of the LPC 10 , (this location is referred to as the “Booster Exit” in Tables 1 and 2, and is the location shown as station 25 in FIG. 4 ). Effectively this produces an inlet chilling effect on the HPC 11 which tends to slow the rpm of the HPT 13 , a counterbalancing tool if the air injection system shown in FIG. 1 produces HP Core shaft 19 speeds that are undesirably high. A second portion of the compressed air that flows to the cooling tower 107 from the exit 306 of the first stage of the auxiliary compressor 400 is cooled and flows from an exit of the cooling tower 107 into the inlet 108 of the second stage 105 of the auxiliary compressor 400 , exits via outlet 109 , is then heated in the recuperator 110 , and injected into the gas turbine system downstream of the HPC 11 , preferably in the combustor 12 .
[0050] Table 1 shows the results of 14.4 lbs/sec injection of compressed air, at approximately 283° F., at the Booster Exit. With injection of the compressed air at this point, the RPM on the HP Core shaft 19 is reduced by approximately 300 RPM. When the temperature of the compressed air injected at the Booster Exit is decreased by cooling in cooling tower 107 to 100° F. to become cool compressed air, this mixes with the 283° F. air and reduces the temperature of the air entering the HPC 11 . (This cooling effect is not shown in Table 1 or 2). Therefore, with the injection of the cool compressed air (at approximately 100° F.) at the Booster Exit, the effective temperature of all of the air entering the inlet of the HPC 11 is reduced to 273° F., yielding 10° F. of inlet cooling which will further decrease the rpm of the HP Core shaft 19 while at the same time increasing the flow through the gas turbine engine by almost 2%.
[0051] As those skilled in the art will readily appreciate, the output of the gas turbine increases from the 0.71 MW improvement shown in Table 1 (44.16 MW-43.45 MW on a hot day) to almost 1.0 MW just from the injection of the 14.4 lbs/sec at the Booster Exit. On a combined injection system (i.e. one that injects 14.4 lbs/sec at the Booster Exit and injects 14.4 lbs/sec into the HPC exit 17 or combustor 12 ), injecting 14.4 lbs/sec of cool air into the Booster Exit and injecting 14.4 lbs/sec of hot air into the HPC exit 17 or combustor 12 (or 5.5% injection into both locations), the HP Core shaft 19 rpm remains almost constant while the gas turbine engine induces an additional 4.8% more flow through the LPC 10 . This combined injection system can be balanced to control the HP Core shaft 19 rpm if required while at the same time almost doubling the flow that produces power in the turbine and generator (load). In this example, the first stage 304 of the multistage compressor 400 is flowing 28.8 lbs/sec and half of the flow is taken off after the cooling tower 107 and this cool compressed air is injected in the Booster Exit and the other half continues through the latter stages 105 of the multistage compressor 400 and is ultimately heated in the recuperator 110 and then the hot compressed air is injected into the HPC exit 17 area (i.e combustor 12 input area). The combined injection system produces 7.67 MW from the injection of hot compressed air at the HPC exit 17 (or combustor 12 inlet) and 1.0 MW from the cold compressed air injected at the Booster Exit, for a total increase of 8.67 MW.
[0052] As those skilled in the art will readily appreciate, the mass flow of the first portion of compressed air flowing from the cooling tower 107 through discharge line 301 injected at the Booster Exit may be substantially different than the mass flow of the second portion of compressed air flowing from the first heat transfer circuit of the recuperator 110 at recuperator exit 112 and preferably injected into the inlet of the combustor 12 . Depending on the particular application, it may be desirable to inject most, if not all of the compressed air entering the cooling tower 107 from exit 306 of the first stage of the auxiliary compressor 400 into the inlet to the HPC 11 downstream of the LPC 10 (i.e. at the “Booster Exit”).
[0053] As those skilled in the art will readily appreciate, each of the embodiments of the present invention includes flow control valves, backflow prevention valves, and shut-off valves as required to insure that the flow of air, compressed air, and exhaust flow only in the directions shown in FIGS. 1-3 . While the particular systems, components, methods, and devices described herein and described in detail are fully capable of attaining the above-described objects and advantages of the invention, it is to be understood that these are the presently preferred embodiments of the invention and are thus representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular means “one or more” and not “one and only one”, unless otherwise so recited in the claim. It will be appreciated that modifications and variations of the invention are covered by the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention.
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The invention relates generally to electrical power systems, including generating capacity of a gas turbine, and more specifically to pressurized air injection that is useful for providing additional electrical power during periods of peak electrical power demand from a gas turbine system power plant, as well as to inlet heating to allow increased engine turn down during periods of reduced electrical demand.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to re-heating and recycling of old and new asphalt for permanent joint free repairs. The prior art is replete with designs having a portable Multi axial Infrared heating system supported on pneumatic wheels. Various mechanisms have been devised for adjusting the three separate infrared heating banks. The adjustments of the infrared heating banks requires a series of adjustment steps; For example there is forward and reverse movement, up and down movement and fold up feature. A primary object of the present invention is to provide in association with a compact Fold up Design, an adjustable mechanism that permits precise Heating Adjustments for various climatic temperature situations and asphalt conditions.
REFERENCES CITED
[0002] U.S. Patent Documents
[0003] U.S. Pat. No. 5,114,284 May 19, 1992 Keizer 404/95, 96;
[0004] An extensive search of U.S. patent resulted in numerous asphalt-heating unit but non-if any with close similarity. The example given U.S. Pat. No. 5,114,284 is a fold up design with a typical stationary heating bed.
SUMMARY OF INVENTION
[0005] The Multi axial designed asphalt heater generally designated in FIG. 5 represents an example of the practical use and ability of the present invention. It is an example of a asphalt heating system Multi axial design that can safely and precisely heat a large or small area of old or new asphalt “Soften” it to a workable state without damaging the asphalt surface, plus offer fold up compact convenience. In theory and practicality the non stationary heating elements with forward and reverse rotation 310 allows the asphalt surface to heat on a graduated scale, each pass of the heating element increases the asphalt temperatures and allow graduating heat penetration. In another aspect of the present invention there is provided a method of adjusting the heating elements mechanically up and down off the asphalt surface with the mechanical lever arm 35 . With forward and reverse motion of the mechanical lever arm 35 urge rotation 30 b , 30 a and lift or decent of the main body, extending track rails and heating elements. Yet another object of the present invention FIG. 5 a is to provide in association with a fold up feature a means of positioning or adjusting angularity the outer extending heating elements. The various positional adjustments angularity upward provides exact heat clearances, avoids overheating and shut down delays. From the practical point of view the Multi Axial design of the present invention provides multi adjustments for precision heating of asphalt in all conditions.
DESCRIPTION OF DRAWING
[0006] FIG. 1 is a perspective left view from an elevated rear vantage plane of the side and top. This view illustrating the initial orientations of the invention in the fold out, full length and width positions in accordance with the present invention.
[0007] FIG. 2 is a detailed right side view, partially cut-away taken in a plane perpendicular to the invention in accordance with the invention.
[0008] FIG. 3 is a front detail view, partially cut-away taken in a plane perpendicular to the invention. Some detail that appears in FIG. 1 wind guard, propane hoses, element baffles have been removed for the purpose of illustrations.
[0009] FIG. 4 is a perspective right view from a slightly elevated front vantage plane of the side and top. This View illustrating the invention in the fold up position. Representational view showing Detail section view of the adjustment mechanism up and down. Some detail that appears in FIG. 1 element baffles has been removed for the purpose of illustrations.
[0010] FIG. 5 is a right side view taken in a plane perpendicular to the invention. It is a representational view showing the tending direction of linear movement of the Multi axial design as a function of its rotation and orientation of the ability.
[0011] FIG. 5 a is a front detail view taken in a plane perpendicular to the invention. It is a representational view showing the tending direction of linear movement of the Multi axial design as a function of its rotation and orientation of the ability.
DETAILED DESCRIPTION
[0012] In a broad aspect of the present invention there is provided a main frame base 5 with a sheet metal pan enclosure 5 a and side supporting frame base 10 with a sheet metal pan enclosure 10 a and pneumatic wheels 15 extending forward and extending to the rear pneumatic swivel casters 20 with locking devises. Extending upwardly from the main frame base 5 is an upper portion 25 pinned mounted atop the lower portion the main frame base and is rotatably mounted on the upper portion and lower portion for rotation about a pin 30 a , 30 b axis. The upper portion 25 of the main frame base 5 is constrained to rotate relative to the lower portion the main frame base. Adjustment to the desired position of rotation may be achieved by the adjustment mechanism or lever arm 35 mounted to the lower portion extending upwards about the skew axis center bolt 40 . A bolt 45 connected to lifting arms 50 aligned on a common axis extends tangentially in relation to the axis center bolt 40 . With the adjustment mechanism or lever arm 35 connected on common axis with forward and reverse motion urge rotation and lift or decent of upper portion relative to lower portion. When a desired position of adjustment has been achieved it may be secured such as with a spring pin method along the tangentially side adjustment plate 55 mounted to lower main frame base 5 or may be secured and locked using the spring loaded locking mechanism 60 attached to the handle 65 extending upward from the main frame base. The adjustment mechanism or Lever arm 35 embodiment the use of a heavy spring 70 , a resistance mechanism from lower portion the main frame base 5 to upper portion 25 . From the skew center bolt 40 extending downwards is a bolt 75 connected to a rotational resistance arm 80 which causes a delay in resistance. From the upward portion 25 of the main frame is a sheet metal enclosure covering top, two sides and front referred to as the main body 85 . Mounted on the Four Comers and exterior of the main body are additional braces 90 a , 90 b , 90 c 90 d , for added strength and body support. An arm extending forward from brace 90 c secures and locks in place the center heater frame 95 . Also extending left and right off the upward portion 25 of the main frame base and main body 85 are the fenders 100 a , 100 b which are rotational secured about a pin axis 30 a Extending forward from the upward part of the main body 85 is the track rail mechanism 105 a , 105 b a left and right side with a radially shaped channel base designed for carrying and supporting radially shaped rollers 110 for rotation extending the full length of the track rail. From the track rail mechanism upwards are the truss mechanism 115 a , 115 b , 115 c , 115 d , 115 e for confining and centering the track rail 105 a , 105 b and supporting the belt guard 120 with limit switches 125 attached on either ends, 125 a (holes) provide adjustment, closing or opening the distance between the limit switches. Cross bracing 130 attached to trusses 115 a , 115 b , and 115 c , provides anti twisting and side play integrity. A support post and a base pad 135 mounted at the far end of the track rail extending downwards adjust up and down and Folds inwards providing end track rail support Radially shaped Hinge mechanism 140 a , 140 b mounted left and right on a given point of the track rail mechanism 105 a , 105 b enables the track to lock in a level position, using a spring pin method or rotate upwards vertically and backwards resting on a adjustable cross beam mechanism 145 attached to truss 115 d . Mounted to the inside of the radially shaped hinge mechanism 140 a is a spring loaded safety, locking arm mechanism 150 which drops downward and over the track opening during the rotation upwards of the track mechanism insuring the center heater frame and heater banks stay lodged in position. As shown in more detail FIG. 2 the rotation cycles of the heating elements forward and reverse is powered electrically with a electric motor 155 and gear reduction mechanism 160 mounted atop the upper portion 25 of the main frame base and is confined with in the thin metal exterior sheeting of the main body 85 . The electric motor and gear reduction mechanism and cog sprocket is assessable through a top inspection plate 165 or through a hinged rotational door 170 at the rear of the main body 85 . Extending forward from the gear reduction mechanism and the cog sprocket, is a cog belt drive system connected on either ends of the center heating frame with an idler pulley 175 located at the far end of the track. The rotation cycle and travel distance forward and reverse is controlled and is adjustable by limit switches 125 mounted on either ends of the belt guard 120 and opposing ends of the track. From the track 105 a , 105 b down wards is the center heater frame 180 it is supported and suspended by the radially shaped carrying rollers 110 . As shown in more detail FIG. 3 the Heater Frames consist of the center frame 180 and a flame to the right 180 a and from the center frame a frame to the left 180 b connected to each other by radially shaped hinge mechanisms 185 which embodiments the use of spring resistance mechanism 190 anchored from the radially shaped hinge arms 185 attached to the center heater frame extending outwardly to anchor brackets located on the left and right heater frames. The radially shaped hinges 185 offers rotation of the right 180 a and left 180 b not the center heater frames 180 up wards with periodically degree adjustment settings 195 to the vertical position. The one half of the radially shaped hinge 185 that is attached to the center frame skew downwards has a slotted flat metal mechanism 200 to attach and adjust the height of an optional wind guard device 205 flat plates extending from left to the right located front and rear of the heating frames with a sewn lower flexible snap on skirt 210 . Attached to The center heater frame 180 skew forward are stabilizer legs 220 a , 220 b rotational up and down position by method of a center pin 225 and locking pin 230 . Extending upwardly from the rear left corner of the center heater frame 180 is a mechanism referred to as the hose whip 235 a device that is spring mounted at the base providing Flexibility, offers resistance and support for the Propane hose 240 during travel between the limit switches mounted on the belt guard on either end of the track From the heater frames downward are the actual heating elements 245 . These heating element are constructed using a stainless steel material and a bank as described consists of two heating elements joined side by side to form a singular bank The center bank two heating elements are supported by the center heating frame, the right bank two heating elements are supported by the right heating frame and the left bank two heating elements are supported by the left heating frame. Various mechanism have been devised from the heating element downwards are heat element baffles 250 on either sides of the heat element banks. These unique baffles safeguards against flame out of the heating elements during windy conditions and provide heat protection for thermocouples.
[0013] Extending upwards from the side supporting frame is the main electrical control panel 255 . From the electrical control panel extending downwards and resting atop the side supporting frame base 10 is the electrical source a gas-powered generator 260 . Extending upwards from the rear portion of the main frame 5 base and the side supporting base 10 is the heating element fuel source two vertically placed propane tanks 265 . The upper rear portion of the handle 65 b provides the stability for the two propane tanks by method of a secure strap 270 and a cross bar extending left and right 275 . Exchange of the two propane tanks is accomplished by releasing the pins 280 located on either side of the handle 65 a , 65 b and removing the rear portion of the handle 65 b and cross bar enabling free unobstructed access. Rotational braking mechanism 285 is a steel pad pin mounted designed to apply compression against the pneumatic wheels. The rear braking lever 300 has a center axis bolt 295 with spring retention allowing the braking lever 300 side to side and forward, reverse movement. The desired lock, unlock settings for braking are achieved with the tangentially side mounted plate 305 with extruded tabs. Rotational movement is transferred from the rear braking lever to the front steel pad with 290 the push, pull connecting rod.
[0014] A variety of modifications, changes and variations to the invention are possible within the spirit and scope of the following claims and will undoubtedly occur to those skilled in art The invention should not be considered as restricted to the specific embodiment that has described and illustrated with reference to the drawings.
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A multi axial designed asphalt heater for re-heating and recycling of old and new asphalt for permanent joint free repairs and restorations. There is provided a method of adjusting the heating elements mechanically up and down off the asphalt surface with the lever arm mechanism and a design featuring a upper portion mounted atop a lower portion rotatable mounted on the upper and lower portion for rotation about a pinned axis. As well there is a method of rotational movement forward and reverse of the heating elements a graduated heating process featuring radially shaped track rails that support radially shaped rollers. Fold-Up design with radially shaped adjustable hinges provide various angularity adjustments not only for compact convenience but also for establishing specific heat clearances, avoiding shut down delays and overheating.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 60/361,282 filed Mar. 4, 2002.
FIELD OF THE INVENTION
[0002] This invention relates specifically to two genes encoding Plasmodium falciparum proteins, methods for the detection of these and similar proteins located on the surface of Plasmodium infected mammalian cells, and vaccines for the protection against malaria in humans and non-human mammals. This invention further relates to the diagnostic, isolation and purification assays based on these Plasmodium proteins. This invention further relates to immunological reagents, specifically antibodies directed against these Plasmodium proteins.
DESCRIPTION OF THE PRIOR ART
[0003] The disease Malaria is caused by infection with one of four species of Plasmodium: P. falciparum, P. vivax, P. malariae and P. ovale. Plasmodium parasites belong to the family Apicomplexa and are eukaryotic protozoan parasites that possess a complex life cycle which involves both an invertebrate host ( Anopheles mosquito) and a mammalian host. The parasite life cycle includes direct inoculation into the mammalian host by the bite of an infected Anopheles mosquito which injects stages of the parasite known as “sporozoites”. The sporozoites rapidly invade cells of the liver by an active invasion process which is thought to involve attachment to the liver cells and which involves a cascade of processes which results in the parasite taken up residence inside a liver cell (hepatocyte) (Hollingdale, McCormick et al. 1998). The parasite undergoes asexual multiplication over a period of several days resulting in production of thousands of parasites which are released into the host circulation. These “merozoite” forms invade host cell erythrocytes (red blood cells) by an active process which involves attachment to the exterior surface of the erythrocyte, reorientation, and invagination (in folding) of the erythrocyte membrane until the parasite is completely enveloped by the erythrocyte (Preiser, Kaviratne et al. 2000). While inside the erythrocyte the parasite begins to grow using the erythrocyte hemoglobin as an energy source and divides into approximately one dozen additional parasites. During this growth phase, some of the Plasmodium proteins are exported to the surface of the erythrocyte and can be found associated with the erythrocyte membrane. Some of these proteins are thought to represent important targets for vaccine development as their location allows them exposure to the host immune system (Chen, Fernandez et al. 1998). Two models are often used to describe the development of immunity to malaria and as a tool for the development of new strategies for malaria vaccine development (Richie and Saul 2002):
[0004] Irradiated Sporozoite Model
[0005] Naturally Acquired Immunity (NAI)
[0006] (a) The irradiated sporozoite model: This model involves immunizing volunteers via the bites of irradiated Plasmodium -infected Anopheles mosquitoes. The parasites within the mosquitoes are damaged but not killed by the radiation, and thus constitute an attenuated whole organism vaccine. They are able to enter the blood stream of vaccinees while the mosquitoes feed, invade liver cells, and undergo limited development, but cannot progress to the pathogenic blood stages due to the attenuation caused by radiation. While undergoing development in the liver, these damaged parasites induce a strong protective immune response directed against liver stage parasites. As mentioned above, it appears that this strong protective immunity represents the sum of many immune responses directed at a variety of antigens derived from the whole organism attenuated sporozoite vaccine. When batches of irradiated, infected mosquitoes are allowed to feed on volunteers over a 6-month period, the level of immunity develops sufficiently to protect at least 95 percent of the human volunteers tested when subsequently challenged with intact parasites. The immunity lasts for at least 9 months and is not strain-specific (but does appear to be species-specific). If that level of immunity could be reproduced with a subunit vaccine, it would be considered very effective because all manifestations of disease would be prevented. Because this immunity is based on liver stage (pre-erythrocytic) immunity, it forms a model for pre-erythrocytic stage vaccines designed to completely prevent malaria infection.
[0007] (b) The naturally acquired immunity (NAI) model: This model is based on studies of children and adults living in malaria-endemic areas. It has been noted that if children who live in malaria endemic areas survive and reach the age of 10, they remain susceptible to infection with malaria parasites, but do not develop severe disease or die of malaria. In other words, they are protected through acquired immunity against severe disease and death due to malaria infection. This immunity persists for the rest of their lives as long as they continue to live in the malarious area. They may continue to be re-infected with parasites, as shown in cleared-cohort studies, but their health will not be significantly affected by the parasites. NAI limits the number of parasites in the blood and reduces their clinical effect on the host. Because this immunity is based on blood stage antigens, it forms a model for erythrocytic stage vaccines designed to curtail disease and death, even if not preventing infection.
[0008] It has been well established that protective immunity against malaria infection is mediated, in part, by circulating antibodies (Mohan and Stevenson 1998). Passive transfer of hyperimmune antibodies obtained from one geographical location can protect against malaria infection in other regions, indicating that the target antigens may be highly conserved among diverse parasite strains (McGregor 1963; McGregor and Wilson 1988). These conserved antigens, located on the surface of parasite-infected erythrocytes thus accessible to protective antibodies, are good vaccine candidates and yet to be identified. A conventional approach to identify surface antigens is to use hyperimmune sera from individuals living in endemic regions (Howard 1988; Fernaders 1998; Kyes 1999). Two surface antigens identified so far by this method, PfEMP1 proteins and Rifins, are highly variable and their roles in the humoral immune protection are still under investigation. In addition, the approach is limited to the identification of highly immunogenic or abundant molecules.
[0009] The completion of P. falciparum genome sequencing project, combined with advanced proteomics technologies and bioinformatics tools, has allowed the profiling of expressed parasite proteins to be carried out in an unprecedented scale, with higher sensitivity and efficiency (Florens, Washburn et al. 2002). The advantage of MudPIT technology, a two-dimensional liquid chromatography coupled with tandem mass spectrometry, is its ability to analyze complex protein mixture, particularly, membrane protein mixture that is difficult resolve in other gel-based protein separation systems (Eng, McCormack et al. 1994; Washburn, Wolters et al. 2001).
[0010] Development of vaccines against malaria is focused on the identification of parasite proteins found to be present at a particular stage of the parasites life cycle, the design and construction of a vaccine delivery system which is meant to stimulate the desired immune response against that identified protein and which is meant to eliminate, disable or interrupt the function of the parasite within the host(s).
[0011] A key component of this vaccine strategy is the identification of proteins at particular stages of the parasite life cycle. Recently, an approach has been developed and applied to the identification of Plasmodium proteins from isolated stages of the parasite life cycle. This approach which employs microcapillary liquid chromatography coupled with tandem mass spectrometry has resulted in the identification of over 2,500 Plasmodium proteins from several stages of the parasite life cycle (Florens, Washburn et al. 2002). Some of these proteins represent potential targets of new malaria vaccines.
[0012] At present, there are no licensed vaccines against malaria. The most effective malaria vaccine that would result in sterilizing protective immunity would be directed toward eliminating the parasite while inside the liver cells. However, vaccines that are designed to reduce the number of circulating and sequestered parasites from the mammalian host blood stream would result in a substantial reduction in morbidity and mortality, especially in children and pregnant women living in areas of malaria transmission. This type of vaccine would mimic the naturally acquired immunity that develops over years of exposure to blood stage parasites living and circulating in the host blood stream. It would also be a vaccine which is directed toward parasite proteins expressed either by the circulating parasites before invasion into red blood cells, or to those parasite proteins expressed on the surface of the red blood cell. The most well characterized protein expressed on the surface of P. falciparum infected red blood cells, PfEMP1 (or variant surface antigen) has been shown actually to represent a large family of diverse proteins and has been shown to stimulate immune responses that can reduce parasite numbers in the circulation. The diversity of this protein within the parasite genome and its role in “antigenic switching” may limit its role in providing long-term protection against P. falciparum. There is a need to identify additional Plasmodium proteins on the surface of infected erythrocytes for the development of vaccines directed against these proteins. It is of further interest to develop diagnostic tests for the presence of Plasmodium infections in mammals. To date, the most reliable diagnostic test and the one that is the gold standard used in clinical laboratories is the examination of blood for the presence of parasites by Giemsa staining methods. This method, however, requires a skillful microscopist who has been trained in the identification of malaria parasites within red blood cells. In many areas of the world where malaria is highly endemic, there are an abundance of skilled microscopists who are adept at reading Giemsa stained blood films. However, in the US and other industrialized nations where malaria infection in humans is not abundant, misdiagnosis of malaria due to the absence of trained microscopists can result in a delay in providing adequate treatment and potential death in those infected. The development of a highly sensitive and reliable in vitro assay to detect the presence of Plasmodium in the blood would likely reduce the rate of misdiagnosis and likely result in prompt and appropriate treatment. The identification of parasite proteins expressed in the blood stage of Plasmodium would form the foundation for the development of a clinical assay for Plasmodium in humans and other mammals. Finally, development of new antimalarial drugs may be accelerated by the identification of Plasmodium parasite proteins and their association with biochemical and signal transduction pathways. Parasite proteins expressed at the surface of red blood cells may provide a link to parasite residing within to the external environment. These proteins may therefore represent components of a signal transduction pathway to which directed interruption either by drug or small molecule could result in the parasite receiving misinformation to its detriment and potential death.
SUMMARY OF THE INVENTION
[0013] It is an object of this invention to identify two Plasmodium falciparum proteins expressed at the surface of infected erythrocytes in humans.
[0014] It is another object of this invention to use these proteins singly or together as vaccines, either as native or recombinant proteins or peptides.
[0015] It is another object of this invention to use the genes encoding these proteins as nucleic acid vaccines or in recombinant viruses, or other vaccine delivery systems whose intent is to generate an immune response in the recipient against these proteins.
[0016] It is another object of this invention to use either the native or recombinant protein or peptide vaccines in combination with nucleic acid, recombinant viral vaccines or other delivery systems whose intent is to generate an immune response in the recipient against these proteins.
[0017] It is another object of this invention to use these proteins or genes encoding these proteins to detect the presence of Plasmodium parasites in the blood or tissues of human or mammals. It is another object of this invention to use these proteins or genes encoding these proteins in the development of drugs or small molecule interventions designed to interrupt metabolic or signaling pathways in Plasmodium.
[0018] It is another object of this invention to identify the orthologous proteins or genes encoding these proteins from Plasmodium where the species is P. vivax, P. ovale or P. malariae. These and additional objects of the invention are accomplished by identifying the presence of these proteins associated with the erythrocyte membrane in Plasmodium infected red blood cells or in the case of other species of Plasmodium ( P. vivax, P. ovale or P. malariae ) orthologous sequences based on sequence similarity comparisons using, for example, the computer program BLAST (Altschul SF et al) to identify proteins of similar primary amino acid sequence or genes of similar nucleic acid sequence. The detection of the proteins associated with the erythrocyte membrane is accomplished by the purification of erythrocyte membrane proteins from infected in vitro culture of P. falciparum using an affinity purification system and subjecting these purified proteins to liquid capillary/tandem mass spectrometry or multidimensional protein identification technology (MudPIT) to generate mass spectral patterns. These mass spectral patterns can be used to search computer databases for predicted mass spectral patterns of known or predicted proteins. When potential proteins are identified and represent Plasmodium proteins expressed in association with erythrocyte membrane, they are subjected to further verification of location by protein chemistry and immunological means. These means would include the production of protein-specific antisera in animals by immunization with native or recombinant protein, peptide, nucleic acid, recombinant virus or other means and the use of these antisera in immunolocalization by confocal microscopy, Immunofluorescence antibody testing, immunoelectron microscopy or other methods to localize the protein within or in association with the host cell. We have used these methods to identify two proteins from Plasmodium falciparum which are associated with the infected human erythrocyte. The proteins, designated PfSA1 for Plasmodium falciparum surface antigen 1 and PfSA2 for Plasmodium falciparum surface antigen 2 have been shown to be associated with the P. falciparum erythrocyte membrane but not from uninfected erythrocytes using antisera raised in mice to peptides derived from each protein by immunolocalization using confocal microscopy. We have further shown that these proteins are associated in part at the exterior surface of infected erythrocytes by demonstrating that exposure of whole infected erythrocytes to trypsin and chymotrypsin which digests proteins at the erythrocyte surface but not within the erythrocyte abolishes the reactivity of the mouse antisera to the infected erythrocytes and is further supported with the demonstration that inclusion of inhibitors to trypsin and chymotrypsin can prevent this abolished reactivity.
[0019] It is also a feature and advantage of the inventive subject matter to provide potential new vaccine target antigens that would stimulate an immune response to Plasmodium infected erythrocytes and result in clearance from the body of these parasites, limit the parasite's ability to replicate inside the host and limit the clinical disease caused by the parasite or as the result of the parasite residing in the host and host cells.
[0020] It is also a feature and advantage of the inventive subject matter to identify drugs or small molecules that would associate with or interact with these proteins causing an alteration in the parasite biological function and which would be deleterious to the survival of the parasite inside the host or interrupt the parasite life cycle.
[0021] The foregoing and other features and advantages will become further apparent from the following detailed description of the presently preferred embodiments, when read in conjunction with the accompanying examples and made with reference to the accompanying drawings. It should be understood that the detailed description and examples are illustrative rather than limitative, the scope of the present invention being defined by the appended claims and equivalents thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a cartoon diagram of the purification process of erythrocyte membranes using a combination of biotin and streptavidin and elution with guanidine.
[0023] [0023]FIG. 2 is a figure demonstrating that the methods of purifying erythrocyte membranes are appropriate and will result in the proper identification of proteins previously demonstrated to be associated with the infected erythrocyte membrane.
[0024] [0024]FIG. 3 is a figure demonstrating the specificity of the antisera raised against the PfSA1 and PfSA2 peptides.
[0025] [0025]FIG. 4 is a figure of immunolocalization of PfSA1 and PfSA2 to the surface of P. falciparum -infected erythrocytes by confocal microscopy in two of six strains of P. falciparum tested.
[0026] [0026]FIG. 5 is a figure of immunolocalization of PfSA1 and PfSA2 to the surface of P. falciparum -infected erythrocytes with P. falciparum Malayan Camp tested where the erythrocytes had been previously treated with trypsin and chymotrypsin and in another case where the erythrocytes has been treated with trypsin and chymotrypsin in the presence of an inhibitor of trypsin and chymotrypsin
[0027] [0027]FIG. 6 is a sequence comparison of the protein sequence of PfSA1 from P. falciparum clone 3D7 against the PfSA1 sequences from three additional P. falciparum isolates (MC, R033 and 7G8).
[0028] [0028]FIG. 7 is a sequence comparison of the protein sequence of PfSA2 from P. falciparum clone 3D7 against the PfSA2 sequences from three additional P. falciparum isolates (MC, R033 and 7G8).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] In accordance with the present invention, there is generally provided, two novel Plasmodium falciparum proteins that are expressed in association with infected human erythrocytes and these proteins are present in numerous additional strains of P. falciparum throughout the world. We have used the application of Multidimensional Protein Identification Technology (MudPIT) (Washburn et al) to analyze a mixture comprised of the P. falciparum parasitized red blood cell (PRBC) surface membrane proteins, and the identification and characterization of two novel conserved surface antigens, PfSA1 (SEQ ID NO:1) and PfSA2 (SEQ ID NO:2). In these experiments we first isolated and identified P. falciparum proteins from infected erythrocyte cultures, then raise antisera against peptide sequences from the resulting identified proteins, then confirmed the localization of the proteins near the infected erythrocyte surface, then demonstrated the protein localization on the surface of the infected erythrocytes and then determined the presence of these proteins and their variants in other P. falciparum isolates.
[0030] In a first embodiment, the invention is directed to the production of a vaccine which contains the nucleic acid sequences (SEQ ID NO:3 and SEQ ID NO: 4) or amino acid sequences (SEQ ID NO:1 and SEQ ID NO:2) of either PfSA1 or PfSA2 or both.
[0031] In a second, third and fourth embodiment this vaccine could be a recombinant protein, peptide vaccine, recombinant viral based vaccine or other vaccine delivery mechanism which when delivered by needle, needleless or ballistic injection into the body with or without adjuvants, excipients, carriers via intramuscular, intradermal, subcutaneous, intranasal, oral or other methods is designed to elicit a humoral immune response, cellular immune response or both in the human or animal in which the vaccine was administered.
[0032] In a fifth embodiment of this invention, the vaccine could be a combination of two or more of the above vaccine delivery systems, for example the delivery of three doses of a PfSA1 DNA vaccine followed by a dose of a recombinant adenovirus expressing PfSA1. The immune response against these proteins delivery by any of the means listed above, would result in a decrease in the number of Plasmodium parasites in the body, the viability of Plasmodium parasites in the body and/or the clinical manifestations of Plasmodium parasite infection. The examples of vaccines listed here are illustrative and are not meant to be exclusive.
[0033] In yet a sixth embodiment of this invention is the development of assays to detect Plasmodium parasites within the body. Antibodies are generated which react specifically with the PfSA1 or PfSA2 proteins and which would allow the development of an immunological detection assay. One example of how this would be accomplished would be to use these antibodies, alone or in combination, on biological samples taken from individuals who are suspected of being infected with Plasmodium parasites. These antibodies, for example, could be used in an Enzyme-Linked Immunosorbant Assay (ELISA) to detect the presence of PfSA1 or PfSA2 proteins in sera from patients, or in microscopic examination of blood films to detect parasites using a fluorescence-based readout. These examples are not meant to be comprehensive but only to illustrate potential uses of antibodies against PfSA1 and/or PfSA2.
[0034] A seventh embodiment of this invention is directed to the development of assays to detect Plasmodium parasites within the body based on detection of nucleic acid sequences of PfSA1 and/or PfSA2. An example of this embodiment is the use of oligonucleotide primer sequences selected from the PfSA1 and/or PfSA2 gene sequence that if used in a polymerase chain reaction assay will amplify PfSA1 and/or PfSA2 DNA or cDNA and enable the detection of the parasites by the presence of this specific nucleic acid product by gel electrophoresis, hybridization methods, or other methods known to those of skill in the art.
[0035] An eighth embodiment of this invention is directed to the identification of drugs or small molecules that can be used-as antimalarial compounds. An example of this would be the identification of a small molecule that is predicted to associate with the portion of either the PfSA1 or PfSA2 protein at the erythrocyte surface and interrupt the function of that protein with the result of causing a disruption in the Plasmodium parasite function.
[0036] The following examples are illustrative of preferred embodiments of the invention and are not to be construed as limiting the invention thereto.
EXAMPLE 1
Isolation of Proteins From P. falciparum Parasitized Erythrocytes
[0037] In order to obtain ALL proteins on the surface of parasitized red blood cells (PRBCs), we developed a method to label the intact PRBCs with two non-permeable biotins, Sulfo-NHS-LC-Biotin and PEO maleimide activated Biotin, with binding specificity to lysine and cystine, respectively (FIG. 1). We chose the late trophozoite-early/schizonte stage (30-36 hours post invasion, named late trophozoite stage thereafter) for the labeling because 1) an extensive surface modification was observed at this developmental stage, 2) the PRBC membrane becomes more permeable at the later developmental stage (36-48 hours post invasion, named schizont stage thereafter), which would complicate data interpretation, and 3) though not accurately quantitative, our preliminary data indicated that the cells may shed surface proteins expressed earlier (FIG. 2). After extensive washes to remove the unbound biotin protein, cells were lysed and cell debris was washed again to remove soluble proteins. Subsequently, the cell membrane was dissolved and the dissolved proteins mixture was loaded onto a streptavidin column which retains labeled proteins via biotin. Hence, the mixture eluted from the streptavidin column was enriched with surface proteins and the complexity of the sample subject to MudPIT analysis was greatly reduced. Western blotting analysis using antibodies against known surface antigens was performed to verify the extraction method (FIG. 2). Recognition of PfEMP-1, Rifin, and CD36 by specific antibodies indicates that the method effectively extracted proteins on the surface of the PRBC. The use of late trophozoite for the MudPIT analysis was supported by the observations that 1) more protein is present in the preparation from late trophozoites (30-36h post invasion) than that from the schizonts; and 2) EBA-175, a component of microneme in merozoites expressed in mature schizonts/segments, was detected in schizont stage, indicating the alteration of the membrane permeability in schizont-infected erythrocytes. In addition, CD36 was only labeled by PEO-maleimide activated biotin, suggested the necessity in using two biotins with different specificities.
EXAMPLE 2
Identification of P. falciparum Proteins From the Purified Parasitized Red Cell Preparation
[0038] The biotin-labeled fraction was digested with trypsin and endopeptidase C, and loaded onto biphasic microcapillary columns installed such as to spray directly into a ThermoFinnigan LCQ-Deca ion trap mass spectrometer equipped with a nano LC electrospray ionization source. Fully automated 12□step chromatography runs were carried out. SEQUEST was used to match MS/MS spectra to peptides in a sequence database combining Plasmodium falciparum and mammalian protein sequences (to account for contaminating host proteins). The validity of peptide/spectrum matches was assessed using the SEQUEST□defined parameters cross-correlation score (XCorr), Delta Cn valuer Sp rank and relative ion proportion. DTASelect (Eng, McCormack, et al 1994) was used to select and sort peptide/spectrum matches passing a conservative set of those parameters. Peptide hits from multiple runs were compared using CONTRAST (Eng, McCormack, et al 1994).
[0039] Four surface protein samples, 2 labeled with lysine-specific Sulfo-NHS-biotin and 2 with cystine-specific PEO maleimide-activated biotin, were analyzed by MudPIT. Compiling peptide hits from those 4 independent samples, 623 unique proteins were confidently identified. Among those proteins, 371 were also found in the proteomic study of whole cell lysates from P. falciparum trophozoites-schizonts (Florens, Washburn, et al 2002). Differential analysis of the sequence coverage observed for those common proteins (i.e. number of peptides leading to protein identification) allowed us to distinguish between contaminating abundant trophozoite-schizont proteins and proteins specifically enriched in the biotin-labeled fractions.
[0040] The proteins were selected for further characterization by the following criteria: 1) the presence of the signal peptide as predicted by SignalP; 2) the presence of transmembrane domain(s) as predicted by TAMP; 3) novel proteins whose function had never been characterized before; and 4) sequence conservation within multiple P. falciparum strains or/and cross Plasmodium ssp. More than 30 hypothetical proteins satisfied these criteria. Two proteins, denoted PfSA1 and PfSA2, from the 30 identified were selected for further characterization.
EXAMPLE 3
Bioinformatic Characterization of PfSA1 and PfSA2
[0041] The informatics package contained within a suite of informatics computer programs on the website www.plasmodb.org were used to characterize the selected proteins. Gene model prediction used GlimmerM (Salzberg, Pertea et al. 1999). PfSA1 is a hypothetical acidic protein of 1297 amino acids with theoretical molecular weight (MW) of 154 kDa and isoelectricfocusing point (IP) of 5.14. It is encoded by a single copy gene 3885 nucleotides long, denoted PfC0435w, located on P. falciparum chromosome 3 (nucleotide positions 444174-448058) and has an orthologue in P. knowlesi.
[0042] PfSA2 is a hypothetical protein of 408 amino acids with theoretical MW of 49 kDa and IP 6.67. It is encoded by a single copy two exon gene near the telomeric region of chromosome 5 (nucleotide sequences 64605-64133 and 64332-65489). It does not have discernible orthologues in other organisms (BlastP cut-off E value of 10 −15 ). Both PfSA1 and PfSA2 are highly conserved in multiple strains of P. falciparum from various geographic locations (FIG. 6) suggesting their potential utility in vaccine construction.
EXAMPLE 4
Production of PfSA1- and PfSA2-Specific Antisera.
[0043] Rabbit antisera were raised against synthetic peptides designed based on PfSA1 and PfSA2. The peptide sequence used for PfSA1 is NNSKFSKDGDNEDFNNKNDLYNPSDKLYNN (SEQ ID NO:5). The peptide sequence used for PfSA2 is YEIMHKEDESKESNQHNYKEGPSYEDKKNMYKE (SEQ ID NO:6). Two specific antibodies, denoted 108 and 112, recognized proteins corresponding to the theoretical MW of PfSA1 and PfSA2, respectively, in the whole cell lysate and the biotin-labeled fraction (FIG. 3).
EXAMPLE 5
Localizing the Expression of PfSA1 and PfSA2 to the Erythrocyte Membrane
[0044] To confirm the surface location of the PfSA1 and PfSA2, we labeled the intact PRBC in suspension with purified IgG from antisera 108 and 112, followed by incubation with goat-anti-rabbit and chicken-anti-goat Alexa Fluor 488 as secondary and tertiary antibodies. Ethidium bromide was added to the incubation to stain the nuclei. The cells were allowed to adhere to cover slips pre-coated with polylysine, and examined by confocal microscopy. FIG. 4 demonstrates the localization of both antigens on the surface of PRBC. The antibody labels were abolished by pre-treating PRBCs with trypsin and chymotrypsin, confirming the surface location of the PfSA1 and PfSA2 (FIG. 5).
EXAMPLE 6
Further Characterizaiton of the Localization of PfSA1 and PfSA2 to Substructures on the Surface of PRBC.
[0045] The pattern of the fluorescent label with both anti-PfSA1 and anti-PfSA2 prompted us to investigate whether the antigens were part of the knobs, a protruding structure on the PRBC surface. A knobless P. falciparum strain Malayan Camp was selected for the study. Whereas the strain was verified as knobless by using an anti-KaHRP, a marker for knob structure, both anti-PfSA1 and PfSA2 were localized on the surface of the parasite, indicating the antigens were not associated with the knobs (data not shown). P. falciparum strains Malayan Camp selected for resetting positive (MCR+), and rosetting-negative (MCR−) were also tested for reactivity with anti-PfSA1 and anti-PfSA2. The antigens were present on the surface of both strains, indicating the antigens are unlikely involved in the resetting process. Of all P. falciparum strains (3D7, R29, MCR+, MCR−, MCK−, T996) test for reactivity against anti-PfSA1 and anti-PfSA2, T996 was the only one shown negative toward both antibodies (data not shown). Since PCR with primers used for sequencing PfSA1 and PfSA2 in other P. falciparum strains (see below and FIG. 6) failed to amplify any sequences from the strain T996, it is likely that the genes were deleted form the strain, or it has diverged beyond recognition. This echoes the findings that a segment of chromosome 9 was also deleted from the strain T996 (Wu, unpublished data).
EXAMPLE 7
Characterization of PfSA1 and PfSA2 From Other Strains of P. falciparum Parasites With Diverse World Origins.
[0046] To investigate the sequence conservation of PfSA1 and PfSA2, specific primers were designed to amplify and sequence the antigens from the selected P. falciparum isolates from various geographic location, 7G8 (South America), Malayan Camp (MC) (Southeast Asia), and R033 (Africa). As shown in FIGS. 6 and 7, both proteins are remarkably conserved with other P. falciparum strains, indicating both could be good vaccine candidates with broad specificity.
[0047] This is the first study applying high throughput proteomics approach toward the identification of proteins on the surface of PRBCs. The method is highly efficient because, of two antigens selected for detailed characterization, both were confirmed to be on the surface of PRBCs. Further evaluation on immunogenicity of PfSAl and PfSA2 and efficacy of anti-PfSA1 and anti-PfSA2 will provide insight whether the antigens can be targets for antimalarial vaccines. Our findings also indicate that the surface composition of PRBC is more complex than we thought, as more candidates as result of our in silico analysis awaits to be analyzed and are also likely to be surface proteins. Some of these proteins might be account for the protective immunity, some might mediate cytoadherence, yet some might be channels responsible nutrient uptake.
PROPHETIC EXAMPLE 8
Development of a PfSA1 Malaria Vaccine
[0048] In this example, a DNA vaccine encoding the full length of PfSA1 or PfSA2 is produced under GMP and is delivered in three doses intramuscularly at 5 milligrams per dose at monthly intervals, to be followed by a recombinant adenovirus vaccine which is designed to express PfSA1 or PfSA2 and which is delivered at dose of 10exp11 viral particles intramuscularly one month after the last dose of DNA vaccine. In another example, a recombinant adenovirus vaccine which is designed to express PfSA1 is delivered in two or three doses at one month intervals at a dose of l0expli viral particles per dose intramuscularly. In these examples, these vaccines could be used alone in a population of children living in SubSaharan Africa to reduce the number of circulating Plasmodium infected erythrocytes and would result in a decrease in morbidity and mortality associated with malaria. These vaccines could also be used in combination with other vaccines which are directed against the liver stages of the parasite to limit the risk of developing severe malaria in those individuals where the liver stage vaccines are less than 100% effective.
PROPHETIC EXAMPLE 9
Development of a Rapid Assay to Detect Plasmodium Infection in Humans
[0049] In this example, polyclonal or monoclonal antibodies raised against polypeptide sequences from PfSA1 or PfSA2 can be used in an immunologic based assay to detect circulating PfSA1 and/or PfSA2 in serum, or to assist in the identification of parasite-infected erythrocytes in blood smears from patients suspected of being infected with Plasmodium. In these examples, the readout could be an enzyme linked immunosorbant assay, a fluorescence-based assay or a calorimetric based assay, though other means of assessing the detection of parasites using these antibodies may also be employed.
PROPHETIC EXAMPLE 10
Method for the Detection of Additional Plasmodium Proteins From the Surface of Plasmodium -Infected Erythrocytes
[0050] In this example, additional Plasmodium proteins that are located on the surface of infected erythrocytes are detected by a similar means as described above. These proteins would represent novel proteins for vaccine development as their location on the surface of infected-erythrocytes predicts that they will encounter cells of the immune system which will respond with the production of a humoral and/or cellular immune response against erythrocyte infected with Plasmodium. These additional proteins and the gene sequences encoding for these proteins can be used as vaccines delivered by DNA vaccine, recombinant protein, recombinant viral vaccine or other vaccine delivery systems.
PROPHETIC EXAMPLE 11
Development of a PfSA1 or PfSA2 recombinant protein malaria vaccine In this example, the DNA sequence of PfSA1 or PfSA2 is cloned into a bacterial expression system and a purified recombinant PfSA1 or PfSA2 protein is purified under cGMP and delivered at a dose of 50 micrograms intramuscularly at one month intervals for three months. In this example, antibodies against the PfSA1 or PfSA2 proteins will be produced will react with these proteins on the surface of the infected erythrocyte and result in the elimination of the infected erythrocyte from the circulation.
References
[0051] Altschul S F, Gish W, Miller W, Myers E W, Lipman D J. Basic local alignment search tool. J Mol Biol Oct. 5, 1990;215(3):403-10
[0052] Chen, Q., V. Fernandez, et al. (1998). “Developmental selection of var gene expression in Plasmoodium falciparum.” Nature 394(6691): 392-5.
[0053] Eng, J. K., A. L. McCormack, et al. (1994). “An approach to correlate tandem mass spectral data of peptides with amino acid sequences in a protein database.” Journal of the American Society for Mass Spectrometry 5: 976-989.
[0054] Fernaders (1998). J Exp Med 190: 1393-1404.
[0055] Florens, L., M. P. Washburn, et al. (2002). “A proteomic view of the Plasmodium falciparum life cycle.” Nature 419(6906): 520-6.
[0056] Hollingdale, M. R., C. J. McCormick, et al. (1998). “Biology of malarial liver stages: implications for vaccine design.” Ann. Trop. Med. Parasitol. 92: 411-417.
[0057] Howard (1988). Prog. Allergy 41: 98-147.
[0058] Kyes (1999). Proc natl Acad Sci USA 96: 9333-9338.
[0059] McGregor (1963). Trans. R. Soc. Tropo. Med. Hyg 57: 170-175.
[0060] McGregor and Wilson (1988). Principles and Practices of Malaria. Malaria. Wensdorfer.
[0061] Mohan, B. N. and Stevenson (1998). Pathogenesis and Protection. Malaria Parasite Biology. Sherman.
[0062] Preiser, P., M. Kaviratne, et al. (2000). “The apical organelles of malaria merozoites: host cell selection, invasion, host immunity and immune evasion.” Microbes Infect 2(12): 1461-77.
[0063] Richie, T. L. and A. Saul (2002). “Progress and challenges for malaria vaccines.” Nature 415(6872): 694-701.
[0064] Salzberg, S. L., M. Pertea, et al. (1999). “Interpolated Markov models for eukaryotic gene finding.” Genomics 59(1): 24-31.
[0065] Washburn, M. P., D. Wolters, et al. ( 2001). “Large-Scale Analysis of the Yeast Proteome via Multidimensional Protein Identification Technology.” Nat Biotechnol.
[0066] The inventive subject matter being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the inventive subject matter, and all such modifications are intended to be within the scope of the following claims.
1
6
1
1294
PRT
Plasmodium Falciparum
1
Met Lys Val Gly Ile Ile Phe Phe Cys Leu Phe Phe Phe Val Val Leu
1 5 10 15
Gly Ala Cys Asn Asn Val Lys Glu Arg Ile Phe Lys Asn Ile Lys Lys
20 25 30
Arg Thr Lys Phe Ile Ile Leu Asn Glu Pro Ile Val Asp Leu Ser Phe
35 40 45
Ser Glu Asn Leu Phe His Thr Leu Leu Phe Asp Leu Asp Val Asp Lys
50 55 60
Asn Leu Tyr Thr Leu Asp Glu Ser Leu Leu Asn Leu Glu Asn Leu Asn
65 70 75 80
Tyr Ser Ser Ile Phe Arg Leu Leu Val Asp Thr Tyr Lys Asn Ile Lys
85 90 95
Glu Asn Glu Asp Asp Asn Lys Asn Ile Arg Tyr Ile Phe Leu Gly Thr
100 105 110
Ser Phe Ser Arg Ile His Pro Leu Asn Phe Glu Tyr Phe Leu Arg Lys
115 120 125
Leu Asn Lys Tyr Ile Tyr Asn Gly Asn Ile Tyr Glu Lys Gly Asn Val
130 135 140
Asp Ile Arg Gly Ile Leu Glu Glu Tyr Asn Lys Glu Ile Glu Glu Lys
145 150 155 160
Lys Leu Glu Lys Gln Lys Leu Asn Lys Ile Lys Asp Lys Asn Asn Asn
165 170 175
Asn Asn Asn Asn Asn Asn Ser Lys Phe Ser Lys Asp Gly Asp Asn Glu
180 185 190
Asp Phe Asn Asn Lys Asn Asp Leu Tyr Asn Pro Ser Asp Lys Leu Tyr
195 200 205
Asn Asn Asn Asp Asp Ile Asp Val His Glu Leu Leu Glu Glu Ile Ile
210 215 220
Thr Lys Glu Lys Arg Phe Phe Leu Asn Asp Asp Asp Asp Asn Asp Ser
225 230 235 240
Asn Asp Lys Tyr Ile Leu Lys Thr Asp Glu Val Asn Lys Tyr Lys Gly
245 250 255
Phe Phe Ile Gly Tyr Gly Phe Asn Asp Asp Ile Pro Ser Val Ile His
260 265 270
His Tyr Asn Phe Asp Lys Asn Phe Leu Phe Pro Ser Leu Asn Ser Gly
275 280 285
Ile Ile Leu Asp Ile Thr Leu Leu Lys Asn Ile Tyr Glu Val Ser Asn
290 295 300
Ile Leu Leu Ser Asn Asn Glu Lys Asp Gln Ser Ile His Ile Asp Tyr
305 310 315 320
Ile Tyr Glu Val Thr Lys Tyr Ile Lys Glu Asn Leu Arg Val Arg Leu
325 330 335
Thr His Ser Glu Asn Val Cys Leu Asn Glu Glu Gln Asn Ile His Leu
340 345 350
Leu Asp Asn Asp Pro Asn Asn Phe Glu Ile Tyr Lys Tyr Tyr Gln Val
355 360 365
Leu Asn Leu Phe Lys Asp Tyr Asn Lys Asn Thr Glu Glu Lys Gln Tyr
370 375 380
Glu Lys Ile Gly His Glu Asn Val Arg His Glu Glu Thr Ser Ser Glu
385 390 395 400
Gly Asn Glu Asn Leu Asn Arg Asn Thr Lys His Asn Asn Asp Asn Asn
405 410 415
Asn Asp Asn Asn Asn Tyr Ser Glu Asp Ala Ile Ala Glu Leu Leu Leu
420 425 430
Ser Tyr Phe Asn Val Phe Tyr Pro Ile Ser Thr Cys Met Cys Tyr Ser
435 440 445
Ile Arg Ser Lys His Glu Ser Leu Met Asp Tyr Asp Lys Tyr His Met
450 455 460
Ile Asn Leu Glu Asn Asp Ile Lys Leu Lys His Tyr Ile Lys Glu Thr
465 470 475 480
Glu Glu Ile His Phe Asn Ser Ile Glu Glu Tyr Lys Met Lys Leu Asn
485 490 495
Arg Ile Asn Tyr Lys Tyr Asp Thr Leu Leu Glu Glu His Glu Asn Leu
500 505 510
Val Thr His Lys Asn Ile Leu Ile Gly Ile Lys Thr Ser Ile Asn Thr
515 520 525
Glu Glu Glu Arg Ile Pro His Ile Lys Asn Thr Tyr Asp Asn Lys Glu
530 535 540
Asn Thr Gln Ile Ile Phe Asn Thr Phe Asn Tyr Asp Asn Lys Leu Lys
545 550 555 560
Glu Lys Asn Thr Phe Gly Phe Tyr Asn Asn Ser Leu Leu Gln Asn Ala
565 570 575
Leu Glu Asn Asp Asn Ile Asp Leu Asp Ile Ile Tyr Met Ser Asp Lys
580 585 590
Glu Ser Gln Lys Tyr Asp Asn Leu Tyr Phe Asn Ser Lys Val Thr Ser
595 600 605
Lys Glu Gly Leu Cys Glu Lys Leu Lys His Met Ile Tyr Tyr Tyr Tyr
610 615 620
Glu Glu Tyr Val Met Lys Asn Ser Glu Lys Lys Tyr Phe Phe Ile Ala
625 630 635 640
Asp Asp Asp Thr Phe Val Asn Val Lys Asn Leu Ile Asp Val Thr Asn
645 650 655
Leu Thr Leu Asn Thr Cys Ser His Ser Lys Lys Tyr Met Tyr Asp Lys
660 665 670
Tyr Ile Lys Ser Tyr Asp Phe Val Lys Glu Asn Glu Ala Leu Phe Leu
675 680 685
Gln Asn Phe Pro Lys Lys Thr Leu Phe Leu Tyr Ser Tyr Leu Lys Asp
690 695 700
Thr Phe Ala Lys Thr Ile Gln Thr Leu Lys Lys Tyr Asp Tyr Val Pro
705 710 715 720
Lys Tyr Cys Gln Gly Gly Ile Leu Ser Lys Lys His Lys Asn Asn Asp
725 730 735
Ser Asp Asp Asp His Asp His His Val Gly Asn Lys Gln Asn Asn Asp
740 745 750
Ser Thr Asn His Gln Asp Ile Glu Lys Asn Gln Val Asn Val Ile Asn
755 760 765
Asn Asn Asn Asn Asn Asn Asn Asn Lys Ala Lys Ser Ile Pro Ile Tyr
770 775 780
Leu Gly Arg Arg Tyr Ser Tyr Asn Thr Phe Ser Thr Asn Ser Asn Glu
785 790 795 800
Tyr Phe Tyr Asp Tyr Leu Thr Gly Gly Ala Gly Ile Leu Ile Asn Asp
805 810 815
Glu Thr Ala Lys Arg Ile Tyr Glu Cys Lys Glu Cys Thr Cys Pro Ser
820 825 830
Thr Asn Ser Ser Met Asp Asp Met Ile Phe Gly Lys Trp Ala Lys Glu
835 840 845
Leu Gly Ile Leu Ala Ile Asn Phe Glu Gly Tyr Phe Gln Asn Ser Pro
850 855 860
Leu Asp Tyr Asn Lys Lys Tyr Ile Asn Thr Leu Val Pro Ile Thr Tyr
865 870 875 880
His Arg Leu Asn Lys Asn Arg Thr Thr Lys Glu Ser Arg Asp Met Tyr
885 890 895
Phe Asn Tyr Leu Val Asn Tyr Asn Arg Asn Asp Lys Glu Gln Asn Lys
900 905 910
Asp Ile Tyr Val Asp Tyr Leu Asp Arg Asn His Lys Asn Met Ile Asp
915 920 925
Asn Val Phe His Tyr Phe Phe Tyr Val Asn Met Tyr Asp Glu Lys Asn
930 935 940
Lys Val Val Thr Lys Ile Glu His Asn Ala Asp Met Asn Ser Lys Lys
945 950 955 960
Asn Lys Ser Lys Asn Pro Gln Lys Leu Asn Asn Thr Gln Gly Asp Lys
965 970 975
Asn Val Asn Asp Asp Glu Asn Val Asn Asp Asp Glu Asn Val Lys Gly
980 985 990
Asp Glu Asn Val Lys Gly Asp Glu Asn Val Lys Gly Asp Glu Tyr Met
995 1000 1005
Lys Gly Asp Glu Asn Val Lys Gly Asp Glu Asn Val Lys Asp Asp
1010 1015 1020
Glu Asn Val Lys Asp Asp Glu Asn Ile Lys Gly Asp Asp Asn Asn
1025 1030 1035
Tyr Asn Val Asp Asn Met Glu Asn Ile Asp Asp Ile Ile Asn Met
1040 1045 1050
Val Glu Ser Val Asp Asp Asp Val Met Glu Arg Asn Lys Lys Gly
1055 1060 1065
Thr Gly Lys Glu Lys Lys Asp Asp Lys Asn His Asn Asn Lys Glu
1070 1075 1080
Lys Ala Thr Asp Val Lys Lys Ser Ser Val Pro Thr Asn Asn Ile
1085 1090 1095
Asp Lys Asn Glu Asp Thr Thr Lys Tyr Val Ile Lys Met Asn Glu
1100 1105 1110
Lys Ile Tyr Asn Arg Met Gln Glu Ser Gly Lys Tyr Lys Gln Leu
1115 1120 1125
Phe Asp Ile Asn Lys Phe Phe Lys Lys Glu Ile Glu Gly His Pro
1130 1135 1140
Tyr Phe Gln Lys Ile Lys Lys Lys Asn Glu Lys Ala Lys Lys Glu
1145 1150 1155
Lys Glu Lys Met Asn Gln Leu Lys Lys Gln Lys Asp Tyr Thr Asn
1160 1165 1170
Asn Tyr Phe His Thr Ser Asn Met Gln Gly Asn Phe Asn Gln Gln
1175 1180 1185
Lys Met Gly Asn Tyr Gln Asn Gln Glu Asn Glu Glu Asn Asp Phe
1190 1195 1200
Phe Asp Gln Arg Pro Glu Ile Glu Glu Asp Ala Ile Asn Pro Met
1205 1210 1215
Asp Tyr Glu Glu Tyr Met Glu Asn Leu Ser Asn Phe Glu Asp Asp
1220 1225 1230
Gly Glu Pro Tyr Asp Glu Tyr Asp Asp Tyr Asp Asp Phe Val Asn
1235 1240 1245
Thr Ile Asn Ala Asp Lys Leu Lys Ile Asn Asp Gln Asn Lys His
1250 1255 1260
Leu Tyr Glu Gln Ile Lys Asp Ile Ala Gln Pro Pro Val Asn Phe
1265 1270 1275
Gln Asn Asp Gln Asn Ser Asn Thr Phe Asp Phe Asp Thr Asp Glu
1280 1285 1290
Leu
2
408
PRT
Plasmodium Falciparum
2
Met Leu Leu Phe Phe Ala Lys Leu Val Val Phe Thr Phe Phe Phe Trp
1 5 10 15
Leu Leu Lys Tyr Gly Lys Thr Arg Ser Tyr Pro Lys Ser Gly His Lys
20 25 30
Gly His Thr Lys Leu Asn Gln Pro Val Val Arg Thr Leu Ala Asp Phe
35 40 45
Asn Asp Met Phe Ala Asn Gln Lys Asn Thr Phe Asn Phe Leu Lys His
50 55 60
Ile Asn His Tyr Lys Asn Glu Gln Asp Thr Asn Asn Thr His Thr Pro
65 70 75 80
Asn His Asp Glu Tyr Ser His Asn Leu Pro Lys Asn His Glu Glu Ser
85 90 95
Asn Ala Asn Met Asn Asn His Asn Ser Phe Asn Asp Lys Ser Val Asn
100 105 110
Lys Lys Glu Ala Phe Asp Gln Phe Leu Gln Thr Leu Leu Asn Asn Tyr
115 120 125
Glu Ile Met His Lys Glu Asp Glu Ser Lys Glu Ser Asn Gln His Asn
130 135 140
Tyr Lys Glu Gly Pro Ser Tyr Glu Asp Lys Lys Asn Met Tyr Lys Glu
145 150 155 160
Ile Leu Lys Gly Tyr Tyr Asn Val Phe Phe Glu Asn Tyr Ala Asn Asp
165 170 175
Thr Glu Ser Asn Val His Asn Lys Pro Glu Glu Val His Lys His Glu
180 185 190
Glu Ile His Lys His Arg Lys Leu His Lys His Glu Glu Val His Lys
195 200 205
Pro Glu Glu Phe His Lys Pro Glu Glu Phe His Lys His Glu Lys Val
210 215 220
His Lys His Glu Glu Val His Lys Pro Glu Glu Val His Lys His Glu
225 230 235 240
Glu Asn His Lys His Glu Glu Asn His Lys Pro Gln Met Val Gly Gln
245 250 255
Ala Pro Pro Glu Lys Glu Ile Arg Gln Glu Ser Arg Thr Leu Ile Leu
260 265 270
Gly Ser Phe Pro Gln Ala Gly Glu Ile Leu Arg Glu Asp Leu Trp Asn
275 280 285
Lys Glu Asp Asn Lys Phe Ser Tyr Ala Leu Asp Pro Asn Asp Tyr Ala
290 295 300
Ser Ile Glu Asp Lys Leu Leu Gly Ser Ile Phe Gly Tyr Phe Lys Lys
305 310 315 320
Asn His Asp Asn Leu Val Lys His Leu Leu Gln Gln Ile Asn Thr Tyr
325 330 335
Lys His Lys Tyr Met Glu Leu Lys Glu Gln Tyr Ile Asn Glu Val Met
340 345 350
Lys Leu Lys Lys Ile Tyr Asn Lys Ser Ile Met Val Ile Phe Ile Ala
355 360 365
Ser Cys Ile Ser Ile Leu Gly Pro Val Met Leu His Met His Gln Asn
370 375 380
Asn Pro Glu Glu Phe Phe Ala Thr Ile Leu Ser Phe Ser Ile Ser Leu
385 390 395 400
Gly Leu His Asn Leu Leu Leu Thr
405
3
3885
DNA
Plasmodium Falciparum
3
atgaaggttg gaattatatt tttttgttta tttttttttg tggttcttgg agcgtgtaac 60
aatgtgaagg aaaggatttt taagaatatt aaaaaaagaa ccaaatttat tatattgaat 120
gagcccatag tagatttaag ttttagtgag aatttatttc atactttatt atttgattta 180
gatgtagata agaatttata tacattggat gagagtttat taaatcttga gaacttgaat 240
tattcctcaa tatttcgttt acttgttgat acctataaga atataaaaga aaatgaagat 300
gataataaaa atattcgata tatattttta ggtacatcgt tttcacgtat tcatccctta 360
aattttgaat attttttgag aaagctgaac aaatatatat ataatgggaa catatatgaa 420
aagggtaatg tggatatcag aggaatattg gaagaatata ataaggagat tgaagagaag 480
aagctagaaa aacaaaaact gaacaagatc aaagataaga ataataataa taataataat 540
aataatagta aattttctaa agatggtgat aatgaagact ttaataataa gaatgatttg 600
tacaatccat cggataaatt atacaataat aatgatgata tcgatgtaca tgaactatta 660
gaagagatta ttacaaaaga aaaaaggttt ttcttaaacg atgatgatga taatgatagt 720
aatgataaat atatattaaa aactgacgag gttaataaat ataaaggatt ttttatagga 780
tatggtttta atgatgatat accatcagta attcatcatt ataattttga taagaacttt 840
ttatttcctt ctttaaatag tggtattata ttagatataa cattattaaa aaatatatat 900
gaagtttcta atatattatt atcgaataat gaaaaggatc aatctattca tatagattat 960
atttatgaag ttacaaaata tataaaagaa aatttaagag tacgtttaac acattccgaa 1020
aatgtatgtt taaacgaaga acaaaatatt catttattag ataatgatcc taataatttc 1080
gaaatatata aatattatca agtgctgaac ttatttaaag attataataa gaatacagaa 1140
gaaaagcaat atgaaaaaat tggccatgaa aatgttagac atgaagaaac atcatctgaa 1200
ggtaatgaaa accttaatag aaataccaaa cataataatg ataataataa tgataataat 1260
aattatagtg aagatgcgat tgccgaatta cttctctcct attttaatgt gttctatcca 1320
atatctacat gtatgtgcta ttcaataaga tcaaaacatg aatccctaat ggattatgat 1380
aaatatcata tgatcaattt agaaaacgat ataaaattaa aacattatat aaaagaaaca 1440
gaagaaatac attttaatag tattgaagaa tataaaatga aacttaatcg tattaattat 1500
aaatatgata ctttattaga agaacatgaa aatttagtaa cacataaaaa tatactcata 1560
ggtataaaaa caagtataaa tacagaagaa gaaagaattc cacatattaa aaatacatat 1620
gataataaag aaaatacaca aataatattc aatacattca actatgataa taaattaaaa 1680
gaaaaaaata catttggatt ttataataat tcccttttac aaaatgcttt agaaaatgat 1740
aatatagatt tagatattat ctatatgtct gataaggaaa gccaaaaata tgataattta 1800
tattttaatt ctaaagtaac atcaaaagaa ggcttatgtg aaaaattaaa acatatgata 1860
tattattatt atgaagaata tgttatgaaa aattcagaaa aaaaatattt ctttattgca 1920
gatgatgata cttttgttaa tgtaaaaaat ttaatagatg taacaaattt aacattaaat 1980
acttgttcac attctaaaaa atatatgtat gataaatata tcaaatctta tgattttgtt 2040
aaagaaaatg aagccttatt tcttcaaaat tttccaaaaa aaactttatt tctttattcc 2100
tatttgaaag atacctttgc caaaactata caaaccttga agaaatatga ctatgttcct 2160
aaatattgtc agggtggtat cctatcaaaa aaacataaaa ataatgatag tgatgatgat 2220
catgatcatc acgtgggtaa taaacaaaat aatgatagta cgaatcatca agatattgaa 2280
aaaaatcaag taaatgtaat aaataataat aataataata ataataataa agcaaaatcc 2340
atacctatat acttaggaag aagatattca tataatacat tttctacaaa ttcaaatgaa 2400
tatttttatg attatttaac tggaggtgct ggtattttaa ttaatgatga aacagctaaa 2460
cgaatatatg aatgcaaaga atgcacatgc ccatcaacaa attcctcaat ggatgatatg 2520
atatttggga aatgggctaa agaattagga attttagcca taaactttga aggatatttt 2580
caaaactccc cacttgatta taacaaaaaa tatattaata ctcttgtacc tattacatat 2640
catagattaa ataaaaatag aacaaccaaa gaatcaagag atatgtattt taattatcta 2700
gtaaattata atagaaatga taaagaacaa aataaagaca tatatgttga ttatctagat 2760
agaaatcata aaaatatgat agataatgta ttccattact ttttttatgt aaatatgtat 2820
gatgaaaaaa ataaagtcgt caccaaaatt gagcacaatg ctgatatgaa cagtaaaaag 2880
aataaatcaa agaacccaca aaaattaaat aatactcaag gggacaaaaa tgtaaatgat 2940
gatgaaaatg taaatgatga tgaaaatgtg aaaggtgatg aaaatgtgaa aggtgatgaa 3000
aatgtgaaag gtgatgaata tatgaaaggt gatgaaaatg tgaaaggtga tgaaaatgtg 3060
aaagatgatg aaaatgtgaa agatgatgaa aatataaaag gtgatgataa taattacaat 3120
gtggataata tggaaaacat agatgatatt attaatatgg ttgaaagcgt tgatgatgat 3180
gttatggaac gtaacaaaaa aggaacgggt aaagaaaaaa aggatgataa gaatcataat 3240
aataaagaaa aagctaccga tgtgaaaaaa tcaagtgtac ctactaataa tatagataaa 3300
aatgaagaca ctacaaaata tgtcataaaa atgaatgaaa aaatttataa tagaatgcaa 3360
gaaagtggta aatacaaaca attattcgat ataaataaat ttttcaaaaa agaaatcgaa 3420
ggacatcctt attttcaaaa aataaaaaaa aagaatgaaa aggccaaaaa agaaaaagaa 3480
aaaatgaatc aattaaaaaa acaaaaggat tatacaaata attatttcca tacatcaaat 3540
atgcagggaa attttaatca acaaaaaatg ggaaactatc aaaatcaaga gaatgaagaa 3600
aatgattttt ttgatcaacg tcctgaaata gaagaagatg caattaatcc aatggattat 3660
gaagaatata tggaaaattt atcaaatttt gaagatgatg gcgaaccata tgacgaatat 3720
gatgattatg atgatttcgt aaatacaatt aatgcagata aattaaaaat taatgatcaa 3780
aataaacact tatatgaaca aatcaaagat atagcgcaac cacctgttaa tttccaaaat 3840
gatcaaaatt caaatacttt tgattttgac acagatgagt tgtaa 3885
4
1120
DNA
Plasmodium Falciparum
4
atgttactct tttttgcaaa acttgtcgta tttacctttt tcttttggct tttaaaatat 60
gggaaaacga ggtcatatcc caaatctggc cataagggac atacgaaatt aaatcaacca 120
gtagttagaa cattagcaga ttttaatgac atgtttgcaa accaaaaaaa tacatttaat 180
tttctaaaac atataaatca ttataaaaat gaacaagata caaataatac acacacgcca 240
aatcatgatg aatattctca taatttgcca aaaaatcacg aagagtcaaa tgcaaatatg 300
aacaatcata attctttcaa tgacaaatct gttaataaaa aagaagcttt cgatcaattt 360
ttacaaacgt tattaaacaa ttatgaaata atgcataaag aagatgaaag taaagaatca 420
aatcaacata actataaaga aggtccctca tatgaagata aaaaaaatat gtacaaagaa 480
atattgaaag gatattataa tgtatttttt gaaaattatg caaacgacac agaatcaaat 540
gtacataata aacctgagga agttcataaa catgaggaaa ttcataaaca taggaaactt 600
cataaacatg aagaagttca taaacctgag gaatttcata aacctgagga atttcataaa 660
catgagaaag ttcataaaca tgaagaagtt cataaacctg aggaagttca taaacatgag 720
gaaaatcata aacatgagga aaatcataaa cctcaaatgg taggtcaagc acctccagaa 780
aaagagatac gccaagaatc aagaactcta atacttggtt catttcccca agcaggtgaa 840
atattaagag aggatttatg gaacaaagag gataacaaat ttagttacgc acttgaccct 900
aatgattatg catctataga agataaactt ttaggatcta tatttggata ctttaaaaaa 960
aatcatgaca atttggttaa acatttgtta caacaaatta atacttacaa acataaatat 1020
atggaactta aagaacaata tattaatgaa gttatgaaac ttaaaaaaat atataacaaa 1080
agcatcatgg tcatatttat agcatcttgt atttcaatat 1120
5
30
PRT
Plasmodium Falciparum
5
Asn Asn Ser Lys Phe Ser Lys Asp Gly Asp Asn Glu Asp Phe Asn Asn
1 5 10 15
Lys Asn Asp Leu Tyr Asn Pro Ser Asp Lys Leu Tyr Asn Asn
20 25 30
6
33
PRT
Plasmodium Falciparum
6
Tyr Glu Ile Met His Lys Glu Asp Glu Ser Lys Glu Ser Asn Gln His
1 5 10 15
Asn Tyr Lys Glu Gly Pro Ser Tyr Glu Asp Lys Lys Asn Met Tyr Lys
20 25 30
Glu
|
Two proteins and their use as substrates for vaccines intended to initiate an immune response in a mammalian subject against infection with species of Plasmodium for use in the diagnosis of Plasmodium infection and for their use in the development of antimalarial drugs. This invention also relates to the diagnostic, isolation and purification assays based on these Plasmodium proteins. This invention further relates to immunological reagents, specifically antibodies directed against these Plasmodium proteins.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to one-way drive, overrunning clutch mechanisms, and more particularly to an improved lightweight, one-way clutch of simplified construction and high torque transmitting capability which is especially well adapted for high speed operation.
2. Description of the Prior Art
One-way drive overrunning clutch mechanisms, hereinafter generally referred to as clutches, or as overrunning clutches, are well known and widely used in a variety of applications ranging from low speed devices such as bicycle drives to high speed mechanisms such as automotive transmissions and torque converters. Commercial clutches employed in high speed automotive transmissions have in the past generally been of the sprag-type or the roller-ramp type, both of which depend on a wedging action to lock up, or to transmit torque between the driving and driven members of the clutch. The wedging action of these clutches produces extremely high stresses in component parts, and the clutches are relatively heavy and expensive to manufacture. Such clutches generally are considered the weakest link in an automatic transmission.
Clutches are also known which employ rigid struts positioned between the driving and driven clutch members, or clutch plates, for pivotal movement between a driving position engaging shoulders defined by notches in the driving and driven clutch plates to transmit torque therebetween upon relative rotation in one direction and to permit overrunning, or free wheeling, upon relative rotation in the opposite direction. Clutches of this type are disclosed, for example, in U.S. Pat. Nos. 5,070,978 and 5,449,057.
In the typical strut-type clutch, the individual struts are mounted for pivotal movement between a driving position in which opposed ends, or opposed edges of at least one strut engages a shoulder formed by notches in closely spaced, opposed faces of the driving and driven clutch plates upon rotation of the driving member in one direction and a retracted position in which the struts are out of engagement with at least one of the clutch plates when the driving member is rotated in the opposite direction relative to the driven member. The struts may be pivotally mounted on a carrier disposed between the clutch faces as in U.S. Pat. No. 5,449,057, but in most commercial drives of this type, the struts are carried in a pocket in one clutch plate face with one end or edge continuously contacting a shoulder defined by the pockets. Whether supported by a carrier or mounted in a pocket in one of the clutch faces, the individual struts are continuously urged to a position to engage both clutch faces by a resilient member, typically a spring, to thereby lock the two clutch plates together upon rotation of the drive member relative to the driven member in one direction. Upon relative rotation in the opposite, or overrunning direction, the spring members continue to urge the struts into contact with the clutch faces and tend to urge the struts into each of the pockets as they are rotated, with the shape of the pockets camming the struts back as rotation continues.
As suggested in the above-mentioned U.S. Pat. No. 5,449,057, the previous overrunning clutches used in high speed transmission mechanisms have required a continuous supply of lubrication to assure that the struts, sprags, or rollers are continuously coated to minimize wear, particularly when the clutch is operated in the overrunning mode. When such clutches are employed in mechanisms such as automatic transmissions containing a reservoir of lubricant which is continuously splashed throughout the interior of the mechanism by the various rotating components, this more or less random distribution of lubricant has been relied upon to lubricate the clutches. It has been discovered, however, that such systems do not always provide adequate lubrication to minimize wear and to enable the most efficient operation, especially in the overrunning mode.
It has been shown that pivotal movement of the struts of strut-type clutches can be effectively damped at high speeds by maintaining the struts submerged in a bath of lubricating oil so that they remain essentially stationary in the overrunning mode. This substantially eliminates rapid depression and expansion of the resilient spring members engaging each strut as the strut passes over the respective recesses in the adjacent clutch face and thereby greatly increases the spring life by effectively eliminating fatigue failures. Further, by maintaining the struts substantially fully submerged in a bath of lubricating oil during all high speed operations, direct metal-to-metal contact between the struts and clutch faces is avoided by the continuous coating of lubricant.
The above-mentioned U.S. Pat. No. 5,070,978 discloses the concept of providing a housing, with seals between the housing and input shaft, to enclose the clutch plates. The sealed housing is filled with oil to assure continuous lubrication to "float" the two opposed clutch plates away from one another during free wheeling or overrunning. This patent also seems to recognize, at column 8, lines 10-12, that filling the housing with oil may have an effect on strut movement during overrunning at high speed, although the patent also states that the struts "hardly move at all" at high speeds even without filling the housing with oil. The housing comprises a generally cup-shaped, output shell having an open end which is closed by a threaded closure plate. The use of a separate housing and threaded closure greatly increases the cost of the clutch, and presents the potential for failure in the event of the threading connector becoming loose during prolonged use. Further, no provision is made for replenishing the oil supply in the event of seal failure, thereby presenting the potential for excessive wear, overheating and eventual failure of the clutch in the event of oil escaping from the sealed housing. The sealed housing would act as a shield effectively preventing splashed oil from reaching the struts in the event of seal failures. Further, the separate housing and threaded closure greatly increases the overall weight and size of the clutch assembly.
Accordingly, it is an object of the present invention to provide an improved lightweight strut-type overrunning clutch assembly having improved means for assuring continuous lubrication for the clutch components.
Another object is to provide such a clutch assembly which assures that the movable struts are continuously submerged in a reservoir of oil during high speed operation regardless of the attitude of the mechanism in which the clutch is used.
Another object is to provide such a clutch assembly having an improved lightweight retaining means retaining the clutch plates in assembled relation and providing an oil-tight joint with one of the clutch members and serving as a weir or dam to retain a reservoir of oil under pressure from centrifugal force between the clutch plates and enveloping the struts and spring members during high speed operation.
Another object is to provide such a clutch assembly including means for providing a continuous flow of oil through the clutch assembly during operation.
Another object is to provide such a clutch assembly which is less expensive to manufacture and which is highly reliable in operation.
SUMMARY OF THE INVENTION
The foregoing and other objects and advantages are achieved in accordance with the present invention in which a plurality of rigid struts are disposed between adjacent, opposed, relatively rotatable faces on a pair of clutch plates for pivotal movement between an engaged position in which at least one strut is rotated to a position engaging a shoulder on both clutch faces to thereby interlock the two clutch plates for rotation together about a common axis in one direction, and a disengage or overrunning position permitting free relative rotation of the clutch plates in the opposite direction. The first clutch plate has an axially extending outer rim portion and a radially inwardly extending integrally formed body portion at one end of the outer rim portion. The second clutch plate also has a substantially radially extending body portion having an outer periphery telescopingly received in the axially extending rim portion of the first clutch plate and preferably has an integrally formed axially extending inner hub telescopingly received in the inner periphery of the first clutch plate with the first and second clutch plates cooperating to define a cavity therebetween. A plurality of struts are mounted in the cavity between the first and second clutch plates for pivotal movement between the engaged or driving position and a disengaged or overrunning position. In the preferred embodiment of the invention, the clutch faces are generally flat parallel annular clutch surfaces similar to the arrangement shown in the above-mentioned U.S. Pat. No. 5,070,978 and in FIGS. 15-27 of copending application Ser. No. 08/382,070, now U.S. Pat. No. 5,597,057.
In the preferred embodiments, the annular rim on the first clutch plate extends axially beyond the body portion of the second clutch plate, and an inwardly directed annular groove is formed in the outer rim portion of the first clutch plate at a location outboard of but immediately adjacent to the body portion of the second clutch plate member. An annular retainer is rigidly fixed in the annular groove and overlying the surface of the second clutch plate to firmly retain the first and second clutch plates in assembled relation. The retainer preferably is initially formed as a continuous annular ring of metal which has a body portion shaped into a generally frustoconical or Belleville washer configuration, and which is then press formed into a substantially flat, planar configuration to expand its outer periphery into the annular groove and to overlie and engage the radially extending body portion of the second clutch plate.
The annular groove and the outer peripheral portion of the retainer are dimensioned such that, upon installing the retainer, the groove engages and swages the retainer edge to conform to the groove geometry and form a fluid tight seal. The inner periphery of the retainer extends radially inward to a location at least substantially equal to the location of the radial innermost part of the rigid struts but outboard of the inner periphery of the body portion of the outer clutch plate. The radially inwardly extending body portion and the outer rim portion of the first clutch plate member and the retainer cooperate to form a generally toroidal, inwardly open enclosure or annular trough surrounding the cavity between the two clutch plates and the outer peripheral portion of the second clutch plate.
An oil supply passage is provided to deliver lubricating oil into the cavity between the opposed clutch faces to provide lubrication for the component parts and to essentially fill the cavity between the clutch faces. Upon rotation of the clutch, centrifugal force acting on the lubricating oil will retain the oil in the toroidal space; thus, as soon as this space is filled with lubricating oil, it will remain filled and under pressure for so long as the clutch continues to rotate at a speed sufficient for the centrifugal force to overcome the force of gravity, regardless of the orientation of the clutch.
centrifugal force will cause the oil to flow between the outer periphery of the second clutch plate body portion and the first clutch plate rim portion, then along the retainer to flow over the edge of the retainer which acts as a weir, assuring that the struts are continuously submerged in a body of pressurized lubricating oil. Preferably, the inner periphery or hub of the second clutch plate and the outer rim portion of the first clutch plate are formed with splines, or gear teeth for cooperating with mating splines or gear teeth on a driving and driven member for the transfer of power upon rotation in one direction only. In a preferred embodiment, oil may be supplied through a drilled passage in a mounting shaft or gear to an annular oil ring communicating with the cavity between the first and second clutch faces as by a drilled oil passage formed in the second clutch plate hub.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages of the invention will be apparent from the detailed description contained hereinbelow, taken in conjunction with the drawings, in which:
FIG. 1 is an elevation view of a clutch assembly according to the present invention;
FIG. 2 is an exploded view of the clutch assembly shown in FIG. 1, with certain parts being omitted for clarity;
FIG. 3 is a sectional view taken on line 3--3 of FIG. 1, with certain elements shown to a different scale for clarity;
FIG. 4 is an enlarged fragmentary sectional view of a portion of the structure shown in FIG. 3;
FIG. 5 is a fragmentary sectional view taken on line 5--5 of FIG. 4;
FIG. 6 is a view similar to FIG. 5 and showing the clutch in an overrunning condition;
FIG. 7 is a perspective view, on an enlarged scale, of a rigid strut employed in the clutch;
FIG. 8 is a sectional view showing the clutch in partially assembled relation with the rigid retainer in position to be installed;
FIG. 9 is a view similar to FIG. 8 and showing a die member for installing the rigid retainer;
FIG. 10 is a view similar to FIG. 9 showing the retainer partially installed;
FIG. 11 is a view of the fully assembled clutch with the die illustrated in final assembly position;
FIG. 12 is an enlarged fragmentary sectional view of an alternate embodiment of the invention with the seal in position to be installed;
FIG. 13 is a view similar to FIG. 4 and showing the clutch components of FIG. 12 in the fully assembled condition; and
FIGS. 14-16 are fragmentary sectional views, each showing a further embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail, a clutch assembly according to the present invention is indicated generally by the reference numeral 10 and includes an outer clutch member or clutch plate 12 and an inner clutch member or clutch plate 14. The clutch 10 is illustrated in FIG. 3 as mounted on a driven shaft 16 and supported against rotation thereon by gear teeth 18 on the inner periphery of clutch plate 14, which gear teeth mate with splines 20 on the outer periphery of shaft 16.
The outer clutch plate 12 includes a ring shaped body portion 22 having a cylindrical inner peripheral surface 24 and a planar, annular inner surface 26, and an outer rim portion 28 extending axially from planar inner surface 26. Gear teeth, or splines 30, are formed around the outer periphery of outer rim portion 28 for engaging with mating gear teeth on a drive gear, not shown.
The inner clutch plate 14 also includes a generally ring shaped body portion 32 having a cylindrical outer peripheral surface 34 dimensioned to fit closely within the cylindrical inner surface 36 of outer rim portion 28 and has on its inner peripheral portion an axially extending hub 38 having an outwardly directed cylindrical surface 40 dimensioned to telescopingly receive the inner peripheral surface 24 of the outer clutch plate 12. The inner clutch plate's body portion 32 also has a planar inner surface 42 disposed in closely spaced, parallel relation to the outer clutch plate's planar inner surface 26 when the clutch is assembled.
The planar inner surface 26 of outer clutch member 12 has a plurality of recesses 44 formed therein with each adapted to receive a strut or key 46. Each recess 44 further includes a secondary recess 48 for receiving a spring 50.
As best seen in FIG. 7, the key 46 includes a rigid, generally rectangular body 52 with laterally extending wings 54 projecting one from each side edge 56 of the body adjacent one end thereof. The front end of body 52, i.e., the end opposite the end having wings 54 formed thereon, may be a substantially, flat planar surface inclined slightly with respect to the opposed planar surfaces of body 52, but preferably is slightly curved, as shown at 58 in FIG. 7. The back end 60, i.e, the end opposite and generally parallel to end 58 is a flat planar surface inclined with respect to the faces of body 52 at an angle generally corresponding to the angle of inclination of the end 58. The angle of inclination of the ends 58, 60 corresponds to the maximum angle of inclination or movement of the key from the engaged or driving position projecting into a recess 44 as shown in FIG. 5 and the retracted or overrunning position withdrawn from the recess 44 as shown in FIG. 6.
The planar annular surface 42 of inner clutch plate 14 is provided with a plurality of key-engaging notches 62 providing a ring of abutment faces or shoulders 64 in position to be engaged by the end 58 of one of the keys 46 in the driving mode. Notches 62 may have a sloped or inclined rear portion 66. As stated above, the front end 58 may be a flat planar surface but preferably is slightly arcuate, with the degree of curvature being exaggerated in FIG. 7 for illustrative purposes. When the end 58 is arcuate, the shoulders 64 will also be correspondingly curved so that, in the engaged position, the ends 58 and shoulders 64 will be in contact along the full length of end 58. At the same time, the slightly arcuate configuration permits sufficient adjustment or movement of the key, under load, to accommodate any slight misalignment which might occur due to manufacturing tolerances, thereby eliminating or minimizing stress concentrations which could be produced as a result of such misalignment. Also, as seen in FIGS. 5-7, the wings 54 preferably are provided with an inclined ramp portion 68 to permit free tilting of the key, under influence of the springs 50 to project the body 52 into a recess 44 as shown in FIG. 5. To facilitate the free flow of lubricating oil into the recesses 44 and subrecesses 48, each recess 44 preferably includes a relief 70 and a similar relief 72 is preferably formed at one end of each subrecess 48.
As thus far described, the structure of the clutch assembly, including the outer clutch plate 12, the inner clutch plate 14, the driving keys, and the resilient springs, may be substantially identical to that disclosed and described in copending application Ser. No. 08/382,070 now U.S. Pat. No. 5,597,057, with the single exception of the preferred arcuate configuration of the key end 58 and the driving notch shoulder 64.
As in the clutch assembly described in the above pending application, when the outer clutch plate 12 is rotated in the driving direction, i.e., to the right in FIG. 5, the spring 50 will urge the key 46 into the notch 62 so that the front end 58 of one key 52 will engage the shoulder 64 of that notch 62. Resistance to movement of the inner clutch plate 14 acting through the key end 58 and shoulder 64 will tend to cam the key into full engagement with the shoulder, thereby assisting the spring 50 in projecting the key fully into the notch.
When the outer clutch plate 12 is rotated in the opposite direction, i.e., to the left in FIG. 6, or when the inner clutch plate 14 tends to rotate faster than the outer clutch plate 12, the inclined surface 66 of notch 62 will cam the key back into the recess 44 to the overrunning position. In this overrunning condition shown in FIG. 6, it is desirable that the recesses 44, subrecesses 48, and notches 62 be completely filled with a lubricating oil to dampen movement of the keys as successive notches 62 pass over the respective keys, thereby preventing the springs 50 from projecting the keys into the notches only to be driven back by impact with the inclined notch surfaces 66. In accordance with the present invention, this supply of pressurized oil completely submerging the body 52 of each key is assured during normal operation of the clutch assembly.
Referring now to FIGS. 3 and 4, it is seen that the outer rim portion 28 of the outer clutch plate 12 is provided at its open end with a counterbore providing a cylindrical surface 74 having a diameter greater than the diameter of cylindrical surface 36 and terminating in a planar annular shoulder 76 lying in a plane parallel to the planar inner surface 26. A generally V-shaped annular groove or notch 77 is formed in the cylindrical wall 74 adjacent the shoulder 76, and a retainer 78 is pressed into and forms a fluid-tight seal with the groove 77 around its entire periphery. In the preferred embodiment of the invention as shown in FIGS. 1-11, the retainer as initially formed (see FIG. 8) has a generally frustoconical ring-shaped body portion 80 having an annular inner peripheral edge 82 and a generally axially extending flange 84 integrally formed on its outer edge. The outer diameter of flange 84 is greater than the diameter of cylindrical surface 36 and slightly less than the diameter of cylindrical surface 74.
As shown in FIGS. 8-11, the generally frustoconical retainer 78 is initially positioned in the counterbore 74 with the flange 84 adjacent the V-shaped groove 77 and with the frustoconical body portion 80 having its inner peripheral edge 82 projecting outwardly from the end of hub 38. The inner peripheral edge 82 of the retainer is then engaged by a shoulder 86 on an axially movable die element 88 which is moved downward to compress the retainer and form its major diameter outwardly and into the V-shaped groove 77. Final movement of the die 88 conforms the axially extending flange portion 84 of retainer 78 firmly into the groove 77 and shapes the body portion 80 into a planar substantially, annular ring overlying the outer surface 90 of inner clutch plate 14.
During press forming of the retainer 78, the inner periperal edge is retained against radial shrinking by the shoulder 86 on die 88. Also, during the final movement of die 88, an annular notch 92 engages the end of flange 84 to swage the retainer to conform to the geometry of the groove 77 and form a fluid tight seal therewith.
The minor diameter of the retainer, in the installed position, extends radially inward to a position at least overlying the body 52 of the keys 46 but radially outboard of the outer clutch plate's inner peripheral surface 24. Thus, the retainer 78, the outer rim portion 28, and the body portion 22 of the outer clutch plate 12 define, in effect, a generally toroidal-shaped, annular cavity containing the keys 46, springs 50, the recesses 44 and subrecesses 48, as well as the notches 62 formed in the planar inner surface 42 of the inner clutch plate 14.
Referring again to FIGS. 3 and 4, it is seen that an oil supply passage 94 extends through the hub 38 and terminates at the intersection of surfaces 42 and 40. Oil, under pressure, may be supplied to the passage 94 through oil supply passages 96, 98 in shaft 16. Although in the static position as shown in FIG. 3, the planar inner surfaces 26 and 42 may be in direct contact, the clutch plates are dimensioned so as to provide some finite clearance between these surfaces during operation so that a film of oil will be present and oil can flow from passage 94 between these surfaces and into the recesses 44 and 48 and the notches 66. The separation of surfaces 26 and 42 is shown somewhat exaggerated in FIGS. 4-6 to illustrate the oil flow passage. Also, a film of oil will be present between opposing cylindrical surfaces 24 and 40 as well as between cylindrical surfaces 34 and 36 to permit restricted flow and to provide lubrication and avoid direct metal-to-metal contact of these surfaces during operation.
During high speed operation, oil in the recesses and notches will surround the keys 46 and be pressurized both by centrifugal force and the pressure of oil flowing through passage 94 from passages 96, 98 and will cause a continuous flow of oil into and through these recesses and notches, and outwardly between surfaces 34 and 36 and along the opposing outer surface 90 of inner clutch plate 14 and the inner surface 91 of the retainer 78. The inner peripheral edge 82 of retainer 78 extends along surface 90 to a position radially between the hub 38 and the radially inner portion of the body 52 of keys 46 and acts as a weir to permit a continuous restricted outward flow of lubricating oil over edge 82 while maintaining the keys submerged in oil during operation.
Since the retainer 78 is rigidly and permanently fixed in the V-shaped groove 77, and forms a fluid-tight seal therewith, the clutch plates 12,14 are continuously maintained in a fixed, spatial relation, with a continuous supply of lubricating oil to all opposing relatively moving surfaces during normal operation. The permanent, interlocked pressure-formed joint between the retainer and the V-shaped notch assures against channeling of lubricating fluid and/or the loss of fluid as a result of improper fitting or loosening of conventional resilient snap ring or threaded retainers of the type employed in the past.
The retaining element 78 is preferably initially stamped and formed from a flat sheet of a suitable steel material as an annular ring which is shaped into the frustoconical configuration having its outermost peripheral edge portion rolled into a configuration to be pressure formed into and form a seal with the groove 77.
While only a single oil passage 94 is shown in the drawings, it should be apparent that a plurality of such passages may be provided if desired. For example, a plurality of such oil passages may be provided at spaced intervals around the inner periphery of hub 38, with oil supply being provided to each from oil passage 96, 98 in shaft 16 communicating with an annular groove (not shown) extending around the shaft so that each such oil passage 94 will be in continuous communication with a supply of oil under pressure during operation. Alternatively, of course, multiple radially extending oil passages 98 might be provided, one in communication with each such passage 94.
In operation of a clutch constructed substantially as described above, with the inner and outer clutch plates being formed from a transparent, thermoplastic material, it has been shown that lubrication filling the void space between the clutch plates 12 and 14 and maintained under pressure produced from centrifugal force, will substantially completely dampen all movement of the keys 46 when the clutch is in the overrunning mode. A high speed camera operating at 20,000 frames per second used to photograph the keys when operating in the overrunning mode showed that no visibly discernible movement of the keys was present at speeds above about 150 rpm. In this experimental clutch formed from synthetic resin material, the outside diameter of the outer clutch member 12 was 6 inches, and the radial distance from the center of the shaft to the outside edge 56 of the keys was 2.5 inches.
Referring now to FIGS. 12 and 13, an alternate embodiment of the invention will be described. In this embodiment, the outer and inner clutch plates, keys and springs are substantially identical to that described above and the same reference numerals are employed herein to designate similar parts. In this embodiment, however, the retainer is initially formed as a frustoconical ring 100 having a substantially uniform thickness throughout. The configuration of the inwardly directed groove 102 formed in the counterbore portion of outer rim portion 28 has a more shallow V configuration than in the previously described embodiment. As shown in FIG. 13, the outer peripheral edge 104 of the retainer 100 is expanded into the groove 102 and swaged into the configuration of the groove by the pressing movement forming the retainer into a substantially flat, planar ring in the manner described hereinabove. Once installed, the clutch assembly is permanently assembled, with the inner peripheral edge thereof acting as a weir in the same manner described above.
FIG. 14 illustrates a modification of the structure shown in FIGS. 12 and 13 in which the retainer 110 is provided around its inner periphery with a reinforcing or stiffening bead, or flange 112, prior to being press formed into the assembled relation overlying the outer surface 90 of inner clutch plate 14. The reinforcing bead 112 provides stiffness and dimensional stability of the retainer 110 and tends to maintain the inner peripheral portion of the planar body of the retainer member in a more flat or plane condition after installation. It is understood that such a reinforcing bead or flange could readily be provided on the embodiment shown and described above with reference to FIGS. 3 and 4.
FIG. 15 illustrates an embodiment wherein the retainer 120 is in the form of a rigid, flat washer or ring which is fitted into the counterbore 74 of outer clutch plate 12 to rest upon the shoulder 76. The outer clutch plate 12 may be identical to that described above with respect to FIGS. 3 and 4; however, as illustrated in FIG. 15, the V-shaped notch in the cylindrical wall of the counterbore is preferably eliminated. In this embodiment, the retainer 120 is rigidly retained in position overlying the outer surface 90 of inner clutch plate 14 by a continuous bead 124 of the material formed from the outer rim portion 28 of the outer clutch plate 12 which is deformed by a known pressing operation in which force is applied to the end of outer clutch plate 12 adjacent the counterbore 74. As a further alternative, the bead 124 may be replaced with a succession of tabs (not shown) formed by a staking operation to deform metal from the outer rim portion 28 of outer clutch plate 12 at spaced intervals around the periphery of the retainer 120. In this staked configuration, the outer diameter of the retainer 120 and the inner diameter of the counterbore are preferably dimensioned to provide a press fit with sufficient interference to form a reliable fluid seal to substantially prevent leakage of oil between the outer diameter of the retainer 120 and the counterbore formed in the end of outer clutch plate 12. A similar interference fit may also be employed where a continuous bead 124 of material is deformed as illustrated in FIG. 15.
A further modification of the invention is illustrated in FIG. 16 wherein the axially extending inner hub (designated at 38 in the embodiment illustrated in FIGS. 3 and 4) has been eliminated. In this embodiment, outer and inner clutch members 132, 134, respectively, have their opposing inner faces formed with a tapered, or bevelled surface 134, 136, respectively, cooperating to provide a generally V-shaped annular channel 138 around the inner periphery of the clutch assembly. The channel 138 is positioned, in operation, in substantially opposed relation to the discharge outlet of the lubricant channel 98 in shaft 16 whereby, upon rotation of the assembly, lubricant discharged from channel 98 will either be discharged from outlet channel 98 under sufficient pressure or be propelled by its own momentum and the influence of centrifugal force, into the channel 138. From the channel 138, oil flows under influence of centrifugal force between the opposing surfaces 26 and 42 and through the recesses 44, 48, and over the surfaces of the keys 52 to be discharged over the inner periphery of the retaining member, acting as a weir, in the same manner described hereinabove.
The embodiment of FIG. 16 is illustrated as employing the retaining element of the same configuration shown in FIG. 14. It is believed apparent, however, that any of the other configurations of the retaining element may be employed with this embodiment.
In each of the embodiments described above, the two ring-shaped clutch members and the retainer cooperate to form a generally toroidal, inwardly open enclosure or annular trough defining a lubricant flow path extending radially outward between the two clutch members and over the struts or keys, then radially inward between the second clutch member and the retainer. The location of the inner periphery of the retainer enables it to act as a weir for the discharge of lubricant to assure that the struts or keys are continuously submerged during operation. The continuous flow of lubricant acts as a coolant and to flush any foreign matter from the clutch as well as to dampen movement of the struts or keys in the overrunning mode.
While preferred embodiments of the invention have been illustrated and described, it is believed apparent that various modifications might be made and it is therefore intended to include all of the embodiments which would be apparent to one skilled in the art and which come within the spirit and scope of the invention.
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An overrunning clutch assembly including first and second ring-shaped clutch members with face surfaces disposed in opposing relation and with at least one rigid strut disposed therebetween for movement to engage recessed pockets in the opposed surfaces upon rotation in one direction and for movement out of engagement with the pockets in at least one of the face surfaces upon relative rotation in the opposite direction. A retaining member permanently retains the clutch in assembled relation and cooperates with the ring-shaped clutch members to form a lubricant reservoir maintaining the struts in a lubricant bath during operation. The retaining member forms a weir over which the lubricant flows from the reservoir at a radial location to assure that the struts remain submerged during operation.
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BACKGROUND
[0001] There are presently numerous mechanical and electronic systems and devices in existence for protection against theft. All these protective devices have a common purpose to prevent theft and/or to detract from stealing. These are either factory-installed or retrofitted later-on, on an as-needed basis.
[0002] Such systems, for example, activate an alarm signal upon breaking-in into a vehicle or by activation of a thermal-, light- or vibration-sensor. That signal may then be visual, audio and/or transmitted to a predetermined party. Likewise, there are similar devices to protect a diversity of objects of value.
[0003] Also, GPS based locators are now common. These are generally temper-proof.
[0004] All these devices may act as a theft deterrent and/or as a locator of disappeared goods, but being detectable by scanners, they are vulnerable to be made inoperative.
SUMMARY OF DESCRIPTION
[0005] The tracking device contains a normally armed, undetectable, miniature, self-sustaining electronic module, inconspicuously installed at an object or vehicle to be protected against theft. This device forms a complete system with a standard receiver/transmitter location on the owner's side.
[0006] Upon a preset motion of the goods, the module detects its physical location and wirelessly transmits that information to a remote owner. Thereafter, the device returns to an undetectable standby sleeping mode until re-activation either through further motion, or through the timer's setting or through wireless remote request by owner.
SUMMARY OF DRAWINGS
[0007] The drawings show the schematic flow arrangement of the tracking device's components, namely under the normal automatic operation mode in FIG. 1 and under the remote operation control mode in FIG. 2 .
DETAILED DESCRIPTION
[0008] The tracking device described below is installed in a vehicle and is normally armed/set on standby, during which the device is kept inactive, the power supply not being enabled. As such, the device remains undiscoverable by electronic scanners as well. Such a tracking device may, however, be installed on other objects of value as well, such as boats, planes, objects of arts, furniture, antiques etc.
[0009] The power supply of the tracking device is provided by its own low voltage, rechargeable Lithium battery ( 5 a ). Alternatively, if the protected good is a vehicle, the tracking device may be tied into an existing power supply, such as the battery of that vehicle. In latter case, if the vehicle's battery should be disconnected, the Lithium battery will still remain operational for a longer period of time.
[0010] Referring to FIG. 1 and FIG. 2 , the tracking device is composed of two major elements: Located at the protected good, a miniature electronic module as a first element and a second element, namely a standard receiver/transmitter at the owner's location.
[0011] The above electronic module contains a motion-sensor ( 5 ), an electronic controller and timer ( 4 ) and a transmitter/receiver ( 3 ). This module is installed in a normally inaccessible location of the protected good ( 1 ), hidden from the view.
[0012] The motion-sensor ( 5 ) works on inertia and is pre-programmed as to a motion limit of the good. When these limits are exceeded, an electronic impulse activates the controller ( 4 ), whereby a relay keeps the controller under power.
[0013] The electronic controller ( 4 ) is pre-programmed with the following information: Day, time, location (GPS coordinates and address), owner's nature of the property (at owner's option, such as car type and registration), owner's phone number and PIN number requirements. In addition, it may be set to control repeated transmittals regular time intervals, while it goes into an undetectable standby sleeping mode between these intervals.
[0014] The further transmitter/receiver ( 6 ), required on the owner's side, is as part of the fully functional system. For this item, many options are open to the owner, such as regular telephone, cellphone, wireless devices, provided they are set on the same frequencies as the module's transmitter/receiver ( 3 ).
[0015] The present description is based on cellphone transmittals, which requires a third party provider ( 7 ), in this case a telephone company. Alternatively, other transmittal systems may be used without a provider, such as APRS, UHF or VHF etc., provided the module is correspondingly programmed.
DETAILED DRAWINGS DESCRIPTION
[0016] FIG. 1 illustrates the case of a break-in or a tow-away theft. The motion-sensor ( 5 ) enables the power supply to the controller ( 4 ). At that point, the controller activates its locator and the pre-stored data, transmits this information to transmitter/receiver ( 3 ) which in turn, through the provider ( 7 ), sends it to the owner's receiver ( 6 ).
[0017] The owner may now initiate actions to recover the goods as promptly as possible.
[0018] FIG. 2 illustrated a remote control mode of the same tracking device. The request for tracking is initiated by the owner through his transmitter/receiver ( 6 ), going through the provider ( 7 ) to the transmitter/receiver ( 3 ) after use of the appropriate PIN Number. At that point, the transmitter ( 3 ) activates the electronic controller ( 4 ). The controller, after proper locating and processing, returns the required information in the usual form, going from item ( 4 ) through ( 3 ), ( 7 ) and ( 6 ) to the owner. One, may note that in this remote control mode, the transmitter/receiver ( 3 ) must be in a prior standby mode.
ILLUSTRATIONS
[0019] FIG. 1 shows a schematic of the tracking device operating in an automatic mode.
[0020] FIG. 2 shows the same tracking device in a remote control mode.
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A device to track and to provide positioning information for goods susceptible to be stolen, such as objects of value and vehicles, based on a undetectable module which can be activated by a motion-sensor, thereby allowing the disappeared goods to be located instantaneously and inconspicuously and, unperceived by the thief, transmitting the position of such goods to their owner.
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BACKGROUND OF THE INVENTION
1. Field:
This invention relates to card games involving spelling, counting and memory. The invention particularly relates to a novel card game in which a word is spelled by deciphering a numerical representation of the word, with memory being used to recall the word spelled, or the game may involve forming the numerical representation from a word, with memory of the numbers being used to recall the numerical representation.
2. State of the Art:
Word games utilizing playing cards have been proposed in the prior art. Such games may involve the use of letter indicia on the cards to form either predetermined words (see for example U.S. Pat. No. 977,117) or to allow the player to form his own words (see U.S. Pat. No. 2,265,334). Other examples of word games using playing cards are shown in U.S. Pat. Nos. 1,076,307; 1,312,278; 1,551,680; 2,783,998, and 4,219,197.
None of the games disclosed in the prior art, however, utilize two sets of cards in which one set include word cards in which numerical representations of the words are printed on the obverse faces of the cards, with the correctly spelled word being printed on the reverse faces of the mutually respective cards. The games of the prior art do not involve deciphering of a numerical representation of the word in letter by letter fashion, with memory of the letters and numbers being used to either spell the word or recall the numerical representation of the word.
OBJECTIVE
It is a principal objective of the present invention to provide an interesting, stimulating, educational card game involving spelling, counting, deciphering and memory.
SUMMARY OF THE INVENTION
In accordance with the present invention, the above objective is achieved by providing a card game involving spelling, counting, deciphering and exercise of memory by those playing the game. In the present invention, there is provided at least one word card and preferably, a plurality of such word cards as to form a deck of word cards. Each word card has a word imprinted on the reverse face thereof and a numerical representation of the same word imprinted on the obverse face thereof. The word which is imprinted on any particular word card is different and distinct from the words on the other word cards. The numerical representation on the obverse face of each word card is formed by a set of numbers in which each number represents a particular letter of the alphabet as determined by the numerical arrangement of the letters in the alphabet.
In addition to the word cards, a plurality of playing cards are provided in which indicia corresponding to the letters of the alphabet or to numbers representing letters of the alphabet are printed on the playing cards. The playing cards are imprinted so that each playing card has a single letter of the alphabet printed thereon or a number representing the letter of the alphabet printed thereon. Thus, each playing card represents a single letter of the alphabet. Sufficient playing cards are provided so that words on the word cards can be spelled out using the playing cards. Preferably, there are at least 52 playing cards comprising a pair of cards for each letter of the alphabet, so that words can be used on the word cards which have double letters therein.
Other objects and features of the invention, including a description of the play of the game, will be described in the following detailed description taken together with the accompanying drawings.
THE DRAWINGS
Preferred embodiments of the present invention representing the best mode presently contemplated of carrying out the invention is illustrated in the accompanying drawings, in which:
FIG. 1 is a view of the reverse face of one of the word cards from the word card deck with the word "WONDER" imprinted thereon;
FIG. 2 is a view of the obverse face of the word card of FIG. 1 with a numerical representation of the word "WONDER" imprinted thereon;
FIG. 3 is a view of six of the playing cards from the deck of the playing cards, with the cards having the letters of the word "WONDER" imprinted thereon; and
FIG. 4 is a view of six of the playing cards from a deck of playing cards having numbers imprinted thereon instead of letters, with the numbers corresponding to the letters in the word "WONDER".
DETAILED DESCRIPTION OF THE INVENTION
In a preferred embodiment of the invention, there is provided a deck of word cards comprising any number of word cards, each card representing a distinct word. In FIG. 1 there is shown a representative word card 10 from the deck of word cards. The cards of this invention, both the word cards and playing cards, are preferably made of plastic, plastic coated paper, or other playing card material as used in standard sets of playing cards.
The word card 10 shown in FIG. 1 has the word "WONDER" printed on its reverse face, the visible face as illustrated in FIG. 1. The word is preferably printed along opposite sides of the reverse face, so that the word can be read from either side of the card 10. In FIG. 2, the obverse side of the word card 10 is shown, with the numerical representation of the word "WONDER" imprinted thereon. The numerical representation is preferably printed along opposite sides of the obverse face, so that the numerical representation can be seen in proper order from either side of the card 10. The first letter of the word "WONDER" is "W" which is the 23rd letter of the alphabet. Thus, the first number in the numerical representation on the obverse face of word card 10 is the number "23". The second number is "15" corresponding to the 15th letter of the alphabet, namely "0". The third through sixth numbers are "14", "4", "5", and "18", respectively. These numbers correspond to the letters "N", "D", "E", and "R" which are the 14th, 4th, 5th, and 18th letters of the alphabet, respectively.
In one aspect of the invention, a deck of playing cards is provided having individual letters of the alphabet printed on the obverse faces of the mutually respective cards. Six representative cards 11 from such a deck of playing cards are shown in FIG. 3. The reverse faces of the playing cards 11 in the deck of playing cards can be imprinted with a common design as is common with ordinary playing cards. As illustrated in FIG. 3, the obverse side of each playing card 11 has an alphabet letter printed thereon. As shown the six cards 11 have the letters "W", "O", "N", "D", "E", and "R" printed thereon respectively. The letters are advantageously printed in opposite corners of the cards 11, with the bottom of the letters toward the midsection of the cards 11.
The deck of playing cards to which the six representative cards 11 shown in FIG. 3 belong, preferably contain at least 52 cards. However, a deck of playing cards containing 26 cards can also be used. With the deck containing 52 cards, words can be formed which contain double letters, inasmuch as the deck of playing cards contains two cards for each letter in the alphabet. When playing with a deck of playing cards containing only 26 cards, words to be formed are restricted to those in which none of the letters therein are duplicates of each other, inasmuch as the deck of playing cards contains only one card for each letter of the alphabet.
In playing a preferred word game in accordance with the invention using a deck of playing cards having alphabet letters imprinted thereon, such as cards 11 of FIG. 3, and a deck of word cards containing word cards such as card 10 of FIGS. 1 and 2, one or more of the word cards are randomly selected from the deck of word cards and placed on a table, with their obverse faces exposed to view, i.e., with the numerical representations of the word of the respective word card being exposed. Playing cards are dealt from the deck of playing cards to the players, preferably such that all the playing cards are dealt out. The players study the exposed word card or cards and begin to play the playing cards from their hand in a pile adjacent to the word card. If the word card shown in FIG. 2 was being played upon, the players would study the first number, i.e., the number "23", then determine the 23rd letter in the alphabet or the letter "W". The player with a "W" in his playing cards then plays that card to start the pile upon which the remaining cards which are to be played for that word will be subsequently played. The players having a playing card with an "O" or the 15th letter of the alphabet then can play that card on top of the "W" card. Likewise, the cards containing an "N", "D", "E", and "R", corresponding to the 14th, 4th, and 5th, and 18th letters of the alphabet are played in order. The players then can call out the word which has been spelled to win that particular play. The player calling out the word lifts the word card to see if the called out word was correct. If it was not, the player replaces the word card to the table, and the remaining players may attempt to call out the correct word.
To increase the difficulty of the game, two or three word cards are played upon simultaneously, i.e., two or three word cards are randomly chosen from the deck of word cards and placed on the table with their obverse face upward. The players then play cards on separate piles one for each word card. Having more than one word card being played upon at a time increases the concentration and memory for each player. Many other variations of the word game using the deck of word cards and the deck of playing cards containing letters imprinted thereon are possible.
In another aspect of the invention, the deck of playing cards contain numbers imprinted on the obverse face thereof instead of the letters of the alphabet. Six representative playing cards 12 from such a deck of playing cards are shown in FIG. 4. As shown, the six cards 12 have the numbers "23", "15", "14", "4", "5", and "18" printed thereon, respectively. The reverse faces of the cards 12 in the deck of playing cards having numbers printed thereon can be imprinted with a common design on the reverse faces as is common with ordinary playing cards. As shown, on the obverse face, the numbers are printed in opposite corners of the cards 12, with the bottom of the numbers toward the midsection of the cards 12. The numbers on the cards 12 correspond to a letter in the alphabet. There are at least 26 cards in the deck each containing a number from "1" to "26". Preferably, the deck of the numbered playing cards 12 will contain 52 cards, with two cards for each number between "1" and "26".
In playing a preferred word game in accordance with the invention using a deck of playing cards having numbers imprinted thereon, such as cards 12 of FIG. 4, and a deck of word cards containing word cards such as card 10 of FIGS. 1 and 2, one or more of the word cards are randomly selected from the deck of word cards and placed on a table, with their reverse faces exposed to view, i.e., with the spelled word on the card being exposed. Playing cards are dealt from the deck of playing cards to the players, preferably such that all the playing cards are dealt out. The players study the exposed word card or cards and begin to play the playing cards from their hand in a pile adjacent to the word card. If the word card shown in FIG. 1 was being played upon, the players would determine that the "W" was the 23rd letter in the alphabet. The player with a playing card having the number "23" then plays that card to start the pile upon which the remaining cards which are to be played for that word will be subsequently played. The player with a card number "15" for the 15th letter of the alphabet can play that card on top of the previous card which has a "23" therein. Likewise, the cards containing a "14", "4", "5" and "18" imprinted thereon are played in order. When the last card in the pile has been played, the players attempt to call out the correct sequence of numbers in the pile. The player calling out the sequence lifts the word card to see if the called out sequence was correct. If it was, that player wins that particular play. If the called out sequence was not correct, the player replaces the word card to the table, and the remaining players may attempt to call out the correct sequence.
To increase the difficulty of the game, two or three word cards can be played upon in the same manner as described hereinbefore with respect to the game in which playing cards having letters imprinted thereon are used. Many other variations of the word game using the deck of word cards and the deck of playing cards containing numbers imprinted thereon are possible.
It is noted that on the obverse face of the word cards such as card 10 shown in FIG. 2, the numbers representing the letters of the word for that card are separated from each other by appropriate marking, coloring or other means. The colors of the numbers could be varied or alternated. Thus the "23" could be in red, the "15" in black, the "14" in red, the "4" in black, the "5" in red, and the "18" in black. Advantageously, the numbers can be separated by a space and a marking therebetween such as the dots shown in the card 10 of FIG. 2.
Although preferred embodiments of the invention have been illustrated and described, it is to be understood that the present disclosure is made by way of example and that various other embodiments are possible without departing from the subject matter coming within the scope of the following claims, which subject matter is regarded as the invention.
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A spelling, counting and memory game is disclosed in which a word card is provided having a word printed on the reverse face thereof and a numerical representation of that word on the obverse side thereof. A plurality of playing cards are provided having indicia printed theron. The indicia can either be letters of the alphabet or numbers representing letters of the alphabet. The playing cards are played from the players' hands in a pile in the order revealed on the word card.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to hydrostatic mechanical face seals for providing, for example, fluid sealing between a housing and a rotating shaft. This invention more specifically relates to a hydrostatic mechanical seal assembly having a local arrangement for pressurizing fluid near the sealing interface. Although not limited to any particular deployment, this invention may be particularly advantageous in various downhole drilling tools such as drilling motors, drill bit assemblies, and rotary steering tools.
BACKGROUND OF THE INVENTION
[0002] Mechanical face seals are used on various types of machines and equipment, such as pumps, compressors, and gearboxes, for providing a seal between, for example, a rotating shaft and a stationary component such as a housing. Such mechanical seals typically include a pair of annular sealing rings concentrically disposed about the shaft and axially spaced from each other. Typically, one sealing ring remains stationary (e.g., engaged with the housing) while the other sealing ring rotates with the shaft. The sealing rings further include opposing sealing faces that are typically biased towards one another. Mechanical seals may be generally categorized as “contacting” or “non-contacting”. In contacting mechanical seals the biasing force is carried by mechanical contact between the annular sealing rings. In non-contacting mechanical seals a pressurized fluid film between the annular sealing rings carries the biasing force. Non-contacting mechanical seals may be subcategorized as “hydrodynamic pressure lubricated” or “hydrostatic pressure lubricated”.
[0003] In a hydrodynamic pressure lubricated mechanical face seal (also referred to herein as a hydrodynamic mechanical seal) the seal faces are provided with features such as grooves or vanes. Relative motion of the faces thus tends to draw the lubricating fluid into the interface between the seal faces and effectively pressurize the lubricating fluid film against the fluid being sealed (e.g., drilling fluid in downhole tools). The hydrodynamic lift (separation) of the faces is dependent on rotational speed, fluid viscosity, and the shape of the hydrodynamic features. Fluid viscosity is typically highly dependent on temperature. Such dependencies on speed and temperature tend to make it difficult to design hydrodynamic seals that meet the criteria required for typical downhole tools.
[0004] In hydrostatic pressure lubricated mechanical face seals (also referred to herein as hydrostatic mechanical seals) an essentially steady state fluid pressure is provided to the interface between the seal faces, for example, by remote pumps or energized accumulators. In a typical hydrostatic pressure lubricated seal, a radial taper is formed in the seal interface. The radial taper typically converges from the higher pressure fluid to the lower pressure fluid and acts to maintain a predetermined gap between the seal faces (the size of the gap being the primary deterrent to fluid leakage). Hydrostatic mechanical seals typically have a broader range of stable operation as compared with hydrodynamic mechanical seals. For example, hydrostatic mechanical seals are typically much less dependent on rotational speed than hydrodynamic mechanical seals.
[0005] In use hydrostatic mechanical seals typically require a stable pressure differential from the higher pressure sealed fluid to the lower pressure excluded fluid. Reversing pressure may be particularly harmful since it may reverse the direction of fluid flow. Such pressure changes may also change the radial taper such that it reverses convergence, thereby allowing contaminants into the sealing interface and compromising the sealing function. Accumulators, in particular, tend to be subject to sticking or fouling, which may cause loss (or reversing of) pressurization in hydrostatic mechanical seals. Such loss (or reversing) of pressurization often allows the excluded fluid to enter the seal interface and thus may result in premature failure of the seal assembly. In certain downhole tools, such as drill bit assemblies, drilling motors, rotational steering tools, measurement while drilling tools, turbines, alternators, and production pumps, such failure of the seal assembly often results in penetration of drilling fluid into the interior of the tool, which is known to have caused serious damage and/or failure of the tool.
[0006] Furthermore, remote pressurizing devices tend to be slow to respond to external pressure variations, for example, drilling fluid pressure spikes in a downhole drilling environment. Such pressure spikes have been observed to cause a pressure reversal in hydrostatic mechanical seals and therefore may also allow excluded fluid, such as drilling fluid, to penetrate into the interior of the tool.
[0007] Therefore, there exists a need for an improved hydrostatic mechanical seal assembly, in particular, an improved hydrostatic mechanical seal assembly including a pressure generating device that might provide improved robustness for use in downhole tools.
SUMMARY OF THE INVENTION
[0008] The present invention addresses one or more of the above-described drawbacks of prior art hydrostatic mechanical sealing assemblies. Aspects of this invention include a hydrostatic mechanical seal assembly comprising a locally deployed pump for pressurizing a lubricant fluid between the opposing faces of a mating ring and a sealing ring. In one embodiment, such pressurization may be achieved via a device that converts the rotational motion of a drive shaft into fluid pressure. For example, a helical groove pump may be deployed integral with a sealing ring carrier. Alternatively, a cam driven piston pump may be deployed, for example, about a rotating shaft in close proximity with the mating and sealing rings. Other alternative embodiments of hydrostatic mechanical sealing assemblies according to this invention may include, for example, piston, vane, gear, positive displacement, electromechanical, and/or centrifugal pumps, and the like deployed locally with the seal assembly.
[0009] Exemplary embodiments of the present invention advantageously provide several technical advantages. In particular, embodiments of this invention may provide a stable positive pressure on the sealing interface between the mating and sealing rings. As a result, various embodiments of the hydrostatic mechanical sealing system of this invention may exhibit improved sealing characteristics, especially in demanding downhole environments. Tools embodying this invention may thus display improved reliability and prolonged service life as compared to tools utilizing conventional hydrostatic mechanical sealing assemblies. The local pressurization provided by this invention also obviates the need for remote pumps and/or energized accumulators typically used in conjunction with conventional hydrostatic mechanical seals.
[0010] In one aspect this invention includes a hydrostatic mechanical face seal assembly. The assembly includes a mating ring having a first sealing face and a sealing ring having a second sealing face, the first and second sealing faces being biased towards one another. The sealing ring is deployed substantially coaxially with the mating ring and further disposed to rotate relative to the mating ring. The assembly further includes a pump disposed to pressurize a lubricating fluid at an interface between the first and second sealing faces. The pump is deployed locally with the mating ring and the sealing ring. In one exemplary embodiment of this invention the mating ring is coupled to a mating ring carrier, the sealing ring is coupled to a sealing ring carrier, and the pump is deployed on a member selected from the group consisting of the sealing ring, the sealing ring carrier, the mating ring, and the mating ring carrier.
[0011] In another aspect, this invention includes a tool having a rotatable drive shaft deployed in a substantially non rotating tool housing and a hydrostatic mechanical face seal assembly disposed to seal a contaminant fluid. The seal assembly includes a mating ring having a first sealing face, the mating ring deployed substantially coaxially about the drive shaft; the mating ring being substantially non rotational relative to the tool housing. The seal assembly also includes a sealing ring having a second sealing face, the sealing ring deployed substantially coaxially about and coupled with the drive shaft, the sealing ring and the mating ring disposed to rotate relative to one another, the first face and the second face biased towards one another. The seal assembly further includes a pump disposed to pressurize a lubricating fluid at an interface between the first and second sealing faces, the pump deployed locally with the seal assembly.
[0012] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0014] FIG. 1 depicts a downhole tool including an exemplary hydrostatic mechanical seal assembly embodiment according to the present invention.
[0015] FIG. 2 depicts, in cross section, an exemplary hydrostatic mechanical seal assembly according to this invention.
[0016] FIG. 3 depicts, in cross section, a portion of the embodiment shown on FIG. 2 .
[0017] FIG. 4 depicts, in cross section, another exemplary embodiment of a hydrostatic mechanical seal assembly according to this invention.
DETAILED DESCRIPTION
[0018] Referring to FIGS. 1 through 3 , it will be understood that features or aspects of the embodiments illustrated may be shown from various views. Where such features or aspects are common to particular views, they are labeled using the same reference numeral. Thus, a feature or aspect labeled with a particular reference numeral on one view in FIGS. 1 through 3 may be described herein with respect to that reference numeral shown on other views.
[0019] FIG. 1 schematically illustrates one exemplary embodiment of a hydrostatic mechanical seal assembly 10 according to this invention in use in a downhole tool, generally denoted 100 . Downhole tool 100 may include substantially any tool used downhole in the drilling, testing, and/or completion of oilfield wells, although the invention is expressly not limited in this regard. For example, as shown in FIG. 1 , downhole tool 100 may include a three-dimensional rotary steering tool (3DRS) in which the seal assembly 10 provides a sealing function between an inner rotating shaft (or cylinder) 120 and an outer housing 110 . In such a configuration, the housing 110 and force application members 115 are typically substantially non-rotational relative to the well bore during the drilling operation. Downhole tool 100 may be configured for mounting on a drill string and thus include conventional threaded or other known connectors on the top and bottom thereof, such as drill bit receptacle 125 . In other exemplary embodiments downhole tool 100 may include drilling motors, drill bit assemblies, stabilizers, measurement while drilling tools, logging while drilling tools, other steering tools, turbines, alternators, production pumps, under-reamers, hole-openers, turbine-alternators, downhole hammers, and the like.
[0020] Although the deployments and embodiments described herein are directed to subterranean applications, it will be appreciated that hydrostatic mechanical seal assemblies according to the present invention are not limited to downhole tools, such as that illustrated on FIG. 1 , or even to downhole applications. Rather, embodiments of the invention may be useful in a wide range of applications requiring one or more mechanical seals, such as for example, pumps, compressors, turbines, gear boxes, motorized vehicles, engines, electric power generation equipment, boats, household appliances, agricultural and construction equipment, and the like.
[0021] With reference now to FIG. 2 , a cross sectional schematic of one exemplary embodiment of a hydrostatic mechanical seal assembly 10 is shown. Seal assembly 10 includes a mating ring 20 having a sealing face 22 and a sealing ring 30 having a sealing face 32 . Seal assembly 10 further includes a biasing member 42 (such as a metal bellows, a spring member, or another suitable equivalent), which resiliently preloads (i.e., biases) the face 32 of sealing ring 30 towards the face 22 of mating ring 20 . It will be appreciated that while the biasing member 42 is shown biasing the sealing ring 30 towards the mating ring 20 on FIG. 2 , the biasing member 42 may be alternatively disposed to bias the mating ring 20 towards the sealing ring 30 . Moreover, one or more biasing members 42 may also simultaneously bias faces 22 and 32 towards one another. Seal assembly 10 further includes a pressure generating device 60 (e.g., a pump) deployed locally with the seal assembly 10 , as described in more detail below with respect to FIGS. 2 and 3 . It will be appreciated that deploying the pressure generating device 60 locally with the seal assembly includes deploying the pressure generating device 60 integrally with, resident on, adjacent to, and in close proximity to one or more members of the hydrostatic mechanical seal assembly.
[0022] With continued reference to FIG. 2 , in exemplary embodiments of seal assembly 10 , mating ring 20 is substantially stationary (i.e., non-rotating) and coupled to (e.g., sealingly engaged with) a mating ring carrier 25 , which may, for example, be coupled to a tool housing 110 . Mating ring 25 may further include a dynamic seal 27 with the drive shaft 120 (or a shaft sleeve 122 ). Sealing ring 30 may be coupled to (e.g., sealingly engaged with) a sealing ring carrier 35 , for example via biasing member 42 , which as described above resiliently preloads the face 32 of sealing ring 30 towards the face 22 of mating ring 20 . Sealing ring carrier 35 may be sealingly engaged via a static seal 37 , for example, to a drive shaft 120 (or a shaft sleeve 122 ) that rotates relative to the housing. One or more radial bearings 50 may be utilized to maintain precise alignment between the rotating and non-rotating components. In the exemplary embodiments shown on FIG. 2 , the pressure generating device 60 is deployed integrally with ring carrier 35 and is configured to provide pressurized lubricant fluid from, for example, a fluid reservoir 70 , to the interface 24 between mating ring 20 and sealing ring 30 . In various exemplary embodiments, pressure generating device 60 is configured to utilize the rotational motion of drive shaft 120 to pressurize the lubricating fluid.
[0023] The mating ring 20 and sealing ring 30 may be made from substantially any suitable material. For downhole deployments of the invention, it may be advantageous to fabricate the mating ring and/or the sealing ring from ultra-hard materials to combat the hard abrasive solids found in certain drilling fluids. A typical ultra-hard mating ring and/or sealing ring might optimally be made from a material having a Rockwell hardness value, Rc, greater than about 65. Such ultra-hard materials include, for example, tungsten carbide, silicon carbide, boron containing steels (boronized steels), nitrogen containing steels (nitrided steels), high chrome cast iron, diamond, diamond like coatings, cubic boron nitride, ceramics, tool steels, stellites, and the like. It will be appreciated that while ultra-hard materials may be advantageous for certain exemplary embodiments, this invention is not limited to any particular mating ring and/or sealing ring materials. In applications where hard abrasive solids need not be combated, conventional carbon graphite may be used as a material from which to manufacture the mating ring and/or sealing ring.
[0024] With continued reference to FIG. 2 , and further reference now to FIG. 3 , one exemplary embodiment of a pressure generating device 60 is described in further detail. As described above, seal assembly 10 includes a pressure generating device 60 (such as a pump) deployed locally with the seal assembly 10 . In various exemplary embodiments, the pressure generating device 60 may be integral with one or more members of the seal assembly. For example, the ring carrier 35 may be fitted with a helical groove pump (also referred to as a screw pump) as shown on FIG. 3 . In the embodiment shown, the outer surface 64 of ring carrier 35 is fitted with one or more helical grooves 62 that serve to pump fluid (thereby increasing the pressure) towards 68 sliding interface 24 upon rotation of the drive shaft 120 . It will be appreciated that while the embodiment shown on FIG. 3 includes a helical groove pump deployed on the sealing ring carrier 35 , the pressure generating device 60 may be deployed substantially anywhere in or about the seal assembly 10 . For example, a helical groove pump (e.g., one or more helical grooves such as grooves 62 in sealing ring carrier 35 ) may likewise be deployed on the inner surface of a housing or mating ring (e.g., mating ring 25 ) adjacent carrier ring 35 , on the outer surface 34 of the sealing ring 30 , on the inner surface 28 of the mating ring carrier 25 adjacent the sealing ring 30 , or substantially any other suitable location. Likewise, it will further be appreciated that substantially any suitable pressure generating device may be utilized in embodiments of this invention. For example, various alternative embodiments may include piston, vane, gear, positive displacement, electromechanical, and/or centrifugal pumps.
[0025] Turning now to FIG. 4 , one alternative embodiment of a sealing assembly according to this invention is shown. Downhole tool 200 includes rotor 290 and stator 295 assemblies of a downhole turbine deployed in a downhole tool body 210 and coupled to a drive shaft 218 and alternator 280 . In the embodiment shown, drilling fluid (drilling mud) is pumped down through annular region 215 to power the turbine. The sealing assembly is similar to that described above with respect to FIG. 2 in that it includes mating 220 and sealing 230 rings having adjacent sealing faces. Coil springs 242 are disposed to bias sealing ring 230 towards mating ring 220 . In the embodiment shown, mating ring 220 is substantially stationary (i.e., non-rotating), while sealing ring 230 and coil spring 242 are disposed to rotate with the drive shaft 220 .
[0026] In the exemplary embodiment shown on FIG. 4 , a piston pump 260 is deployed substantially adjacent to sealing ring 230 . The piston pump 260 is driven by an eccentric diameter cam 262 formed in the drive shaft 220 and is disposed to provide pressurized fluid from a fluid reservoir 272 to the pump 260 through passageway 265 and on to the interface between the mating 220 and sealing 230 rings via passageway 264 . The piston pump 260 includes a dynamic seal 263 with the drive shaft 220 to prevent pressure loss in the pressurized fluid (i.e., to separate the high and lower pressure fluid). The tool 200 may optionally include a bladder 275 (e.g., an elastomeric boot) disposed in the fluid reservoir 272 for providing pressure equalization between drilling fluid in annular region 215 and lubricating fluid in the fluid reservoir 272 . Use of the bladder 275 advantageously tends to equalize pressure spikes between the drilling fluid and sealed fluid and therefore tends to reduce the likelihood of pressure reversals at the interface between the mating 220 and sealing 230 rings.
[0027] As described above, the exemplary embodiments shown on FIGS. 2 and 4 include pumps 60 and 260 deployed locally with the sealing members. In the embodiment shown on FIG. 2 , the pump 60 is deployed integrally with the sealing ring carrier 35 . In the exemplary embodiment shown on FIG. 4 , pump 260 is deployed in close proximity to mating 220 and sealing 230 rings. In this exemplary embodiment, pump 260 is deployed about 6 inches above the mating 220 and sealing 230 rings. Of course, the invention is not limited in these regards. Rather, these exemplary embodiments shown on FIGS. 2 and 4 are intended to illustrate what is meant by “local deployment” of the pumping mechanism. In the exemplary embodiments shown, the pumps 60 and 260 are deployed near enough to the respective sealing interfaces so that there is substantially no pressure loss in the lubricating fluid between the pumps 60 and 260 and the sealing interfaces. This is in contrast to prior art arrangements in which remote deployment of the pump and/or accumulator often results in a pressure loss (drop) in the lubricating fluid between the pump and the sealing interface. Such pressure losses are typically due to both the distance between the pump and the sealing interface and the tortuous fluid flow path therebetween. As described above in the Background Section, such pressure drops and/or spikes are known to result in premature seal failure, especially in downhole tools. In many prior art arrangements the pump and/or accumulator is deployed 2 feet or more above or below the sealing members.
[0028] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alternations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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A hydrostatic mechanical seal assembly includes a locally deployed pump for pressurizing a lubricant fluid between the opposing faces of a mating ring and a sealing ring. In one exemplary embodiment, such pressurization may be achieved via a device that converts the rotational motion of a drive shaft into fluid pressure. The locally deployed pump is intended to advantageously provide a stable positive pressure on the sealing interface between the mating and sealing rings, which may provide improved sealing characteristics, especially in demanding downhole environments.
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This application is a continuation of application Ser. No. 214,679, filed Dec. 9, 1980, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fluid-pressure apparatus for controlling a slave member to follow a master member in motion.
2. Description of the Prior Art
Conventional master/slave actuator apparatuses include an electro-hydraulic servo valve which are supplied with an electrical signal responsive to angular displacement of a master arm and another electrical signal responsive to angular displacement of a slave arm for controlling a hydraulic actuator which drives the slave arm so as to follow the master arm in angular motion.
As is well known, the electro-hydraulic servo valve is of poor reliability and tends to malfunction when used in adverse environments. More specifically, dirt in hydraulic operating fluid is likely to get jammed in the orifice of a nozzle-flapper or the small clearance around a spool. The magnetic characteristics of a solenoid coil may be changed due to drastic changes in ambient temperature, resulting in malfunctioning of the value. The valve is liable to operate improperly when the hydraulic operating oil is heated with resulting changes in viscosity and expansion of a spool. The electro-hydraulic servo valve is also disadvantageous in that its manufacture requires high precision and hence is expensive to manufacture. The master/slave actuator apparatuses which rely on such an electro-hydraulic servo valve are accordingly not reliable in operation in harmful applications and are costly to construct. Such apparatuses have found little use in rugged applications such as for example manipulators in foundries and smith shops, tunnel boring machines, construction machines, loading and unloading machines, or machines for use in ocean development.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a master/slave fluid-pressure apparatus which is reliable in operation in harmful applications.
Another object of the present invention is to provide a master/slave fluid-pressure apparatus which is inexpensive to construct.
According to the present invention, a hydraulic actuator for actuating a slave arm is connected to a source of fluid pressure via a three-position directional valve having a pilot chamber to which is applied a pressure signal from a first mechanism for converting a displacement of a master arm into a fluid pressure, and another pilot chamber to which is applied a pressure signal from a second mechanism for converting displacement of the slave arm into a fluid pressure to thereby control the directional valve so as to enable the slave arm to follow the master arm in motion. The first and second mechanism may includes either pressure reducing valves or relief valves.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed descripton when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts through the several views and wherein:
FIG. 1 is a circuit diagram of a fluid-pressure apparatus according to a first embodiment of the present invention;
FIG. 2 is an enlarged cross-sectional view of a pressure control valve in the apparatus shown in FIG. 1;
FIG. 3 is a circuit diagram of a fluid-pressure apparatus according to a second embodiment of the present invention;
FIG. 4 is an enlarged cross-sectional view of a pressure control valve in the apparatus shown in FIG. 3; and
FIG. 5 is a graph illustrative of the performance of the apparatus of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, the master/slave fluid-pressure apparatus of the present invention includes a master boom 1 which has one end 1a pivotally connected to a shaft 2 and is connected at the other end 1b by a shaft 4 to a master arm 3 at an end 3a thereof, the master arm 3 being angularly movable about the shaft 4 with respect to the master boom 1. Master arm 3 has a cam 5 mounted on the end 3a thereof. Master boom 1 supports on its end 1b a first remote control valve 6 which coact with the cam 5 to convert positional changes of the master arm 3 into pressure changes as described herein. Valve 6 has an inlet port 7 connected via a fluid line 8 to a port 10 of a source of hydraulic pressure 9.
As shown in FIG. 2, the valve 6 is in the form of a pressure reducing valve including a valve body 11 having a spool chamber 12 in which a spool 13 is slidably fitted. Valve body 11 also includes a pair of chambers 14, 15 spaced axially from each other and located one on each side of the spool chamber 12 in communication therewith. A compression coil spring 16 is disposed in the chamber 14 and has one end held against an end of the spool 13. The other end of the spring 16 is held against an end of a roller lever 18 which is axially slidable in the valve body 11 and supports on the other end thereof a roller 17 serving as a cam follower rollingly engaging the cam 5 of the master arm 3. The chamber 15 contains therein a compression coil spring 19 having one end held against the other end of the spool 13, the spring 19 being weaker in strength than the spring 16 for positioning the spool 13.
Spool chamber 12 has axially spaced, annular grooves 22a, 22b, 22c. The annular groove 22a is held in fluid communication with the intake port 7, the annular groove 22b with the chamber 15 through a passage 21, and the annular groove 22c with a tank port 24. Valve body 11 has an outlet port 23 communicating with the chamber 15.
Spool 13 has axially spaced, annular lands 25a, 25b, 25c. Spool 13 is determined as to its axial position in the spool chamber 12 by the resilient force from the spring 16 and the fluid pressure in the chamber 15, such that the land 25b is axially positionable between an inner annular surface 26 defined between the annular grooves 22a, 22b and an inner annular surface 27 defined between the annular grooves 22b, 22c to allow fluid to flow from the inlet port 7 through the passage 21, the chamber 15 to the outlet port 23. When the outlet port 23 is pressurized up to a predetermined point, excess fluid from the inlet port 7 is discharged through the port 24. Accordingly, the fluid pressure in the outlet port 23 is responsive to the force of the spring 16 as varied by axial movement of the roller lever 18. Spool 13 has an axial passage 29 which provides fluid communication between the chamber 14 and the port 24.
In FIG. 1, a slave boom 31 is pivotally mounted at an end 31a on a shaft 32. To the other end 31b of the slave boom 31, there is connected by a shaft 34 an end 33a of an angularly movable slave arm 33 having a cam 35 with which coacts a second remote control valve 36 fixedly mounted on the end 31b of the slave boom 31. The second valve 36 is of the same construction as that of the first valve 6, and has an inlet port 37 connected via a fluid line 38 to the port 10 of the fluid pressure supply 9.
A hydraulic actuator or cylinder 40 is secured to the end 31b of the slave boom 31, the cylinder 40 including a piston rod 41 having a distal end pivotally coupled by a pin 43 to a lobe 42 on the end 33a of the slave arm 33. Thus, the slave arm 33 is angularly movable by the hydraulic cylinder 40 relatively to the slave boom 31.
A closed-center, three-position directional valve 45 has a port A side connected via a fluid line 46, a port 47a to a rod-side chamber 40a of the cylinder 40, and a port B connected via a fluid line 48, a port 47b to a blind-side chamber 40b of the cylinder 40. The directional valve 45 also has a pressure port P connected via a fluid line 49 to a port 50 of the fluid-pressure source 9, and a tank port T connected via a fluid line 51 to a tank 52 in the supply 9. Directional valve 45 has at one end thereof a pilot chamber 55 coupled via a pilot line 56 to the outlet port 23 of the first remote control valve 6, and at the other end a pilot chamber 57 coupled via a pilot line 58 to an outlet port 59 of the second remote control valve 36.
Fluid-pressure supply 9 includes a high-pressure pump 61 and a low-pressure pump 62, both of which are coupled to a motor 60 for being driven thereby. The pump 61 is connected via a fluid line 63 to the port 50, and the pump 62 is connected via a fluid line 64 to the port 10. Fluid lines 63, 64 are connected respectively to relief valves 65, 66 for protection against an excessive pressure build-up. A pair of pressure gauges 67, 68 are connected to the fluid lines 63, 64, respectively. Pump 61, 62 are connected to the tank 52 via a filter for being supplied with oil.
The tank port 24 of each remote control valve 6, 36 is connected via a fluid line 70 to the tank 52 as shown in FIG. 2.
The master/slave fluid-pressure apparatus thus constructed will operate as follows:
When the master arm 3 is angularly moved by a suitable means (not shown) with respect to the master boom 1 in a clockwise direction as shown in FIG. 1, the cam 5 depresses the roller of the valve 6 to compress the spring 16 so that the fluid pressure in the outlet port 23 of the valve 6 will be increased. More specifically, compression of the coil spring 16 causes the spool 13 to move downwardly (FIG. 2) to allow more fluid to flow through the passage 21 until the pressure in the chamber 15 counterbalances the force of the spring 16, whereupon the pressure in the outlet port 23 is higher than it was before the master arm 3 has been angularly moved.
With a pressure build-up in the fluid line 56, the pilot chamber 55 is pressurized to move the valve spool of the directional valve 45 leftwards as shown in FIG. 1, thereby allowing fluid to flow from the pump 61 through the fluid lines 63, 49, the valve 45, the fluid line 48, and the port 47b into the fluid-side chamber 40b of the cylinder 40. Therefore, the piston rod 41 of the cylinder 40 is extended to cause the slave arm 33 to be angularly moved about the shaft 34 clockwise with respect to the slave boom 31. At this time, the roller of the second remote control valve 36 is depressed by the cam 35 to pressurize the outlet port 59 of the valve 36 and hence the pilot chamber 57 of the directional valve 45 through the fluid line 58. The slave arm 33 continues to move angularly until such time as the pressure in the pilot chamber 57 builds up to a point where it counterbalances the pressure in the pilot chamber 55, whereupon the spool of the directional valve 45 starts being shifted rightwards. Upon arrival at an intermediate position, the directional valve 45 cuts off oil supply to the cylinder 40, stopping the angular movement of the slave arm 33.
When the slave arm 33 has angularly moved due for example to inertia beyond an angular extent dictated by the master arm 3, the roller of the second remote control valve 36 is depressed further, causing the outlet port 59 of the valve 36 to be pressurized further. Accordingly, the pressure in the pilot chamber 57 overcomes the pressure in the pilot chamber 55, so that the spool of the valve 45 continues to be shifted rightwards until it allows fluid to flow from the pump 61 through the fluid lines 63, 49, 46 to the rod-side port 47a. The piston rod 41 is now retracted to enable the slave arm 33 to be angularly moved back counterclockwise. With such an arrangement the directional valve 45 is controlled by the remote control valves 6, 36 to enable the slave arm 33 to follow the master arm 3 in angular motion reliably without fail.
Upon completion of the angular follow-up movement of the slave arm 33, the outlet ports 23, 59 of the remote control valves 3, 36, and hence the pilot chambers 55, 57 of the directional valve 45 are pressurized equally.
FIGS. 3 and 4 show a master/slave fluid-pressure apparatus according to another embodiment of the present invention. The corresponding elements referred to in FIGS. 1 and 2 are denoted by the same reference numerals in FIGS. 3 and 4. According to this embodiment, a first relief valve 6a is mounted on the master boom 1 for coaction with the cam 5 of the master arm 3. Valve 6a has an inlet port 7a connected to the port 10 of the fluid-pressure supply 9 via a fluid line 9a, a restrictor 8a and a fluid line 21a. Fluid line 9a is connected via a fluid line 56a to the pilot chamber 55 of the directional valve 45. First relief valve 6a also has an outlet port 23b connected to the tank 52 via a line 13a.
A second relief valve 36a which is mounted on the slave boom 31 for coaction with the cam 35 of the slave arm 33 includes an inlet port 37a coupled to the port 10 of the fluid-pressure supply 9 via a fluid line 39a, a restrictor 38a, and the fluid line 21a. Pilot chamber 57 of the directional valve 45 is connected to the fluid line 39a through a fluid line 58a. Second relief valve 36a also has an outlet port 59a connected via the fluid line 13a to the tank 52.
First and second relief valves 6a, 36a are of the same construction, and each includes, as shown in FIG. 4, a valve body 16a having a chamber 17a therein, a poppet 18a axially movably disposed in the chamber 17a and urged against a seat 20a under the force from a coil spring 19a placed in compression in the chamber 17a so as to block fluid communication between the ports 23b (59a) and 7a (37a). The coil spring 19a is held against one end of a 23c axially slidably disposed in the valve body 16a and supporting on the other end a roller 23a which is held in rolling engagement with the cam 5 (35). With the relief valve 6a, 36a thus constructed, passage of fluid from the port 7a (37a) to the port 23b (59a) is controlled by a difference between the fluid pressure in the port 7a (37a) and the force of the spring 19a as varied by depression of the roller 23a. Therefore, the pressure in the port 7a (37a) is a function of the force of the spring 19a is controlled by the roller 23a. More specifically, as the coil spring 19a is compressed by engagement of the roller 23a with the cam 5 (35), the poppet 18a restricts fluid flow from the port 7a (37a) to the port 23b (59a). Thus, the pressure in the port 7a (37a) and hence the pressure in the fluid lines 9a, 56a (39a, 58a) varies with the force of the spring 19a which is a function of angular movement of the master arm 3 or the slave arm 33.
When the master arm 3 is angularly moved clockwise as shown in FIG. 3, the cam 5 depresses the roller 23a of the first relief valve 6a. Coil spring 19a is compressed to increase the fluid pressure in the port 7a and hence in the fluid lines 9a, 56a. Thus, the spool of the directional valve 45 is shifted leftwards by pressurization of the pilot chamber 55 until fluid is allowed to flow from the pump 61 through the fluid lines 63, 49, the valve 45, the fluid line 48 and the port 47b into the blind-side chamber 40b of the cylinder 40, while fluid is drained from the rod-side chamber 40a via the port 47a, the fluid line 46, the valve 45, and the fluid line 51 to the tank 52. Piston rod 41 is now extended to cause the slave arm 33 to be angularly moved clockwise in follow-up relation to the master arm 3. At the same time, the roller 23a of the second relief valve 36a is depressed by engagement with the cam 35 to cause a pressure build-up in the fluid lines 39a, 58a. When the fluid pressure in the pilot chamber 57 counterbalances the fluid pressure in the pilot chamber 55, the spool of the directional valve 45 is shifted rightwards to its intermediate position, whereupon oil flow is blocked to de-activate the cylinder 40. The clockwise angular movement of the slave arm 33 is now stopped.
Any excessive angular movement of the slave arm 33 due for example to inertia beyond an angular extent which the master arm 3 dictates, causes the cam 35 to depress the roller 23a further, resulting in a further pressure build-up in the pilot chamber 57 which enables the spool of the directional valve 45 to be moved rightwards until it allows oil flow to go into the rod-side chamber 40a via the fluid lines 49, 46 and the port 47a. Therefore, the piston rod 41 is retracted to enable the slave arm 33 to be angularly moved counterclockwise until such time as the pressures in the pilot chambers 55, 57 are held in equilibrium or in a state of balance.
FIG. 5 shows curves or waveforms experimentally obtained of pressure in or displacement of various parts of the apparatus shown in FIGS. 3 and 4 when the master arm 3 is subjected to a force applied thereto which periodically changes in a triangular waveform as a frequency of 0.06 Hz or a period of 16.5 sec. In FIG. 5, designated at (A) is a curve for angular displacement of the master arm 3, (B) a curve for angular displacement of the slave arm 33, (C) and (D) curves for control pressures of the first and second reief valves 6a, 36a, respectively, (E) and (F) curves for pressures in the pilot chambers 55, 57, respectively, of the directional valve 45, and (G) and (H) curves for pressures in the rod-end and blind-end chambers 40a, 40b of the cylinder 40. From the graph shown in FIG. 5, it will be seen that the slave arm 33 can follow the master arm 3 in angular motion precisely without substantial time delay.
Although certain preferred embodiments have been shown and described in detail, it should be understood that various changes and modifications may be made therein without departing from the scope of the appended claims. For example, the slave boom 31 may be arranged to follow the master boom 1 in angular motion by rendering the master and slave booms 1, 31 angularly movable. Furthermore, the present invention is useful in an application where the master and slave arms make rectilinear motion rather than angular motion.
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A master/slave fluid-pressure apparatus having a first valve respective to angular movement of a master arm for producing fluid pressure which is applied as a pilot pressure to shift a closed-center three-position directional valve in one direction, which then allows a fluid-pressure actuator to be operated to cause a slave arm to follow the master arm in angular motion. The angular movement of the slave arm actuates a second valve coacting therewith to develop a fluid pressure which is applied as another pilot pressure to the directional valve. When the fluid pressure from the second valve reaches a predetermined point, the directional valve is shifted in the opposite direction to stop operation of the fluid-pressure actuator. The first and second valves may either be pressure reducing valves or relief valves.
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This application is a continuation of Ser. No. 367,313, filed on June 16, 1989, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a heat treating apparatus used in the manufacturing of a semiconductor device, a liquid-crystal driving circuit board, and so on and, in particular, to the improvement of a reaction tube cooling system for this type of heat treating apparatus.
2. Description of the Related Art
As part of the process for manufacturing semiconductor devices, liquid crystal driving circuits, and so on, a vertical or a horizontal type heat treating apparatus is in widespread use for heating products, such as semiconductor wafers and circuits, requiring heat treatment, thereby to facilitate film formation, diffusion, oxidation, etching, and so on.
In the aforementioned heat treating apparatus, the reaction tube into which is placed those products to be heat treated, is constructed of a cylindrical tube made of, for example, quartz, and in a typical apparatus, has a cylindrical liner tube made of, for example, silicon carbide located around the outer periphery thereof. A heating element is wound in the form of a coil around the liner tube, and is itself surrounded by heat insulation.
In use, the interior of the reaction tube is initially heated to a predetermined treatment temperature--for example, several hundred to a thousand and several hundred of degrees--and products to be heat treated, such as the semiconductor wafers on a wafer boat, are loaded into the reaction tube through the lower opening thereof in the case of a vertical type apparatus, and through one end thereof in the case of a horizontal type apparatus. Then, a predetermined reaction gas, such as SiH 4 , O 2 , B 2 H 6 , and PH 3 is supplied into the reaction tube so as to form a film on the semiconductor wafer or to perform some other treatment, such as diffusion.
As products to be heat treated become increasingly sophisticated, it is necessary that the heat treating apparatus be provided with a cooling system which can rapidly and uniformly cool the entire reaction zone within the reaction tube, since the above cooling treatment is important in order to obtain a uniform thermal treatment history in the one or more semiconductor wafers being treated, as well as to reduce the process time.
Japanese Patent Publication (KOKOKU) 58-24711 discloses a cooling system used in a horizontal type heat treating apparatus. In this cooling system, a cooling pipe is arranged within the heat insulation surrounding the heating coil, resulting in a cooling function of low efficiency.
Japanese Patent Publication (KOKOKU) 60-8622 discloses another type of cooling system used in a horizontal type heat treating apparatus. In this system, a heater is directly located around the reaction tube and is enclosed in a heater casing, as a result of which a liner tube is not required. A cooling fluid is moved, by means of a blower, from one end of the reaction tube into a space between the outer surface thereof and the inner surface of the heater casing, and is exhausted through the other end of the tube. In the system as set forth above, the flow of cooling liquid along the reaction tube is, however, likely to deviate from a desired flow pattern, failing to cool the entire reaction zone within the reaction tube uniformly.
Japanese Utility Model Disclosure (KOKAI) 61-157325, on the other hand, discloses a cooling system used in a barrel type heat treating apparatus. In this cooling system, a heating coil is located inside the inner cylinder of a reaction tube on which a semiconductor wafer is supported by means of a susceptor. A cooling liquid is blown from the upper portion of the apparatus in a tangential direction of the outer cylinder of the reaction tube to allow it to flow along the outer surface of the outer cylinder of the reaction tube, and is exhausted through the lower portion of the apparatus. In this system, a cooling function is not so efficient, due to the lingering heat of the heating coil situated within the inner cylinder of the reaction tube. Furthermore, due to a greater temperature difference between both side surfaces of the semiconductor wafers, the semiconductor wafers might be deformed when they were cooled rapidly.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a heat treating apparatus having a reaction tube cooling system which, in order to obtain a uniform thermal treatment history in one or more products to be heat treated, can uniformly cool the entire reaction zone within the reaction tube.
Another object of the present invention is to provide a heat treating apparatus having a reaction tube cooling system which, in order to achieve positive reaction control and reduce the process time, can rapidly and uniformly cool the entire reaction zone within the reaction tube.
In order to achieve the aforementioned object, according to the present invention, there is provided a heat treating apparatus comprising a reaction tube for enclosing products to be heat treated within an inner, uniformly heated zone, a heater for enclosing the reaction tube, inlet nozzles for blowing a cooling fluid around the reaction tube substantially perpendicular to the axis of the reaction tube and exhaust means for collecting that cooling fluid which is heated after the cooling function thereof has been achieved, in which a flow of the cooling fluid from the inlet means toward the exhaust means is created beyond the whole length of the uniformly heated zone.
The uniformly heated zone has to cover at least a reaction zone for performing a heat treatment of the products to be treated or adequately cover it.
In some embodiments, the cooling fluid may be created along the outer surface of the reaction tube so as to directly cool the outer surface of the reaction tube, or, alternatively, may be created to indirectly cool the outer surface, in the case of other embodiments.
The inlet nozzles may blow a cooling fluid in one direction around the outer periphery of the reaction tube in the case of the reaction tube having a substantially vertical longitudinal axis and in two directions around the outer periphery of the reaction tube in the case of the reaction tube having a substantially horizontal longitudinal axis.
If the inlet nozzle is provided at one place in the longitudinal direction of the reaction tube whose longitudinal axis is substantially vertical, then it may be located at a substantially lowest portion of the reaction tube.
If, on the other hand, the inlet nozzle is provided at a plurality of places in the longitudinal direction of the reaction tube whose longitudinal axis is substantially vertical, the intervals of the inlet nozzle may become smaller toward the upper portion of the uniformly heated zone along the longitudinal direction of the reaction tube.
In the case where the inlet nozzle is provided at a plurality of places in the longitudinal direction of the reaction tube whose longitudinal axis is substantially horizontal, the inlet nozzle may be located opposite to the lowest portion of the reaction tube in a symmetrical relation to a center of a length of the uniformly heated zone.
If the inlet nozzle is provided at a plurality of places in the longitudinal direction of the reaction tube, a plurality of temperature sensors may be provided along the longitudinal direction of the uniformly heated zone in which case a flow of a cooling fluid blown from the inlet means may be individually controlled based upon the detection temperature data of the sensors.
If the inlet nozzle is provided at a plurality of locations in the longitudinal direction of the reaction tube with a liner tube placed between the reaction tube and the heater, the inlet nozzle may be movable between a position where the forward end portion of the inlet nozzle extends through the inner surface of the liner tube toward the proximity of the reaction tube and a position where the forward end portion of the nozzle is retracted into the inner surface of the liner tube.
The features and advantages of the present invention will become apparent from the following explanation made in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view, partly in longitudinal cross-section showing a vertical type heat treating apparatus with a reaction tube cooling system according to one embodiment of the present invention;
FIG. 2 is a bottom view, partly in cross-section, showing the apparatus of FIG. 1;
FIG. 3 is a front view, partly in cross-section, showing a vertical type heat treating apparatus with a reaction tube cooling system according to a second embodiment of the present invention;
FIG. 4 is a bottom view, partly in cross-section, showing the apparatus of FIG. 3;
FIG. 5 is a front view, in cross-section, showing a horizontal type heat treating apparatus with a reaction tube cooling system according to a third embodiment of the present invention;
FIG. 6 is a side view, partly in cross-section, showing the apparatus of FIG. 5; and
FIG. 7 is a view showing a flow pattern of a cooling fluid along a longitudinal direction of the reaction tube in the apparatus shown in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a reaction tube (process tube) 12 of a cylindrical configuration made of, for example, quartz is substantially vertically placed at a center of a vertical heat treating apparatus 10 with a reaction tube cooling system according to one embodiment of the present invention. A pipe 14 is connected to the top of the reaction tube 12 to introduce a predetermined reaction gas in which the pipe is connected to a gas feeding source, not shown. An exhaust pipe 16 is connected to the bottom of the reaction tube 12 and communicates with a recovery section, not shown.
In order to provide a uniformly-heated zone 18 within the reaction tube 12, a liner tube 22 made of, for example, silicon carbide is coaxially located around the outer periphery of the reaction tube 12 and a heating device, such as a coil-like heater 24, is wound around the outer periphery of the liner tube 22 with a spacing left therebetween. The outer diameter of the reaction tube 12, the inner diameter of the tube 22 and the inner diameter of the heater are 208 mm, 250 mm, and 285 mm, respectively. Heat insulation 26 is located around the outer periphery of the heater 24 and has a dense and smooth inner wall surface, preventing generation of dust resulting from a flow of a cooling fluid.
A cooling fluid pipe 32 which is connected to, for example, a blower (not shown) is arranged at the outer lower area of the heat insulation 26 as shown in FIG. 2 and four inlet nozzles 34 extend at a 90° interval from the pipe 32 toward an inner spacing, that is, their forward ends extend through the heat insulation 26 into a spacing which is defined between the tube 22 and the heat insulation 26 with the heater 24 located therebetween. A blowing port 36 of the forward end portion of the respective inlet nozzle 34 is oriented such that, as viewed in a top plan, the cooling fluid is blown in a counter-clockwise direction.
Cooling fluid exhaust pipe 42 which is connected to a suction means, not shown, is located at the upper area of the exterior of heat insulation 26, in the same fashion as that of the cooling fluid inlet pipe 32; that is, its nozzles 44 extend at a 90° interval from the discharge pipe 42 toward an inner spacing. The exhaust nozzle 44 is similar in configuration to the inlet nozzle 34, but an opening 46 of the nozzle 44 is oriented in a direction opposite to the blowing port 36.
In use, the reaction tube 12 of the aforementioned vertical heat treating apparatus 10 has an inner spacing initially heated by the heater 24 to a predetermined heat treating temperature of, for example, hundreds to one thousand and several hundred degrees, and products to be heat treated, such as semiconductor wafers W on a wafer boat 28, are loaded by, for example, a boat elevator (not shown), through the lower opening. A predetermined reaction gas, such as SiH 4 , O 2 , B 2 H 6 and PH 3 is supplied into the reaction tube 12 to form a film on the semiconductor wafers or to subject the semiconductor wafers to diffusion etc.
If the interior of the reaction tube 12 is to be rapidly cooled, such as upon the conclusion of a reaction, a cooling fluid such as chilled air is fed from the cooling fluid inlet pipe 32 into the aforementioned spacing to provide forced air cooling for about 30 minutes. The air is blown horizontally (in a counter-clockwise direction as viewed in an upper plan view) from the inlet nozzles 34 into the spacing between the heat insulation 26 and the liner tube 22 around which the heater 24 is located. By virtue of heat emitted from the heater 24, the air ascends in spiral fashion, swirling around the tube 22, and is exhausted via the exhaust nozzles 44. By means of this air flow, the heater 24 is directly cooled at which time the interior of the reaction tube 12 is cooled. Furthermore, the air flows upwardly, while being spirally rotated around the tube 22, providing a uniform temperature within a horizontal plane.
A vertical type heat treating apparatus 50 with a reaction tube cooling system according to a second embodiment of the present invention, as shown in FIG. 3, has basically the same structure as that of the aforementioned vertical type heat treating apparatus 10. In the arrangement shown in FIG. 3, the same reference numerals are employed to designate the parts of units corresponding to those shown in FIG. 1.
To the top of a reaction tube 12 which is substantially vertically arranged, a pipe 14 is connected to admit a predetermined reaction gas into the reaction tube 12 and leads to a gas supply source, not shown. An exhaust pipe 16 is connected to the bottom of the reaction tube 12 and communicates with a recovery or collection section, not shown.
In order to provide a uniformly heated zone 18 within the reaction tube 12, a liner tube 22 made of, for example, silicon carbide is coaxially located around the outer periphery of the reaction tube 12 and a heating device, such as a coil-like heater 24, is wound around the outer periphery of the tube 22 with a spacing left relative to the outer surface of the tube 22. The outer diameter of the reaction tube 12, the inner diameter of the tube 22, and the inner diameter of the heater 24 are 208 mm, 250 mm, and 285 mm, respectively. Heat insulation 26 is located around the outer periphery of the heater 24 and has a dense and smooth inner wall surface.
In the arrangement of the present apparatus, the heater 24 is divided into a lower zone A, a middle zone B and an upper zone C, these zones can be independently operated so that the uniformly heated zone 18 in the reaction tube 12 may be controlled positively. The temperature prevailing at the uniformly heated zone 18 in the reaction tube 12 is detected on a continuous basis by sensors 20, such as thermocouples located at a plurality of locations along the uniformly heated zone 18. The detection temperature level is transmitted as data to a control mechanism, not shown. The control mechanism controls, based on the temperature level data, electric power to the heater 24 or the amount of fluid flowing through respective cooling fluid inlet nozzle 54 as will be set forth below.
The cooling fluid inlet nozzles 54 are horizontally arranged at four places, at a 90° interval, around the reaction tube 12 as shown in FIG. 4. In all, six sets of inlet nozzles 54 are located at the aforementioned three zones, with one set in the lower zone A, two sets in the middle zone B, and three sets in the upper zone C, as shown in FIG. 3, as viewed along the vertical direction of the reaction tube. The inlet nozzle 54 is made of ceramics and has an inner diameter of 6 to 8 mm. The inlet nozzles extend through both the heat insulation 26 and liner tube 22 into a spacing which is defined between the liner tube 22 and the reaction tube 12. The blowing port 56 of the forward end portion of the inlet nozzle 54 is oriented to blow a cooling fluid in the counter-clockwise direction, as shown in FIG. 4, as viewed in a top plan view.
Each inlet nozzle 54 is connected via a pipe 52 to a manifold 62 which, in turn, is connected to a cooling fluid supply source 58 via a means such as a blower, not shown. A control valve 64 is provided at that pipe 52 associated with the nozzle 54 which is located near the manifold 62. This pipe arrangement allows the amount of cooling fluid which is to flow through the nozzle 54 to be controlled independently for each nozzle 54.
Outside the heat insulation 26, six inlet nozzles 54 in the same vertical plane are fixed to a common support plate 66. A pair of piston rods 72 which are associated with air cylinders 68 are attached to a corresponding one of both ends of the support plate 66. The driving of the air cylinder 68 causes the support plate 66 to be moved toward and away from the outer surface of the heat insulation 26 and hence the forward ends of the inlet nozzles 54 to be moved to an extending position where they extend through the liner tube 22 to the proximity of the reaction tube 12 and to a retracted position where they are retracted into the inner surface of the liner tube 22.
At the outer upper portion of the heat insulation 26, a cooling fluid exhaust pipe 42 which is connected to a suction means is located in the same fashion as in the embodiment shown in FIGS. 1 and 2. Four exhaust nozzles 74 extend at a 90° interval from the pipe 42 into an inner spacing; that is, the ports of the forward end portions of the four nozzles 74 extend through the liner tube 22 into a spacing which is defined between the reaction tube 12 and the liner tube 22.
Although, in the arrangement shown in FIG. 3, a piping array leading from the inlet nozzle 54 to the cooling fluid supply source 58, support plate 66 for driving the nozzles 54, air cylinders 68, and so on have been explained in connection with the six inlet nozzles 54 as indicated by the right side in FIG. 3, the same thing can be true of the other inlet nozzles 54 which are located at a 90° interval and at the other three places around the reaction tube 12.
In use, the interior of the reaction tube 12 is initially heated by the heater 24 to a predetermined treatment temperature and a plurality of products, such as semiconductor wafers W, are loaded into the reaction tube 12 via the lower opening of the reaction tube. A predetermined gas is fed into the reaction tube 12 to form a film on the semiconductor wafer or to subject the semiconductor wafer to treatments, such as diffusion. At the time of heating the reaction tube 12, the air cylinder 68 is operated by a control mechanism (not shown) so that all the inlet nozzles 54 are held at the retracted position. Thus the inlet nozzles 54 are held retracted from the inner surface of the liner tube 22, thus preventing a fall in thermal efficiency resulting from the conduction of heat, etc., via the nozzle 54.
If the interior of the reaction tube 12 is to be rapidly cooled, then the air cylinder 68 is operated by the control mechanism (not shown) and all the input nozzles 54 extend through the inner surface of the liner tube 22 toward the proximity of the reaction tube 12, that is, are moved to the extended position. The flow control valve 64 associated with the respective nozzle 54 is opened and a cooling fluid of 0.1 to 10 m 3 /min, for example, 3 m 3 /min, such as chilled air is fed via the blow-in port 56 of the inlet nozzle 54 into the spacing between the reaction tube 12 and the liner tube 22 to subject that area to forced air cooling for about 30 minutes. The respective air coming from the inlet nozzle 54 is blown horizontally (in the counterclockwise direction as viewed in the top plan view) into the ambient around the reaction tube 12 and, while being spirally rotated around the reaction tube 12 by absorbing the heat of the reaction tube 12, eventially exhausted via the topmost exhaust nozzle 74. As set forth above, the temperature prevalent in the uniformly heated zone 18 in the reaction tube 12 is detected on a continuous basis, and the amount of cooling fluid coming from the respective inlet nozzle 54 is individually controlled in accordance with the detection temperature level. The control of the fluid flow is accomplished by operating the respective control value 64 on the basis of the aforementioned detection temperature data and controlling the degree of opening of the control valve 64.
In the above embodiment, not only is it possible to obtain uniformity of heat in the horizontal plane, since the respective air stream, that is, chilled air, ascends spirally around the reaction tube 12, but it is also possible to assure vertical uniformity of temperature along the length of the heated zone 18, since the cooling fluid is blown at a plurality of locations, along the length of the reaction tube 12 and the flow of the fluid is varied in accordance with the detected temperature data. High cooling efficiency can be obtained, due to the direct cooling of the reaction tube 12 by a combined stream of the chilled air emitted from the respective nozzles. It is also possible to avoid a possible adverse effect caused by the oxidation, etc., resulting from the direct contact of the fluid, such as chilled air, with the heater 24 placed under a high temperature condition.
FIG. 5 shows a horizontal type heat treatment apparatus 100 with a reaction tube cooling system according to a third embodiment of the present invention.
A pipe 104 is connected to one end of a substantially horizontally arranged reaction tube 102 to conduct a predetermined reaction gas to the reaction tube. The pipe is connected to a gas supply source 112. The other end of the reaction tube 102 is closed by an end cap 114 equipped with a closure 116, and an exhaust pipe 106 leading to a recover section 118 is connected to the cap 114.
In order to provide a uniformly heated zone 108 within the reaction tube, a liner tube 122 made of, for example, silicon carbide is coaxially arranged around the reaction tube 102. A heating device, such as a coil-like heater 124, is wounded around the liner tube 122 with a spacing left therebetween. Heat insulation 126 is arranged around the heater 124 and has a dense and smooth inner wall surface.
The temperature of a uniformly heated zone 108 in the reaction tube 102 is detected on a continuous basis by sensors 110, such as thermocouples located at three places. The detection temperature level is transmitted as data to the control mechanism (not shown). The mechanism controls, based on the temperature level data, electric power to the heater 124 and an amount of fluid coming from respective cooling fluid inlet nozzles 134 as set forth above.
As shown in FIG. 6, a plurality of cooling fluid inlet nozzles 134 are provided in one array substantially along a whole length of the uniformly heated zone such that they face the lowest portion of the reactor tube 102. Although, in the arrangement shown in FIG. 5, nine inlet nozzles are shown by way of example, fifteen or more inlet nozzles may be provided in actual practice, in accordance with the size, etc., of the reaction tube. The inlet nozzles 134 are made of ceramics and have an inner diameter of 6 to 8 mm. The inlet nozzle 134 extend through those slits of the heat insulation 126 and liner tube 122 into an inner spacing; that is, the forward ends of the inlet nozzles extend into the inner spacing between the reaction tube 102 and the liner tube 122. The blow in ports of the forward ends of the respective inlet nozzles 134 are so oriented as to inject a cooling fluid in two directions along the outer surface of the reaction tube 102 in a vertical plane, as shown in FIG. 6, which is viewed in the horizontal direction.
The respective inlet nozzles 134 are connected via the pipe 132 to a manifold 142 which, in turn, is connected via a blower, not shown, to a cooling fluid supply source 138. In the neighborhood of the manifold 142, control valves 144 are provided one for each pipe 132 associated with the nozzle 134 whereby a flow of the cooling fluid can be controlled independently for each inlet nozzle.
Outside the heat insulation 126, the respective inlet nozzles 134 are fixes to a common support plate 146 which, in turn, is attached at each end to a piston rod 152 which is associated with an air cylinder 148. The support plate 146 is driven by the air cylinder 148 and moved toward and away from the outer surface of the heat insulation 126. As a result, the respective inlet nozzles 134 can be moved between an extending position where the forward ends of the inlet nozzles 134 extend through the inner surface of the liner tube 122 toward the reaction tube 102 and a retracted position where the forward ends of the inlet nozzles 134 are retracted into the inner surface of the liner tube 122.
Cooling fluid discharge nozzles 154 are so provided as to face both end portions of the uppermost side of a longitudinal section of the reaction tube 102. Outside the heat insulation 126, the exhaust nozzles 154 is connected to a suction means not shown and the forward end portions of the exhaust nozzles extend through the liner tube 122 into a spacing between the liner tube 122 and the reaction tube 102 so that their suction ports open into that spacing.
In use, the interior of the reaction tube 102 in the aforementioned heat treating apparatus 100 is initially heated by the heater to a predetermined treatment temperature. Then a closure 116 of an end cap 114 is opened and a plurality of products, such as semiconductors wafers W on a wafer boat 128, are loaded (for example softly landed). A predetermined reaction gas flows into the reaction tube 102 to form a film, on or conduct diffusion and so on of the semiconductor wafer. At the time of heating the reaction tube 102, the air cylinders 148 are operated by a mechanism, not shown, to hold all the inlet nozzles 134 at the retracted position. Thus the input nozzles 134 are held in the inner surface of the liner tube 122, preventing a fall in thermal efficiency resulting from the conduction etc., of heat through the nozzle.
If the interior of the reaction tube 102 is to be rapidly cooled, the air cylinder 148 is operated by the control mechanism, not shown, all the inlet nozzles 134 are so moved that their forward end portions are shifted through the inner surface of the liner tube into the proximity of the reaction tube 102. The flow control valves 144 associated with the nozzles 134 are opened, feeding a cooling fluid of 0.1 to 10 cm 3 /min, for example, 3 m 3 /min, such as chilled air, via the blow in ports 136 into the spacing between the reaction tube 102 and the liner tube 122 to allow forced air cooling to be carried out for about 30 minutes. The respective air coming from the respective inlet nozzle 134 is blown in two directions along the circumference of the reactor tube 102 to follow a flow pattern as indicated in FIG. 6. At the same time, as shown in FIG. 7, the air generally moves in a flow pattern in the longitandinal directions, being drawn through the discharge nozzles 154 which are provided at both the end portions of the reaction tube 102. The moving air as set out above absorbs heat from the reaction tube 102 and is exhausted eventually through the exhaust nozzles 154. As set forth above, the temperature prevailing in the uniformly heated zone 108 within the reaction tube 102 is detected on a continuous basis, and the amount of cooling fluid flowing from the inlet nozzle 134 is individually controlled in accordance with the detected temperature level. The control of the flow, as set forth above, is carried out by operating the control mechanism to vary the degree of opening of the control valve 144, on the basis of the detected temperature data.
In the embodiment as set forth below, the air, that is, the cooling fluid is blown at a plurality of spots in the aforementioned spacing generally over a whole length of the uniformly heated zone at a flow level of the fluid which is varied in accordance with the detected temperature data. Since the fluid is so blown into that spacing while being drawn in the directions in which the exhaust nozzles 154 are formed, the uniformity of the temperature is obtained both in the direction horizontal to the length of the uniformly heated zone 18 and in the direction perpendicular to the horizontal direction. The reaction tube 12 is directly cooled in a combined flow pattern, assuring a high cooling efficiency and thus avoiding an adverse effect caused from the cooling fluid, such as the oxidation etc., resulting from the direct contact of the chilled fluid (air) with the hot heater 24.
Although the present invention has been described in detail in conjunction with the desired embodiments illustrated in the accompanying drawings, it should be understood that various changes and modifications of the present invention can be made without departing from the spirit and scope thereof.
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A cooling system is disclosed which is incorporated in a heat treating apparatus for use in a manufacturing process of a semiconductor device etc. The heat treating apparatus includes a reaction tube for receiving products to be heat treated in its uniformly heated zone, and a heater which surrounds the reaction tube. Inlet means for blowing a cooling fluid and exhaust means for collecting that cooling fluid which is heated after the cooling function thereof has been achieved are provided. The fluid is blown from the inlet means around the reaction tube, substantially perpendicular to the axis of the reduction tube, and as a result, a flow of cooling fluid from the inlet means toward the exhaust means is established beyond the length of the uniformly heated zone, thus the entire reaction zone within the reaction tube is uniformly cooled.
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TECHNICAL FIELD
This invention relates to an apparatus for dispensing accurately metered quantities of paint colorant for use in tinting paint.
BACKGROUND
Paint of virtually any color may be custom mixed by adding precisely measured amounts of one or more differently colored paint colorants to a base. The color of paints can be greatly affected by small variations in the amount of colorant added. Consequently, paint colorant dispensers must provide precise, repeatable, settings.
A paint colorant dispenser typically has a reservoir and a metering device which allows the user to accurately dispense a desired quantity of paint colorant. The reservoir is typically a canister capable of holding 1 or 2 liters of paint colorant. Manual paint colorant dispensers are commonly used in paint stores, hardware stores, and other establishments where small batches of colored paint are prepared. In such dispensers the metering device typically includes a pump having a piston movable within a measuring cylinder. A valve allows an operator to selectively place the interior of the measuring cylinder either in fluid communication with the paint colorant reservoir or in fluid communication with an outlet nozzle. An adjustable stop limits the travel of the piston within the measuring cylinder.
To dispense a measured quantity of paint colorant, an operator sets the stop at a position which corresponds to the desired quantity, sets the valve to place the interior of the measuring cylinder in fluid communication with the reservoir and then moves the piston along the measuring cylinder until it is prevented from travelling further by the stop. The operator then switches the valve to a dispensing position in which the interior of the measuring cylinder is in fluid communication with the outlet nozzle. Finally, the operator pushes the piston along the measuring cylinder to expel the measured quantity of paint colorant through the outlet nozzle. The amount of paint colorant dispensed is determined by the stroke of the piston (as limited by the stop) and the bore of the cylinder.
A typical paint coloring station has several (typically between 10 and 16) paint colorant dispensers each containing a different paint colorant so that a user can rapidly add precise amounts of several different paint colorants to a base to obtain a desired color.
One problem with existing paint colorant dispenser technology is that different units of measure are used in different parts of the world to measure volumes of paint colorant. To enable quick and accurate metering of paint colorants it is generally desirable that a paint colorant dispenser have a stop for which the discrete stop positions correspond to the locally used units of measure. Even in the same geographical region it may be desirable to provide different discrete stop locations for different colorants. For example, a more finely graduated stop might be desirable in a dispenser for paint colorants which are typically used in smaller quantities whereas a stop having fewer, more widely separated discrete positions might be desirable in a dispenser used for colorants which are typically used in larger quantities.
The need to provide stops which are calibrated in different units provides a difficulty for the manufacturers of paint colorant dispensers. Existing paint colorant dispensers have gauge rods having precisely located holes which define the stop positions. The gauge rods can be removed and replaced to alter the stop positions. Such gauge rods tend to be expensive to make. In some cases a gauge rod may have fifty or more holes. Making parts with a great many precisely located holes tends to be expensive even with modern manufacturing methods. Consequently, it is not possible to provide paint colorant dispensers which include interchangeable gauge rods as cost effectively as would be desired.
Another disadvantage of currently available paint colorant dispensing technology is that paint colorants can be very messy if they escape from containment. The valves in a paint colorant dispenser must be made very precisely to avoid any leakage of paint colorant. Manufacturing valve parts to very close tolerances is expensive. Even where valves are precisely made, some paint colorants are quite abrasive and tend to cause significant wear in valves. There is a need for a type of valve suitable for use with manual paint colorant dispensers which can operate smoothly and without leakage and yet is not unduly expensive to fabricate and service.
A further disadvantage of prior art manual paint colorant dispensers is that paint colorants, by their nature, are affected by contact with air and can dry out. Typically after paint has been dispensed through the dispensing nozzle of a paint colorant dispenser a small droplet of paint remains on the nozzle. More paint colorant remains inside the nozzle after paint colorant has been dispensed. There is a need for reliable means to seal off the nozzle of a paint colorant dispenser after use to prevent paint colorant within and adhering to the nozzle from drying out between uses.
A further problem with prior art paint dispensers is that typically the discrete stop positions do not provide fine enough increments in cases where it is necessary to dispense only very small quantities of paint colorant. Tinting formulae for making particular colors of paint typically specify the amounts of different colorants to add to one gallon of base material to achieve the desired colours. The amounts of each paint colorant in the formula must be proportionally reduced to tint a smaller amount of base material. For example, the amounts of colorant specified by a formula for making 1 gallon of paint must be divided by 8 if only one pint of paint is being tinted. As a result it is often necessary to accurately measure very small quantities of paint colorant.
In general, with a paint colorant dispenser having a stop which can be fixed only in discrete stop positions which permit dispensing paint colorant in multiples of one unit, it is not easily possible to dispense a fraction of a unit of paint colorant. For example, many paint colorant dispensers are calibrated in units of 1/48 fluid ounce. With such paint colorant dispensers it is not easy to accurately dispense 1/96 fluid ounce or 1/192 fluid ounces of paint colorant. Some prior paint colorant dispensers approach the problem of accurately dispensing small amounts of paint colorant by requiring the user to replace a gauge rod in the stop assembly with a separate gauge rod. The separate gauge rod allows the stop to be fixed in a position which allows only a small volume of colorant to be dispensed. A problem with this approach is that the dispenser should be separately calibrated for use with the separate gauge rod. Also, the separate gauge rod is easily lost. Installing the separate gauge rod during the dispensing process introduces extra steps and raises the possibility of errors. Other paint colorant dispensers have a separate pump for dispensing small volumes. Both of these approaches significantly increase manufacturing costs.
SUMMARY OF THE INVENTION
This invention provides a paint colorant dispenser having a valve assembly which addresses some of the deficiencies of previous paint colorant dispensers. One aspect of the invention provides a paint colorant dispenser comprising a reservoir for holding paint colorant, a dispensing nozzle, a pump and a spool valve. The spool valve comprises a housing having a bore and first, second and third ports in an inner wall of the bore. The housing may be moulded integrally with the canister from a suitable plastic material. The first second and third ports are respectively in fluid communication with the reservoir, the pump, and the nozzle. The valve has a rotatable spool member received in the bore and a sealing member on the spool member. A spring in the spool member forces the sealing member against the inner wall of the bore. When the spool member is in a first position the first and second ports are in fluid communication with one another and the sealing member seals closed the third port and when the spool member is in a second position the second and third ports are in fluid communication with one another and the sealing member seals closed the first port. The spring accommodates any wear in the bore or the sealing member. The sealing member is preferably resilient and has an undeflected radius of curvature greater than a radius of curvature of the inner wall of the bore. This causes the sealing member to have a large area of contact with the bore to ensure a good seal. The sealing member preferably has a thicker central portion and thinner lateral edge portions.
Preferred embodiments of the invention provide a wiper assembly coupled to the spool member by a linkage. The wiper includes a wiper which covers an outlet of the nozzle when the spool member is in its first position. The wiper is preferably suspended from a track by a pair of resilient side members. The resilient side members bias the wiper against the nozzle when the spool member is in its first position so that the wiper seals the opening of the nozzle. The wiper and resilient side members are preferably combined in a single unitary plastic part.
Another aspect of the invention provides a valve for use in a paint colorant dispenser, the spool valve has a housing having a bore and first, second and third ports in an inner wall of the bore. A rotatable spool member is received in the bore. A sealing member is located on the spool member. A spring in the spool forces the sealing member against the inner wall of the bore. When the spool member is in a first position the first and second ports are in fluid communication with one another and the sealing member seals closed the third port. When the spool member is in a second position the second and third ports are in fluid communication with one another and the sealing member seals closed the first port.
Further features and advantages of the invention are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate non-limiting embodiments of the invention
FIG. 1 is front isometric view of a paint colorant dispenser incorporating a wiper assembly according to the invention;
FIG. 2 is a action through the paint colorant dispenser of FIG. 1 in which some elements have not been sectioned for clarity;
FIG. 3 is a section through a locking mechanism for the stop assembly of the invention;
FIG. 4 is a section through a valve and nozzle portion of the dispensing mechanism of the invention;
FIGS. 5 and 6 are details illustrating configurations of the stop locking mechanism sets to dispense small quantities of paint colorant;
FIG. 7 is an isometric view looking up from below a nozzle assembly in a paint colorant dispenser according to the invention;
FIG. 8 is a section through a valve and nozzle portion of the dispensing mechanism of a paint colorant dispenser according to the invention in a sane perpendicular to the section of FIG. 2;
FIG. 9 is a plan view of a valve member for use in the invention;
FIG. 10 is an isometric view of a valve member from a paint colorant dispenser according to the invention; and,
FIG. 11 shows a stop member equipped with an alternative spring.
LIST OF REFERENCE NUMERALS USED IN THE DRAWINGS
______________________________________List of Reference Numerals Used in the Drawings______________________________________10 paint colorant dispenser 12 canister 14 valve assembly 16 pump assembly 18 measuring cylinder 20 piston 22 piston rod 24 dispensing handle 26 seals 30 lower portion of measuring cylinder 32 stop assembly 34 stop member 35 projection 36 lower end of stop member 40 stop gauge rod 42 groove in stop member 44 bulges in gauge rod 46 alignment block 46A alignment notch 48 adjustment screw 50 notch 50A partial notch 50B small increment notch 50C adjacent notch 51 edge of gauge rod 52 stop locking assembly 54 stop locking blade 56 spring 58 scale 60 stop locking button 62 spring 62' spring 64 nozzle 66 valve spool 70 valve bore 72 valve operating handle 74 sealing member 76 groove 78 valve spring 80 nozzle port 84 canister port 86 pump port 88 indentations 89 projections 90 seals 92 O-rings 94 O-ring grooves 98 wiper assembly 100 wiper 104 track 106 arrow 110 resilient side portion 112 inclined portion 114 wings 116 grooves 118 ramped portion 120 lever 124 lever 126 block 130 cavity______________________________________
DESCRIPTION
As shown in FIGS. 1 and 2, a paint colorant dispenser 10 has a canister 12 which provides a reservoir for paint colorant. A metering device comprising a valve assembly 14 and a pump assembly 16 is connected to canister 12. Canister 12 typically includes an agitator (not shown) for stirring the paint colorant within canister 12.
Pump assembly 16 comprises a measuring cylinder 18 and a piston 20 which is slidably and sealingly mounted inside measuring cylinder 18. A piston rod 22 connects piston 20 to a handle 24. Piston 20 has suitable seals 26 so that paint colorant is confined to a lower portion 30 of measuring cylinder 18 between piston 20 and valve assembly 14. An operating handle 24 is mounted at the upper end of piston rod 22. By grasping handle 24 and moving it vertically a user can move piston 20 in measuring cylinder 18 to vary the volume of lower portion 30.
The travel of piston 20 within measuring cylinder 18 is limited by a stop assembly 32. A user can lift operating handle 24 only until stop assembly 32 prevents further travel of piston 20. Stop assembly 32 comprises a movable stop member 34. In the illustrated embodiment, there are two piston rods 22 which connect operating handle 24 to piston 20. Stop member 34 is T-shaped in section, fits through a T-shaped aperture in operating handle 24 and extends into measuring cylinder 18 between piston rods 22. The stroke of piston 20, and, therefore, the quantity of paint colorant dispensed in a single stroke of piston 20 can be adjusted by moving stop member 34 upwardly or downwardly to a position where a stroke of piston 20 will dispense the desired amount of paint colorant. When stop member 34 is in position the stroke of piston 20 is limited by projections 35 on stop member 34 which block passage of operating handle 24. In the alternative, a lower end 36 of stop member 34 could provide a definite limit to the travel of piston 20. When stop member 34 is positioned to allow a desired amount of paint colorant to be dispensed then stop member 34 is locked in place as described below.
Stop assembly 32 comprises a gauge rod 40. Gauge rod 40 is removably attachable to stop member 34. In the illustrated embodiment, gauge rod 40 is received within a groove 42 in stop member 34. Stop gauge rod 40 may be held in place within groove 42 by stamped bulges 44 which snap into place in recesses (not shown) within groove 42. An alignment block 46 in stop member 34 is received in a notch 46A in gauge rod 40. Block 46 and notch 46A preserve vertical alignment between gauge rod 40 and stop member 34. An adjustment screw 48 in operating handle 20 allows fine adjustment of the stroke of piston 20.
Gauge rod 40 comprises a number of notches 50 equally spaced apart along one of its edges 51. A stop locking assembly 52 comprising a blade 54 is mounted to measuring cylinder 18. Blade 54 is biased into engagement with edge 51 of gauge rod 40 by a spring 56. Stop member 34 is prevented from moving when blade 54 is engaged in a notch 50. By engaging blade 54 in a particular one of notches 50 the volume of paint colorant dispensed in a single stroke of piston 20 can be set at a desired amount. A scale 58 on a front surface of stop member 32 indicates the number of units of paint colorant which will be dispensed in a stroke of piston 20, as limited by the current position of stop member 34. In the preferred embodiment, when operating handle 24 is in its lowermost position, the top of operating handle 24 intersects scale 58 at an indicia which indicates the number of units of paint colorant which will be dispensed in a stroke of piston 20.
A user can adjust the position of stop member 34 by depressing a stop locking button 60 which moves blade 54 rearwardly, out of engagement with notches 50. Stop member 34 can then be freely adjusted upwardly or downwardly to a desired position.
The set of available discrete positions in which stop member 34 can be locked can be changed by simply removing gauge rod 40 and replacing gauge rod 40 with another gauge rod 40 having differently spaced notches 50. A particular advantage of the illustrated design is that stop gauge rod 40, including notches 50 may be accurately stamped, in a single operation, from a sheet of a suitable material such as steel. A gauge rod 40 as illustrated in the drawings is far less expensive to manufacture than a gauge rod which has a large number of precisely located holes.
Paint colorant dispenser 10 is capable of accurately metering small quantities of paint colorant. Moving stop member 34 from one discrete position to an adjacent discrete position (i.e. moving blade 54 from one notch 50 into an adjacent notch 50) varies the amount of paint colorant dispensed by one unit of volume. Stop assembly 32 of paint colorant dispenser 10 can be set to dispense one half of a unit or one quarter of a unit of paint colorant.
The invention provides a novel way to dispense small volumes of paint colorant. As shown best in FIGS. 5 and 6, gauge rod 40 has an uppermost notch which comprises a partial notch 50A on the side of a deeper notch 50B. As shown in FIGS. 5 and 6, partial notch 50A comprises a recess capable of receiving blade 54 in one wall of deeper notch 50B.
An adjacent notch 50C is smaller than other notches 50 so that it does not interfere with partial notch 50A. When blade 54 is engaged in partial notch 50A, as shown in FIG. 5, the travel of piston 20 is limited so that a small amount, for example, one half unit of paint colorant is dispensed in a stroke of piston 20. When blade 54 is engaged in notch 50B, as shown in FIG. 6, then a still smaller amount, for example, one quarter of a unit of paint colorant is dispensed in each stroke of piston 20. Partial notch 50A preferably has a back surface which is flat or else contoured in some other way such that blade 54 does not tend to slip out of engagement with partial notch 50A but blade 54 can slip into deeper notch 50B if stop member 34 is displaced downwardly while blade 54 is engaged in partial notch 50A.
A spring 62 is provided on stop member 34. Spring 62 biases gauge rod 40 against blade 54 when blade 54 is engaged in partial notch 50A. This prevents stop member 34 from dropping downwardly. If stop member 34 were not prevented from dropping downwardly then blade 54 could slide out of partial notch 50A into deeper notch 50B. In the illustrated embodiments, spring 62 is mounted on stop member 34. In the embodiment of FIGS. 2 and 3, spring 62 is mounted at an upper end of stop member 54 and is located so that it begins to bear against the upper end of operating handle 24 as stop member 34 is lowered into a position where blade 54 can be engaged with partial notch 50A.
In the embodiment of FIG. 11, spring 62' is U-shaped and is mounted to lower end 36 of stop member 34. Spring 62' bears against piston 20 so as to bias stop member 34 upwardly when blade 54 is engaged in partial notch 50A. In the embodiment of FIG. 11 spring 62' is protected inside measuring cylinder 18 and is not likely to snag a user's clothing or become damaged in use.
Spring 62 (or 62') facilitates setting stop assembly 32 for dispensing 1/4 unit of paint colorant. A user can push stop release button 60, and, with dispensing handle 24 in its lowermost position, depress stop member 34 until spring 62 (or 62') bears against the top of dispensing handle 24 (or the top of piston 20). The user can then release stop release button 60 to allow blade 54 to engage partial notch 50A.
If the user wishes to dispense only 1/4 unit of paint colorant then a user can set stop assembly 32 to dispense 1/2 unit of paint colorant, as described above, and then the user can push down on stop member 34 against the action of spring 62 (or 62') until blade 54 snaps into position in notch 50B. In the alternative, the user can depress stop release button 60, push stop member 34 fully downwardly and then release stop release button 60 so that blade 54 engages notch 50B. Notch 50B is wider than other notches 50 so that blade 54 can enter notch 50B even when stop member 34 is in its lowermost position. It is not necessary that the small increments of paint colorant to be dispensed are 1/2 unit or 1/4 unit. Notches 50A and 50B could be located to allow stop member 32 to be positioned to allow, for example, one third or two thirds of a unit of paint colorant to be dispensed.
Paint colorant dispenser 10 can be used to dispense a measured quantity of paint colorant from canister 12 by setting stop assembly 32 in a position corresponding to the desired measured quantity and placing valve assembly 14 in a configuration such that canister 12 is in fluid communication with measuring cylinder 18 (as shown in FIG. 2). A measured quantity of paint colorant can then be drawn into measuring cylinder 18 by lifting operating handle 24 to draw piston 20 upwardly from its lowermost position within measuring cylinder 18 until stop member 34 prevents further travel of piston 20. As piston 20 is raised, paint colorant is drawn from canister 12, through valve assembly 14 into lower portion 30. The volume of paint colorant drawn into measuring cylinder 18 depends upon the diameter of measuring cylinder IS and the stroke of piston 20. When the desired quantity of paint colorant has been drawn into measuring cylinder 18 then valve assembly 14 may be set so that measuring cylinder 18 is in fluid communication with a nozzle 64 (as shown in FIG. 4). The paint colorant can then be dispensed from measuring cylinder 18 through nozzle 64.
Valve assembly 14 is then configured so that measuring cylinder 18 is in fluid communication with nozzle 64. When a user subsequently lowers piston 20 by depressing operating handle 24 the paint colorant filling lower portion 30 is forced through valve assembly 14 and expelled through nozzle 64.
Paint colorant dispenser 10 comprises a valve assembly 14 which alleviates the problems of valve leakage and valve wear. Valve assembly 14 comprises a valve spool 66 which is received within a valve bore 70. Spool 66 may be rotated about its axis within bore 70 by means of valve operating handle 72. Spool 66 carries a sealing member 74 on its outer surface and has a circumferentially extending groove 76. Sealing member 74 is biased by a strong valve spring 78 so that it bears tightly against the inner surface of valve bore 70. Valve spring 78 preferably has a spring constant on the order of 130 pounds/inch.
In a first position, as shown in FIG. 2, sealing member 74 blocks a nozzle port 80 which connects valve bore 70 to nozzle 64 and permits paint colorant to flow from canister 12 into lower portion 30 through a canister port 84, groove 76 and a pump port 86. Canister port 84 may be called a "first" port, pump port 86 may be called a "second" port and nozzle port 80 may be called a "third" port. In a second position, which is illustrated in FIG. 4, sealing member 74 blocks canister port 84 and a places nozzle 64 in fluid communication with lower portion 30 by way of pump port 86, groove 76 and nozzle port 80.
Because strong spring 78 is continuously biasing sealing member 74 against inner surfaces of valve bore 70, valve assembly 14 continues to provide good sealing even if some wear occurs on sealing member 74 and/or on valve bore 70. Sealing member 74 and valve bore 70 may both be made of the same plastic material. Acetal or Delrin™ are good materials for sealing member 74 because of their desirable wear, bearing and resilience properties.
Preferably sealing member 74 is resilient and has edge portions which are thinner than its central portion. Sealing member 74 is preferably made of plastic. Most preferably when sealing member 74 is not being exposed to any external forces (i.e. is "undeflected") the outer surface of sealing member 74 has a radius of curvature slightly greater than that of valve bore 70. Spring 78 causes sealing member 74 to flex as it forces the central portion of sealing member 74 against the interior of valve bore 70. This insures a large area of contact between sealing member 74 and valve bore 70.
As shown best in FIGS. 9 and 10, sealing member 74 has indentations 88 which engage projections 89 in valve spool 66. This prevents sealing member 74 from slipping relative to valve spool 66 as valve spool 66 is rotated within bore 70. End seals 90 which comprise o-rings 92 received within grooves 94 in valve spool 66 are provided to prevent axial leakage of paint colorant from valve bore 70.
A further feature of paint colorant dispenser 10 is the wiper assembly 98 which comprises a wiper 100 which seals the bottom of nozzle 64 at times when paint colorant is not being dispensed through nozzle 64. Wiper assembly 98 can slide inwardly or outwardly along a track 104 as indicated by arrow 106. When handle 72 is in its first position, as shown in FIG. 2, wiper 100 covers the exit of nozzle 64. As valve handle 72 is moved from its first position to its second position wiper assembly 98 is pulled inwardly, thereby exposing the end of nozzle 64.
Wiper 100 is suspended from resilient side portions 110 and has an inclined portion 112 on its front surface. Side portions 110 are preferably U-shaped sections of resilient plastic. Most preferably wiper assembly 98 comprises a single unitary plastic part. When handle 72 is moved from its second position back to its first position wiper 100 approaches nozzle 64. As inclined portion 112 encounters nozzle 64 wiper 100 is forced downwardly against the resilient action of resilient side portions 110. Wiper 100 continues to move until handle 72 is back in its first position. At this point, wiper 100 once again covers the lower end of nozzle 64 and resilient side portions 110 hold wiper 100 in tight contact with the lower end of nozzle 64.
Nozzle 64 has wing portions 114. Wing portions 114 engage in grooves 116 which are located on wiper assembly 98 above resilient side portions 110. Wings 114 hold the upper portion of wiper assembly in position to insure that wiper 100 will be biased against the lower end of nozzle 64 with sufficient force to provide a good seal. Forward ends 118 of grooves 116 are ramped so that wings 114 tend to push wiper assembly 98 upwardly as wiper 100 moves back in a direction opposite to arrow 106 to cover the lower end of nozzle 64.
Wiper assembly 98 is linked to valve operating handle 72 by a linkage which allows wiper 100 to continue to completely cover the lower end of nozzle 64 until valve operating handle 72 is nearly in its second position. In the illustrated embodiment, the linkage connecting wiper 100 to valve operating handle 72 comprises a pair of operating levers 120 and 124 which are mounted on either end of valve spool 66. Each of operating levers 120 and 124 has a block 126 which engages a circumferentially extending cavity 130 in valve spool 66. As handle 72 is moved from its first position toward its second position, operating levers 120 and 124 initially do not move. Eventually, for example when valve operating handle 72 is about 30 degrees away from its second position, blocks 126 abut against the ends of circumferentially extending cavities 130. Further motion of valve operating handle 72 causes operating levers 120 and 124 to pull wiper assembly 100 inwardly, away from nozzle 64.
A paint colorant dispenser 10 according to the invention may be made almost entirely of plastic. Only gauge rod 40, blade 54, springs 56, 62 and 78, any necessary screw fasteners and measuring cylinder 18 are preferably fabricated of metal.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. By way of example only, springs 62 and 62' have been provided as bias means for biasing stop member 34 away from piston 20. Springs 62 and 62' do not need to be connected to stop member 34 but could be mounted on adjacent structures. Spring 62 or 62' could have a different shape from the shapes illustrated. Springs 62 and 62' could, for example, be replaced by a coil spring received in a well in an upper end of piston 20. Another suitable bias means could be used in place of springs 62 and 62'. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
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A paint colorant dispenser has a notched gauge rod on a stop member. The notched gauge rod can be easily replaced to change the units of measure for the paint colorant dispenser and is also inexpensive to manufacture. A double notch at an extreme end of the gauge rod facilitates accurate metering of small quantities of paint colorant. The dispenser has a spool valve which includes a resilient sealing member which is biased against an inner surface of a valve bore by a strong spring. The sealing member provides a good seal and accommodates wear without leakage. With the exception of the spring, the valve may be made of plastic. The valve does not need to be manufactured to extremely precise tolerances. The paint colorant dispenser has a wiper assembly coupled to operate with the valve. The wiper assembly includes a resiliently mounted wiper which closes off a lower end of the nozzle except when the valve is set to dispense paint colorant through the nozzle.
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REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/715,084, filed Mar. 1, 2010, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to the use of recycled scrap materials and, in particular, to the production of molded, multi-layered structural panels using such materials.
BACKGROUND OF THE INVENTION
[0003] The advent of prepreg technology for high-performance aerospace, railway, energy, marine, sports and leisure applications has resulted in the pioneering use of multi-layered composites, or sandwiches, for structural applications.
[0004] A prepreg consists of a combination of a matrix (resin) and fiber reinforcement in the form of woven or non-woven mats. Fiber reinforcement is available in unidirectional form (one direction of reinforcement) or in fabric form (several directions of reinforcement). The role of the matrix is to support the fibers and bond them together in the composite material. In order to give the finished composite environmental and temperature resistance, matrix resins are in their overwhelming majority thermoset materials.
[0005] Depending upon final temperature exposure and desired mechanical properties, the resin is selected from three different polymer classes: phenolic, epoxy and bismaleimide/polyimide. Recent developments, however, have demonstrated that unsaturated polyester resins, which are easier to handle than epoxy resins, can be also used for prepreg manufacturing.
[0006] Wetted fibers, through the application of the matrix resin, become stronger and stiffer; as a result, they support most of the applied loads. Unidirectional composites have mechanical properties in one direction (anisotropic); on the other hand metals are isotropic, i.e. have equal properties in all directions.
[0007] Prepreg sandwich constructions ( FIG. 1 ) are the most prevalent composites in use today. Such constructions consist of thin, high strength skins (or outer layers) bonded through the optional use of an adhesive film layer to a thicker, light weight core material that can be balsa wood, foam or a circular or polygonal-hollowed construction, generally a honeycomb having an hexagonal shape ( FIG. 2 ).
[0008] Performance characteristics of this type of construction are:
[0009] Tensile and compression stresses are supported by the skins,
[0010] The skins are stable across their whole length,
[0011] Shearing stress is supported by the core (honeycomb),
[0012] Rigidity is available in several directions, and
[0013] Excellent weight savings.
[0014] Prepreg sandwiches can be manufactured by complex and costly processes such as autoclaving or vacuum bag molding. However, press or compression molding has also been used ( FIG. 3 ) and has become more prevalent.
[0015] In summary, prepreg technology is a complex and costly process whose use is justified by the demanding and highly critical technical requirements of targeted aerospace applications. Its benefits are lower weights than these available with previously-used metallic constructions, greater strength and higher stiffness.
[0016] More recently, technical advances in the field of polyurethane chemistry and processing have made the prepreg sandwich concept and its production more affordable and easier to implement. This has resulted in molded polyurethane articles, such as polyurethane foams and polyurethane composites that are now extensively used by the automotive, construction and furniture industries. Such articles are generally available in the form of sandwich, or multi-layered, constructions, that produce high strength, structural parts.
[0017] The leading polyurethane technology, marketed under the trade name Baypre® F (Bayer AG, Germany), is described in U.S. Pat. No. 6,156,811 (hereafter referred to as the '811 patent) and U.S. Pat. No. 7,419,713 B2 (hereafter referred to as the '713 patent).
[0018] This approach relies on a multi-step process whereby a composite component is created by producing a sandwich structure made of at least one core layer located between at least two outer layers. The steps described in the '713 patent are the following ( FIG. 4 ):
[0019] (i) Insert the core and the outer layers into a compression mold, the core being located between the outer layers. The core is a honeycomb structure and the outer layers are glass fiber or natural fiber mats.
[0020] (ii) Apply a polyurethane resin either by a casting or a spraying operation on one or both outer layers. Steps (i) and (ii) can be performed in any order.
[0021] (iii) Compression mold under high heat the core with the outer layers to cure the resin and form the sandwich structure.
[0022] (iv) Optionally attach decorative layers on top of the top outer layer and or below the bottom outer layer only after steps (i) to (iii) are completed.
[0023] The present invention improves on the above process by sequentially placing bottom outer layer, core layer, and top outer layer in the compression mold and allowing the finished part or component to be manufactured in a single press mold, using a single step or molding process, without the additional step of applying a polyurethane resin. Optional bottom decorative layers and top decorative layers can be added as part of the process, if desired.
[0024] The present invention therefore presents two key benefits over the prior art, by providing a single step process to produce a finished component, including the optional addition of decorative layers, in a single mold, and the elimination of resin application to the outer layers which results in less expensive and lighter weight panels.
SUMMARY OF THE INVENTION
[0025] This invention is concerned with molded, multi-layered articles prepared from recycled material such as automotive interior trim scrap, and the use of such articles in the automotive, construction and furniture industries. In the preferred embodiment, multi-layer, finished components or parts are formed in a single process involving two outer layers positioned on each side of a core layer. Decorative layers can be optionally positioned on top of the top outer layer and, or, below the bottom outer layer. The core layer can have a corrugated structure, a honeycomb structure, a solid structure, or a partially voided structure created by the presence of circular or other “tubes” arranged in a parallel fashion.
[0026] The two outer layers are preferably obtained by shredding automotive interior trim scrap or components into a fluff, and adding an isocyanate adhesive composition, as described in U.S. patent application Ser. No. 12/715,084, incorporated herein by reference. A press mold having top and bottom platens may be used in manufacture. The process includes depositing on the bottom of the mold the fluff mixed with the adhesive composition (bottom outer layer). The core layer is then placed on top of the bottom outer layer; a second layer of fluff mixed with the adhesive composition (top outer layer) is deposited on top of the core layer. In the preferred embodiments, the core layer and outer layers are neither chemically nor mechanically bound, but are instead placed in contact within the forming mold.
[0027] An advantage of the invention over prior art processes is the ability to apply on either or both sides of the sandwich comprising the fluff and adhesive placed on both sides of the honeycomb core in the compression mold, a decorative coverstock or textile or other polymeric film, sheet or scrim, without additional adhesive, to produce a trim panel with decorative coverstock or other polymeric film, sheet or scrim adhered either on one side or both sides of the panel.
[0028] The decorative coverstock or other polymeric film, sheet or scrim can be dispensed onto the panel as discrete films, sheets, scrims or as continuous rolls. The final step involves the thermal compression molding of the involved layers for a specified amount of time to produce the finished composite. Using a single, compression molding process and a single piece of equipment, a lightweight finished article is produced that is strong, rigid and stiff without the need for cast or spray resin compositions or the use of reinforcing fiber mats, as dictated by the prior art.
[0029] Articles produced in accordance with the invention exhibit structural performances at lower weight and cost than components fabricated using prior art methods. Moreover, existing methods require multiple steps and multiple layers to form the desired sandwich structure, followed by attaching one or more optional decorative layers through an additional, subsequent step.
[0030] The finished articles may be directed to any structural application in the automotive, construction, furniture, marine, railway, energy, leisure and sports industries. In the automotive industry, for example, finished articles and parts may include, without limitation, headliners, sun shades, moon roofs, package trays, spare tire covers, load floors, rocker panels and other structural parts such as wall panels. In the construction industry, finished goods may be used as sound-insulating and thermal-insulating panels. The invention is not limited in terms of end use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 illustrates a honeycomb construction used in prepreg structures;
[0032] FIGS. 2A-2C shows the types of honeycomb cores used in honeycomb constructions;
[0033] FIG. 3 depicts a prepreg compression molding process;
[0034] FIG. 4 shows the Baypreg® F Molding Process;
[0035] FIG. 5 illustrates a cross-sectional plan view of a finished product manufactured in accordance with the invention;
[0036] FIG. 6 is the innovative process to form the finished product;
[0037] FIG. 7 is the innovative process to form the finished product;
[0038] FIG. 8 is the innovative process to form the finished product including a top decorative layer;
[0039] FIG. 9 is the innovative process to form the finished product; and
[0040] FIG. 10 is the innovative process to form the finished product including a top decorative layer.
DETAILED DESCRIPTION OF THE INVENTION
[0041] FIG. 5 is a cross-sectional plan view of a finished product manufactured in accordance with the invention. The lightweight composite structure 10 is produced using a one-step molding process described herein below and depicted in FIGS. 6-10 . FIG. 6 shows the loading of core layer 44 , as a discrete sheet, on top of bottom outer layer 42 which had previously been placed on bottom of tool 36 . As represented in FIG. 2A , core layer 44 can incorporate foam, including but not limited to polyurethane foam, preferably rebounded rigid polyurethane foam produced as described in patent application Ser. No. 12/715,084.
[0042] The foam core can have a solid structure, or have a partially hollowed space created by the presence of a plurality of tube members arranged parallel to each other and transverse or perpendicular to the planes of the outer layers. Such tubes may be circular or may have a polygonal structure, preferably a honeycomb-like structure, thereby creating open spaces between the outer layers 42 and 43 to produce a rigid and self-supporting core layer 44 . FIG. 5 shows a molded core layer 12 having a honeycomb geometry between two molded outer layers 16 . Panel thickness ranges from 5 mm to 30 mm. In addition to other core geometries, other panel thicknesses are possible.
[0043] Making reference to FIG. 2B , the core structure, whether honeycomb or not, may be constructed from paper or cardboard, resin-impregnated paper or cardboard, metal, including but not limited to aluminum, magnesium, titanium, and alloys thereof, plastic material, including but not limited to polyester, polyurethane, polyamides, polycarbonates, polystyrenes, acrylonitrile butadiene styrene (ABS), and mixtures thereof, and aramid polymers, including but not limited to Nomex and Kevlar. Alternatively, as shown in FIG. 2C , the core layer may be corrugated paper or cardboard or corrugated resin-impregnated paper or cardboard.
[0044] Resin impregnation of the paper or cardboard or corrugated structures enhances strength and helps resist moisture and fungus, said resin being selected from phenolic resins. Resin content can be varied to match the application and desired physical properties of the molded sandwich; resin content generally ranges from 5% to 30% by weight, preferably 10 to 25%.
[0045] Core layer 44 thickness, prior to molding, is in the range of 2 mm to 50 mm, preferably 5 mm to 30 mm. Core layer 44 volumetric density, prior to molding, ranges from 16 to 160 kg/m 3 , preferably 18 kg/m 3 to 96 kg/m 3 .
[0046] A honeycomb or corrugated core layer 44 is further characterized by its cell size, defined as the width of the honeycomb or corrugated repeat unit. Core layers used in this invention have cell sizes selected from the group consisting of 6.35 mm (¼ in), 9.53 mm (⅜ in) 12.7 mm (½ in), 15.88 mm (⅝ in), 19.05 mm (¾ in), 23.81 mm ( 15/16 in), and 25.4 mm (1.0 in).
[0047] The preferred composition of the outer layers 42 and 43 has been previously described in parent application Ser. No. 12/715,084. Landfill-bound scrap material, also referred to as fluff, is obtained by shredding automotive interior trim scrap or components into smaller particles. Such automotive interior trim scrap or components may include the following polymers or a combination of the following polymers and fillers including, but not limited to: flexible, semi-rigid and rigid polyurethane foam, nylon, polyester, filled EVA (ethylene vinyl acetate), polypropylene, glass fibers, cotton and in some cases other natural fibers, such as flax, kanaf, hemp, jute, sisal, wheat straw, coconut husk, and bamboo among others. The composition of the outer layers 42 and 43 does not require the presence of any type of polyurethane foams, but can accommodate these polymers, if present.
[0048] The fluff is then blended with an isocyanate adhesive composition that comprises a curable non-aqueous polyisocyanate or curable non-aqueous isocyanate prepolymer. The isocyanate prepolymer can be prepared using an isocyanate component, illustratively including a diisocyanate component and/or a polyisocyanate component. As defined, the terminology polyisocycanate is to be construed as including prepolymers and free polyisocyanates. The isocyanate component generally provides reactive groups, i.e., NCO groups, during subsequent reactions. The isocyanate component may be selected from the group of toluene diisocyanate (TDI), methylene diphenyl diisocyanate (MDI), including dimers, trimers, and higher oligomers thereof. A combination of TDI and MDI may also be used, the TDI may be present in the isocyanate component in an amount of from 65 to 80 parts by weight based on 100 parts by weight of the isocyanate component.
[0049] In the case of the isocyanate prepolymer, the isocyanate component is reacted with an isocyanate-reactive component to form a prepolymer. The isocyanate-reactive component generally provides hydroxyl groups for reaction with the NCO groups of the isocyanate component. More specifically, the isocyanate-reactive component may include a polyol. The isocyanate-reactive component may also include at least two polyols. Any known polyol suitable for reaction with the isocyanate component is suitable for purposes of the present invention. For example, the isocyanate-reactive component may be selected from the group of polyether polyols, polyoxyalkylene polyols, polyester polyols, graft polyols, polymer polyols, polyols derived from renewable resources, such as, but not limited to, soy polyols, castor oil polyols, canola oil polyols, rapeseed oil polyols, palm oil polyols, and combinations thereof. Examples of suitable polymer polyols include, but are not limited to, polyol dispersions of styrene/acrylonitrile particles (SAN) and polymer-modified polyols such as polyisocyanate polyaddition (PIPA) polyols and poly Harnstoff dispersion (PHD) polyols.
[0050] When the adhesive composition is blended with the fluff, moisture cure of the adhesive composition under heat and pressure yields a molded panel. However, the composition of top and bottom outer layers 42 and 43 , positioned on either side of the core layer can be the same or different. Furthermore, top and bottom outer layers 42 and 43 can have the same thickness and surface density, the same thickness and different surface densities, or different thicknesses and the same surface density.
[0051] Outer layer 42 and 43 thickness generally ranges from 0.1 mm to 12 mm, preferably 0.5 mm to 10 mm. Surface density, defined as the weight per unit area of outer layers 42 and 43 , generally ranges from 200 g/m 2 to 2000 g/m 2 , preferably 500 g/m 2 to 1850 g/m 2 . Prior to the compression molding process of this invention, the outer layers 42 and 43 are not connected to the core 44 by way of adhesive or other mechanical devices; they are merely placed in contact with each other for final product formation. Surface density, or weight per unit area of the molded sandwich structure 10 (without optional decorative layer 48 ), generally ranges from 1200 g/m 2 to 2500 g/m 2 , preferably 1500 g/m 2 to 2050 g/m 2 .
[0052] There can be one optional decorative layer 48 on top of outer the top layer 43 , one optional decorative layer 48 on the surface of the mold 36 and below the core layer 44 , two optional decorative layers 48 —one on top of the outer top layer 43 , the other on the surface of the mold 36 —or no decorative layers. The optional decorative layers 48 positioned on top of the top outer layer 43 and below the bottom outer layer 42 can be the same or different. The optional decorative layer 48 ( FIG. 8 ) includes, but is not limited, to woven and non-woven carpet, woven and non-woven fabrics, felts, knitted fabrics, braided fabrics, leather, polyurethane, glass, polymers, films, laminates, sheets and scrims, said decorative layers can be with or without adhesive coatings or backings.
[0053] The finished article is produced when the outer layers 42 and 43 and the core layer 44 are attached under heat and pressure in the mold. The isocyanate adhesive composition contained in the outer layers 42 and 43 has a double role: after heat and pressure have been applied during the molding process, the moisture-cure adhesive cures the fluff in the outer layers 42 and 43 into two solid outer layers 16 and 17 while at the same time creating a chemical bond between the outer layers 42 and 43 and the core layer 44 , yielding molded article 10 comprising molded outer layers 16 and 17 and molded core layer 12 ( FIG. 5 ).
[0054] The innovative process is described in detail in FIGS. 6-10 . FIG. 6 shows the loading of the honeycomb core layer 44 from a stack of honeycomb sheets or layers onto the top of the bottom outer layer 42 which had already be placed on the bottom press platen or bottom surface of the compression mold 36 . In FIG. 7 , the top outer layer 43 is transported as a mat on a belt then transferred to the compression mold where it is placed on top of the core honeycomb layer 44 . The process for laying the bottom outer layer 42 in the bottom of the compression mold 36 in FIG. 6 is identical to the one just described for the top outer layer 43 in FIG. 7 .
[0055] FIG. 8 illustrates the optional presence of a decorative layer or coverstock 48 which is placed on top of the top outer layer 43 before the press operation. The outer layer 43 is not connected to the decorative layer 48 by way of adhesive or other mechanical devices; decorative layer 48 and outer layer 43 are merely placed in contact with each other in the molding equipment. Decorative layer 48 can also be placed in the bottom of the tool 36 . In the FIG. 8 representation, the decorative layer 48 is dispensed as a discrete sheet, layer, film or scrim; it can also be dispensed from continuous rolls.
[0056] FIG. 9 shows a representative press set-up for molding the innovative structural component 10 from its constituent layers, bottom outer layer 42 , core honeycomb layer 44 and top outer layer 43 . The press has a top platen 34 and bottom platen 36 . Once all layers have been placed in the tool as described in FIGS. 6-8 , pressing and heat curing take place by bringing top platen 34 and bottom platen 36 together to close the mold at temperatures ranging from 130° C. to 200° C., preferably between 160° C. and 190° C. Molding times during which the press remains closed generally range from 30 seconds and 10 minutes, preferably between 1 minute and 5 minutes.
[0057] FIG. 10 shows a molded process similar to the one of FIG. 9 , with the additional presence of a decorative layer 48 positioned on top of the top outer layer 43 , as described in FIG. 8 .
Example 1
[0058] Waste rigid polyurethane foam laminated to plastic film obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (14.3% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. Fluff blended with the adhesive composition (30 g) is placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0059] A 203 mm×203 mm×9.53 mm (8 in×8 in×⅜ in) corrugated cardboard honeycomb weighing 16 g and having a cell size of 9.53 mm (⅜ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 30 g of aforementioned fluff blended with the adhesive composition; finally fluff blended with the adhesive composition (30 g) is placed on the top of the core layer and the entire sandwich is compressed to a nominal 12.7 mm (0.5 in) total thickness.
[0060] Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 11.68 mm (0.46 in) thick, weighted 70 g and had a surface density of 1,695 g/m 2 (158.6 g/ft 2 ). It was stiff and could not be bent without a substantial effort.
Example 2
[0061] Waste rigid polyurethane foam laminated to plastic film obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (14.3% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. Fluff blended with the adhesive composition (30 g) is placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0062] A 203 mm×203 mm×9.53 mm (8 in×8 in×⅜ in) corrugated cardboard honeycomb weighing 18 g and having a cell size of 6.35 mm (¼ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 30 g of aforementioned fluff blended with the adhesive composition; finally fluff blended with the adhesive composition (30 g) is placed on the top of the core layer and the entire sandwich is compressed to a nominal 12.7 mm (0.5 in) total thickness.
[0063] Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 12.70 mm (0.50 in) thick, weighted 72 g and had a surface density of 1,745 g/m 2 (162 g/ft 2 ). It was stiffer than Sample 1 and could not be bent without a substantial effort.
Example 3
[0064] Waste rigid polyurethane foam laminated to plastic film obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (14.3% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. A 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold, comprising the optional bottom decorative layer. Fluff blended with the adhesive composition (30 g) was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0065] A 203 mm×203 mm×9.53 mm (8 in×8 in×⅜ in) corrugated cardboard honeycomb weighing 18 g and having a cell size of 6.35 mm (¼ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 30 g of aforementioned fluff blended with the adhesive composition; fluff blended with the adhesive composition (30 g) which comprises the top outer layer is placed on the top of the core layer and the entire sandwich is compressed to a nominal 12.7 mm (0.5 in) total thickness.
[0066] Finally, a 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, comprising the optional top decorative layer, was placed on the top of top outer layer. Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 13.72 mm (0.54 in) thick, weighted a total of 82 g and had a surface density of 1,985 g/m 2 (184.5 g/ft 2 ). It was much stiffer than Sample 2 and could not be bent without a substantial effort.
Example 4
[0067] Waste rigid polyurethane foam laminated to plastic film obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (14.3% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. A 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold, comprising the optional bottom decorative layer. Fluff blended with the adhesive composition (28 g) was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0068] A 203 mm×203 mm×9.53 mm (8 in×8 in×⅜ in) phenolic impregnated (15% content) corrugated cardboard honeycomb weighing 20 g and having a cell size of 6.35 mm (¼ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 28 g of aforementioned fluff blended with the adhesive composition; fluff blended with the adhesive composition (28 g) which comprises the top outer layer is placed on the top of the core layer. Finally, a 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, comprising the optional top decorative layer, was placed on top of top outer layer.
[0069] Compression sufficient to maintain a nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 13.72 mm (0.54 in) thick, weighted a total of 74 g and had a surface density of 1,790 g/m 2 (166.5 g/ft 2 ). It was much stiffer than Sample 3 and could not be bent without a substantial effort.
Example 5
[0070] Waste rigid polyurethane foam laminated to plastic film obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (14.3% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. Fluff blended with the adhesive composition (28 g) is placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0071] A 203 mm×203 mm×15.88 mm (8 in×8 in×⅝ in) cardboard honeycomb weighing 16 g and having a cell size of 15.88 mm (⅝ in), forms the core layer of the sandwich. This honeycomb material, commercially available from Cortek, Inc., is placed on top of the 28 g of aforementioned fluff blended with the adhesive composition; finally fluff blended with the adhesive composition (32 g) is placed on the top of the core layer and the entire sandwich is compressed to a nominal 12.7 mm (0.5 in) total thickness.
[0072] Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 11.43 mm (0.45 in) thick, weighted 68 g and had a surface density of 1,647 g/m 2 (153 g/ft 2 ). It was not as stiff as Sample 1 and could be slightly bent with a less than substantial effort.
Example 6
[0073] Waste rigid polyurethane foam laminated to plastic film obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (14.3% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. A 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold, comprising the optional bottom decorative layer. Fluff blended with the adhesive composition (28 g) was placed on the bottom of the 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0074] A 203 mm×203 mm×15.88 mm (8 in×8 in×⅝ in) cardboard honeycomb weighing 16 g and having a cell size of 15.88 mm (⅝ in), forms the core layer of the sandwich. This corrugated material, commercially available from Cortek, Inc., is placed on top of the 28 g of aforementioned fluff blended with the adhesive composition; fluff blended with the adhesive composition (32 g) which comprises the top outer layer is placed on the top of the core.
[0075] Finally, a 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, comprising the optional top decorative layer, was placed on the top of top outer layer. Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 13.72 mm (0.54 in) thick, weighted a total of 74 g and had a surface density of 1,790 g/m 2 (166.5 g/ft 2 ). It was substantially less stiff than Sample 3 and could be bent with some effort.
Example 7
[0076] Waste headliner material obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (17.5% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. Fluff blended with the adhesive composition (35 g) is placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0077] A 203 mm×203 mm×9.53 mm (8 in×8 in×⅜ in) corrugated cardboard honeycomb weighing 16 g and having a cell size of 6.35 mm (¼ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 35 g of aforementioned fluff blended with the adhesive composition; finally fluff blended with the adhesive composition (35 g) is placed on the top of the core layer and the entire sandwich is compressed to a nominal 12.7 mm (0.5 in) total thickness.
[0078] Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 11.56 mm (0.455 in) thick, weighted 76 g and had a surface density of 1,840 g/m 2 (171 g/ft 2 ). It was stiffer than Sample 1 and could not be bent without a substantial effort.
Example 8
[0079] Waste headliner material obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (17.5% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. A 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold, comprising the optional bottom decorative layer. Fluff blended with the adhesive composition (30 g) was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0080] A 203 mm×203 mm×9.53 mm (8 in×8 in×⅜ in) corrugated cardboard honeycomb weighing 16 g and having a cell size of 6.35 mm (¼ in.), forms the core layer of the sandwich. The corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 30 g of aforementioned fluff blended with the adhesive composition; fluff blended with the adhesive composition (30 g) which comprises the top outer layer is placed on the top of the core layer.
[0081] Finally, a 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, comprising the optional top decorative layer, was placed on the top of top outer layer. Compression sufficient to maintain a nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 11.05 mm (0.435 in) thick, weighted a total of 76 g and had a surface density of 1,840 g/m 2 (171 g/ft 2 ). It was slightly less stiff than Sample 3 and could not be bent without a substantial effort.
Example 9
[0082] Waste headliner material obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (17.5% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. Fluff blended with the adhesive composition (35 g) was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0083] A 203 mm×203 mm×9.53 mm (8 in×8 in×⅜ in) phenolic-impregnated (15% content) corrugated cardboard honeycomb weighing 20 g and having a cell size of 6.35 mm (¼ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 35 g of aforementioned fluff blended with the adhesive composition; fluff blended with the adhesive composition (35 g) which comprises the top outer layer is placed on the top of the core layer and the entire sandwich is compressed to a nominal 12.7 mm (0.5 in) total thickness.
[0084] Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 11.43 mm (0.45 in) thick, weighted a total of 80 g and had a surface density of 1,937 g/m 2 (180 g/ft 2 ). It was slightly stiffer than Sample 2 and could not be bent without a substantial effort.
Example 10
[0085] Waste headliner material obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (17.5% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. A 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 3 g, was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold, comprising the optional bottom decorative layer. Fluff blended with the adhesive composition (30 g) was placed on the bottom of the 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0086] A 203 mm×203 mm×9.53 mm (8 in×8 in×⅜ in) phenolic impregnated (15% content) corrugated cardboard honeycomb weighing 20 g and having a cell size of 6.35 mm (¼ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 30 g of aforementioned fluff blended with the adhesive composition; fluff blended with the adhesive composition (30 g) which comprises the top outer layer is placed on the top of the core layer. Finally, a 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 3 g, comprising the optional top decorative layer, was placed on top of the top outer layer.
[0087] Compression sufficient to maintain a nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 11.43 mm (0.45 in) thick, weighted a total of 80 g and had a surface density of 1,937 g/m 2 (180 g/ft 2 ). It was about the same stiffness as Sample 3 and could not be bent without a substantial effort.
Example 11
[0088] Waste headliner material obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (17.5% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. Fluff blended with the adhesive composition (25 g) is placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0089] A 203 mm×203 mm×12.70 mm (8 in×8 in×½ in) corrugated cardboard honeycomb weighing 18 g and having a cell size of 9.53 mm (⅜ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 25 g of aforementioned fluff blended with the adhesive composition; finally fluff blended with the adhesive composition (35 g) is placed on the top of the core layer and the entire sandwich is compressed to a nominal 12.7 mm (0.5 in) total thickness.
[0090] Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 11.18 mm (0.44 in) thick, weighted 72 g and had a surface density of 1,744 g/m 2 (162 g/ft 2 ). It was as stiff as Sample 1 and could not be bent without a substantial effort.
Example 12
[0091] Waste headliner material obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (17.5% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. A 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold, comprising the optional bottom decorative layer. Fluff blended with the adhesive composition (25 g) was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0092] A 203 mm×203 mm×9.53 mm (8 in×8 in×⅜ in) corrugated cardboard honeycomb weighing 18 g and having a cell size of 6.35 mm (¼ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 25 g of aforementioned fluff blended with the adhesive composition; fluff blended with the adhesive composition (35 g) which comprises the top outer layer is placed on the top of the core layer and the entire sandwich is compressed to a nominal 12.7 mm (0.5 in) total thickness.
[0093] Finally, a 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, comprising the optional top decorative layer, was placed on the top of top outer layer. Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 10.67 mm (0.42 in) thick, weighted a total of 76 g and had a surface density of 1,840 g/m 2 (171.5 g/ft 2 ). It was not as stiff as Sample 3 but could not be bent without a substantial effort.
Example 13
[0094] Waste headliner material obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (17.5% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. A 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold, comprising the optional bottom decorative layer. Fluff blended with the adhesive composition (30 g) was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0095] A 203 mm×203 mm×12.7 mm (8 in×8 in×½ in) corrugated cardboard honeycomb weighing 18 g and having a cell size of 9.53 mm (⅜ in.), forms the core layer of the sandwich. This corrugated material, commercially available from Tricel Honeycomb Corp., is placed on top of the 30 g of aforementioned fluff blended with the adhesive composition; fluff blended with the adhesive composition (30 g) which comprises the top outer layer is placed on the top of the core layer.
[0096] Finally, a 203 mm×203 mm (8 in×8 in) sheet of leather whose uneven back surface is to be put in contact with the top outer layer, was placed on top of said top outer layer. The leather sheet weighted 40 g; it comprised the optional top decorative layer. Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 5 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite weighted a total of 110 g. It was not as stiff as Sample 3 but could not be bent without a substantial effort.
Example 14
[0097] Waste headliner material obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (17.5% by weight) is added to said fluff, as described in U.S. patent application Ser. No. 12/715,084. Fluff blended with the adhesive composition (28 g) is placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0098] A 203 mm×203 mm×15.88 mm (8 in×8 in×⅝ in) cardboard honeycomb weighing 16 g and having a cell size of 15.88 mm (⅝ in), forms the core layer of the sandwich. This honeycomb material, commercially available from Cortek, Inc., is placed on top of the 28 g of aforementioned fluff blended with the adhesive composition; finally fluff blended with the adhesive composition (32 g) is placed on the top of the core layer and the entire sandwich is compressed to a nominal 12.7 mm (0.5 in) total thickness.
[0099] Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 11.18 mm (0.44 in) thick, weighted 70 g and had a surface density of 1,695 g/m 2 (158 g/ft 2 ). It was about as stiff as Sample 5 and could be slightly bent with a substantial effort.
Example 15
[0100] Waste headliner material obtained from an automotive headliner manufacturing process is shredded into a fluff and an isocyanate adhesive composition (17.5% by weight) is added to said fluff, as described in patent application Ser. No. 12/715,084. A 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, was placed on the bottom of a 203 mm×203 mm (8 in×8 in) mold, comprising the optional bottom decorative layer. Fluff blended with the adhesive composition (28 g) was placed on the bottom of the 203 mm×203 mm (8 in×8 in) mold and forms the bottom outer layer of the sandwich.
[0101] A 203 mm×203 mm×15.88 mm (8 in×8 in×⅝ in) cardboard honeycomb weighing 18 g and having a cell size of 15.88 mm (⅝ in), forms the core layer of the sandwich. This corrugated material, commercially available from Cortek, Inc., is placed on top of the 28 g of aforementioned fluff blended with the adhesive composition; fluff blended with the adhesive composition (32 g) which comprises the top outer layer is placed on the top of the core layer.
[0102] Finally, a 203 mm×203 mm (8 in×8 in) sheet of 50 g/m 2 polyester scrim having a light adhesive backing and weighing 2 g, comprising the optional top decorative layer, was placed on the top of top outer layer. Compression sufficient to maintain the nominal 12.7 mm final thickness is applied using a Carver press. The sample was left in the press for 3 minutes at a temperature of 180° C. (355° F.). After trimming, the produced composite was 11.56 mm (0.455 in) thick, weighted a total of 76 g and had a surface density of 1,840 g/m 2 (171 g/ft 2 ). It was slightly less stiff than Sample 6 but could be bent with some effort.
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A composite structure is based on a sandwich construction and a one-step molding process. The composite structure or component comprises a core layer having two outer layers on each side of the core layer. The outer layers may be composed of automotive interior trim scrap adhered with an isocyanate adhesive composition. Core layer and outer layers are thermally pressed in a single step or process to form the finished structural, multi-layer product. Decorative layers can be added as part of the one-step process. The resulting panels can be used in the manufacture of automotive, construction, furniture and other components.
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RELATED CULTIVARS
[0001] ‘Sizzleness Salmon’ is related to ‘Sizzleness’ (U.S. Plant Patent pending), of which plant it is a color sport.
BACKGROUND OF THE INVENTION
[0002] ‘Sizzleness Salmon’ is a product of a breeding and selection program which had the objective of finding color mutants of ‘Sizzleness’. The new plant of the present invention comprises a new and distinct cultivar of Chrysanthemum plant that is a natural occurring sport of a parent Chrysanthemum named ‘Sizzleness’. A comparison with Parent Chrysanthemum ‘Sizzleness’ is also made in this application. The new cultivar was discovered as a whole plant mutation in 2002 by Mark Roland Boeder in a controlled environment (greenhouse) in Rijsenhout, Holland. The first act of asexual reproduction of ‘Sizzleness Salmon’ was accomplished when vegetative cuttings were taken from the initial selection in 2002 in Rijsenhout, Holland.
SUMMARY OF THE INVENTION
[0003] The present invention is a new and distinct variety of Chrysanthemum bearing medium sized decorative blooms with elongated quilled dark salmon ray-florets and a green center.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The present invention of a new and distinct variety of Chrysanthemum is shown in the accompanying drawings, the color being as nearly true as possible with color photographs of this type.
[0005] FIG. 1 shows a plant of the cultivar in full bloom.
[0006] FIG. 2 shows the various stages of bloom of the new cultivar.
[0007] FIG. 3 shows the foliage of the new cultivar.
DESCRIPTION OF THE INVENTION
[0008] This new variety of Chrysanthemum is of the botanical classification Chrysanthemum morifolium L. The observations and measurements were gathered from plants grown in April/May in a greenhouse in Rijsenhout Holland in a photo-periodic controlled crop under conditions generally used in commercial practice. The greenhouse temperatures during this crop were at day-time between 18° C. and 25° C. and at night 20° C. After a long day period of 14 days the photo-periodic response time in this crop was 52 days. After the long day period to flowering growth retardants were applied 2 to 3 times in an average dose of 2.5 gram/liter water. No tests were done on disease or insect resistance or susceptibility. No tests were done on cold or drought resistance. This new variety produces medium sized blooms with dark salmon ray-florets and blooming on the plant for 5 weeks. This new variety of Chrysanthemum has been found to retain its distinctive characteristics throughout successive propagations however the phenotype may vary significantly with variations in environment such as light intensity and temperature. To show the phenotype as described ‘Sizzleness Salmon’ can be planted without assimilation lightning (high pressure sodium lamps) between week 1 and week 35 year under greenhouse conditions in Holland. With assimilation light (minimum level 2500 lux) it can be planted year round under greenhouse conditions in Holland.
[0009] From the cultivars known to inventor the most similar existing cultivars in comparison to ‘Sizzleness Salmon’ is the parent ‘Sizzleness’ and the sports ‘Sizzleness Pink’ and ‘Sizzleness Purple’. When ‘Sizzleness Salmon’, ‘Sizzleness Pink’, ‘Sizzleness Purple’ and the parent ‘Sizzleness’ are being compared the following differences and similarities are noticed: The difference of ‘Sizzleness’ and its sports ‘Sizzleness Salmon’, ‘Sizzleness Pink’ and ‘Sizzleness Purple’ is (1) Color ray florets. The color is for ‘Sizzleness’ purple and cream, while it is dark salmon for ‘Sizzleness Salmon’, dark pink for ‘Sizzleness Pink’ and purple for ‘Sizzleness Purple’. For which charecteristic ‘Sizzleness Salmon’ has been selected from the original ‘Sizzleness’. All other characteristics of ‘Sizzleness’ and ‘Sizzleness Salmon’ are similar.
[0010] The following is a description of the plant and characteristics that distinguish ‘Sizzleness Salmon’ as a new and distinct variety. The color designations are taken from the plant itself Accordingly, any discrepancies between the color designations and the colors depicted in the photographs are due to photographic tolerances. The color chart used in this description is: The Royal Horticultural Society Color Chart, edition 1995.
TABLE 1 Botanical Description of cultivar ‘Sizzleness Salmon’ Bud Size Medium, cross-section 0.6 cm, height 0.6 cm Outside color Yellow-greem 145C Involucral bracts 2 rows, length 7 mm, width 3 mm Involucral bracts among disc-florets Not present Involucral bracts color Green 138B Inflorescence Type Decorative Height 3 cm Size Medium Fully Expanded 5 cm Peduncle lenght Near the top 7 cm, near the middle 10 cm, near the bottom 15 cm. Peduncle color Green 138B Number of inflorescences per stem Average of 20 Performance on the plant 5 weeks Seeds (if crossed) Produced in small quantities, oval shaped, grey-brown 199A, 2 mm in length. Fragrance Typical chrysanthemum Color Center of the flower Immature Yellow-green 145B Mature Yellow-green 154C Color of the ray-florets Upper surface Greyed-red 182B Lower surface Greyed-red 182D Tonality from Distance A spray mum with dark salmon flowers and a green disc Color of the upper surface of the Greyed-red 182B ray florets after aging of the plant Ray florets Texture Upper and under side smooth Number 100 Shape Elongated quilled Longitudinal axis of majority Straight Length of corolla tube Long; 2 cm Ray-floret margin Entire Ray-floret length 2.5 cm Ray-floret width 0.2 cm Ratio length/width High Shape of tip Rounded Disc florets Disc diameter 0.6 cm Distribution of disc florets Few, only visible in mature stage of flowering. Shape Tubular Color Yellow-green 154C Receptacle shape Domed raised Reproductive Organs Stamen (present in disc florets only) Thin Stamen color Yellow-green 144 B Pollen Produced in small quantity Pollen color Yellow-orange 14 A Styles (present in both ray and disc Thick florets) Style color Yellow-green 150C Style Length 4 mm Stigma color Yellow-green 145 D Stigma Width 1 mm Ovaries Enclosed in perianth Plant Form A spray mum meant for erect culture Growth habit Upright Growth rate Medium vigor Height 90 cm Width 28 cm Internode lenght 2-3.5 cm Spray formation Cylindrical Stem Color Yellow-green 148A with at base streaks of Greyed-red 182C Stem Strength Strong Stem Brittleness Not brittle Stem Anthocyanin Coloration Present Flowering Response(photo-periodic 52 Days controlled crop, not natural season) Foliage Color immature stage Upper side Green 141B Under side Green 139C Color mature stage Upper side Green 137A Under side Green 138A Color midvein Upper side Yellow-green 145C Under side Yellow-green 148C Size Medium; length 11 cm, width 5 cm Quantity (number per single stem) 26-30 Shape Elliptic Texture upper side Fleshy and glabrous Texture under side Pubescent Venation arrangement Palmate Shape of the margin Dentate Shape of Base of Sinus Between Diverging Lateral Lobes Margin of Sinus Between Lateral Rounded Lobes Shape of Base Obtuse to truncate Apex Mucronulate Petiole length 2 cm Petiole color Yellow-green 145C
[0011]
TABLE 2
Differences with the comparison Varieties
‘Sizzleness
‘Sizzleness
‘Sizzleness
Salmon’
Pink’
Purple’
‘Sizzleness’
Color upper
Greyed-red
Red-purple
Red-purple
Purple-violet
side ray-
182B
70B
70A
80C and
florets
Yellow 4D
Color lower
Greyed-red
Red-purple
Red-purple
Purple-violet
side ray-
182D
70D
70C
80D and
florets
Yellow 4D
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A Chrysanthemum plant named ‘Sizzleness Salmon’ characterized by its medium size decorative infloresences with elongated quilled dark salmon ray-florets, with a response time of 52 days.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 12/953,343, filed Nov. 23, 2010, which claims priority to and the benefit of Korean Patent Application No. 10-2010-0040043, filed on Apr. 29, 2010, in the Korean Intellectual Property Office, the entire content of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] An embodiment of the present invention relates to an organic light emitting display.
[0004] 2. Description of Related Art
[0005] Recently, various flat panel displays (FPDs) capable of reducing weight and volume, which are disadvantages of cathode ray tubes (CRTs), have been developed. The FPDs include liquid crystal displays (LCDs), field emission displays (FEDs), plasma display panels (PDPs), and organic light emitting displays.
[0006] Among the FPDs, the organic light emitting display displays an image using organic light emitting diodes (OLEDs) that generate light by the recombination of electrons and holes.
[0007] The organic light emitting displays are being widely applied in personal digital assistants (PDAs), MP3 players, and mobile telephones due to advantages such as excellent color reproducibility and reduced thickness.
[0008] FIG. 1 is a circuit diagram illustrating a pixel of an organic light emitting display. Referring to FIG. 1 , the pixel is coupled to a data line Dm, a scan line Sn, and a pixel power source line coupled to a pixel power source ELVDD and includes a first transistor M 1 , a second transistor M 2 , a capacitor Cst, and an organic light emitting diode OLED.
[0009] In the first transistor M 1 , a source is coupled to the pixel power source line ELVDD, a drain is coupled to the OLED, and a gate is coupled to a first node N 1 . In the second transistor M 2 , a source is coupled to the data line Dm, a drain is coupled to the first node N 1 , and a gate is coupled to the scan line Sn. The capacitor Cst is coupled between the first node N 1 and the pixel power source ELVDD to maintain a voltage between the first node N 1 and the pixel power source ELVDD for an amount of time (e.g., a predetermined time). The OLED includes an anode electrode, a cathode electrode, and a light emitting layer. In the OLED, the anode electrode is coupled to the drain of the first transistor M 1 and the cathode electrode is coupled to a low potential power source ELVSS, so that when current flows from the anode electrode to the cathode electrode, the light emitting layer emits light, and brightness is controlled corresponding to the amount of current.
[0010] In the pixel having the above structure, current corresponding to EQUATION 1 flows to the OLED.
[0000]
I
d
=
β
2
(
Vgs
-
Vth
)
2
=
β
2
(
ELVdd
-
Vdata
-
Vth
)
2
EQUATION
1
[0000] wherein, I d , Vgs, Vth, ELVdd, Vdata, and β represent current that flows to the OLED, a voltage between the gate and source of the first transistor, a threshold voltage of the first transistor, a voltage of the pixel power source, a voltage of the data signal, and a constant, respectively.
[0011] Since the current that flows to the OLED is as represented by EQUATION 1, when the voltage of the pixel power source ELVDD changes, the amount of current that flows also changes.
[0012] Therefore, since a magnitude of internal resistance of the pixel power source line to which the pixel power source ELVDD is coupled varies with a distance of the pixel from the pixel power source ELVDD, a difference in brightness between pixels may be generated.
SUMMARY
[0013] Accordingly, embodiments of the present invention have been made to provide an organic light emitting display capable of reducing variations in power transmitted to pixels to reduce or prevent non-uniformity of pixel brightness.
[0014] In order to achieve the foregoing and/or other aspects of the present invention, according to a first aspect of the present invention, there is provided an organic light emitting display including a pixel including a red sub pixel, a green sub pixel, and a blue sub pixel and first pixel power source lines for supplying a first pixel power from a first pixel power source to the red sub pixel, the green sub pixel, and the blue sub pixel, wherein the first pixel power source lines coupled to at least two different color sub pixels of the red, green and blue sub pixels have different widths.
[0015] The widths of the first pixel power source lines may correspond to a voltage drop of the first pixel power source.
[0016] The widths of the first pixel power source lines may correspond to deterioration of the respective sub pixels to which they are coupled.
[0017] The first pixel power source lines coupled to the blue sub pixels may have a largest width among the first pixel power source lines.
[0018] The organic light emitting display may further include a data driver for transmitting data signals to the pixel and a scan driver for transmitting scan signals to the pixel.
[0019] The first pixel power source lines coupled to the green sub pixels may have a smallest width among the first pixel power source lines.
[0020] The first pixel power source lines may include a first main pixel power source line electrically coupled to a first sub pixel power source line.
[0021] In the organic light emitting display according to embodiments of the present invention, variation in the power transmitted to pixels is reduced to reduce or prevent non-uniformity of pixel brightness. In addition, a change in an aperture ratio is reduced, making it possible to reduce or prevent brightness deterioration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The accompanying drawings, together with the specification, illustrate exemplary embodiments of the present invention, and, together with the description, serve to explain the principles of embodiments of the present invention, wherein:
[0023] FIG. 1 is a circuit diagram illustrating a pixel of an organic light emitting display;
[0024] FIG. 2 is a schematic diagram illustrating an organic light emitting display according to an embodiment of the present invention;
[0025] FIG. 3A is a graph illustrating the current error ratios of a red sub pixel, a green sub pixel, and a blue sub pixel, which are caused by the internal resistance of first pixel power source lines;
[0026] FIG. 3B is a graph illustrating the voltage drops of the red sub pixel, the green sub pixel, and the blue sub pixel, which are caused by the internal resistance of the first pixel power source lines; and
[0027] FIG. 4 is a layout diagram illustrating the pixel of the embodiment shown in FIG. 2 .
DETAILED DESCRIPTION
[0028] In the following detailed description, only certain exemplary embodiments of the present invention have been shown and described, simply by way of illustration.
[0029] As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive. In addition, when an element is referred to as being “on” another element, it can be directly on the element or be indirectly on the element with one or more intervening elements interposed therebetween. Also, when an element is referred to as being “connected to” or “coupled to” another element, it can be directly connected to the element or be indirectly connected to the element with one or more intervening elements interposed therebetween. Hereinafter, like reference numerals refer to like elements.
[0030] Hereinafter, embodiments of the present invention will be described as follows with reference to the attached drawings.
[0031] FIG. 2 is a schematic diagram illustrating an organic light emitting display according to an embodiment of the present invention. FIG. 3A is a graph illustrating current error ratios of a red sub pixel, a green sub pixel, and a blue sub pixel, which are caused by internal resistance of first pixel power source lines. FIG. 3B is a graph illustrating voltage drops of the red sub pixel, the green sub pixel, and the blue sub pixel, which are caused by the internal resistance of the first pixel power source lines.
[0032] Referring to FIG. 2 , the organic light emitting display includes a display unit 100 , a data driver 200 , and a scan driver 300 . The display unit 100 includes a plurality of data lines D 1 , D 2 , . . . , Dm−1, and Dm, a plurality of scan lines S 1 , S 2 , . . . , Sn−1, and Sn, and a plurality of pixels 101 formed in regions defined by the plurality of data lines D 1 , D 2 , . . . , Dm−1, and Dm and the n scan lines S 1 , S 2 , . . . , Sn−1, and Sn. In addition, each of the pixels 101 receives power from a first pixel power source ELVDD and a second pixel power source ELVSS to be driven. At this time, the power from the first pixel power source ELVDD is received (e.g., commonly received) through a plurality of first pixel power source lines and the power from the second pixel power source ELVSS is received (e.g., commonly received) through an electrode deposited on the front surface of the display unit.
[0033] Each pixel 101 includes a red sub pixel, a green sub pixel, and a blue sub pixel. In addition, each of the sub pixels includes a pixel circuit and an organic light emitting diode (OLED), and generates pixel current that flows from the pixel circuit to the pixel corresponding to data signals transmitted through the plurality of data lines D 1 , D 2 , . . . , Dm−1, and Dm and scan signals transmitted through the plurality of scan lines S 1 , S 2 , . . . , Sn−1, and Sn, so that the pixel current flows to the OLED.
[0034] At this time, as illustrated in FIGS. 3A and 3B , the current error ratios and the voltage drops of a red sub pixel, a green sub pixel, and a blue sub pixel, which are caused by the internal resistance of the first pixel power source lines being different from each other, are shown. For example, the current error ratio of the blue sub pixel is 7%, the current error ratio of the red sub pixel is 4.9%, and the current error ratio of the green sub pixel is 4.4%. In addition, the voltage drop of the green sub pixel is 94 mV, the voltage drop of the red sub pixel is 47 mV, and the voltage drop of the green sub pixel is 35 mV. The current error ratio and voltage drop of the blue sub pixel are larger than the current error ratios and voltage drops of the red sub pixel and the green sub pixel. Therefore, the non-uniformity of brightness of the blue sub pixel is larger than the non-uniformity of brightness of the other two sub pixels. A width of the first pixel power source lines may be increased to reduce the current error ratios and voltage drops of the first pixel power source lines. However, when the width of the first pixel power source lines is increased as if all of the first pixel power source lines are coupled to blue sub pixels, the widths of the first pixel power source lines coupled to red sub pixels and green sub pixels are unnecessarily large, and an aperture ratio is reduced.
[0035] Therefore, according to an embodiment of the present invention, widths of the first pixel power source lines of the sub pixels vary. That is, the thicknesses (or widths) of the first pixel power source lines coupled to the red sub pixel, the green sub pixel, and the blue sub pixel vary (e.g., are independently set) so that the width of the first pixel power source line coupled to the red sub pixel is determined in accordance with the voltage drop and current error ratio of the red sub pixel, and the width of the first pixel power source line coupled to the green sub pixel is determined in accordance with the voltage drop and current error ratio of the green sub pixel. In addition, the width of the first pixel power source line coupled to the blue sub pixel is determined in accordance with the voltage drop and current error ratio of the blue sub pixel.
[0036] The data driver 200 is coupled to the m data lines D 1 , D 2 , . . . , Dm−1, and Dm and generates data signals to sequentially transmit the data signals row-by-row to the m data lines D 1 , D 2 , . . . , Dm−1, and Dm (e.g., to the data lines one row at a time).
[0037] The scan driver 300 is coupled to the n scan lines S 1 , S 2 , . . . , Sn−1, and Sn and generates scan signals to transmit the scan signals to the n scan lines S 1 , S 2 , . . . , Sn−1, and Sn. A specific row (e.g., a specific scan line) is selected by the scan signals and the data signals are transmitted to the pixels 101 positioned in the selected row so that currents corresponding to the data signals are generated in the pixels.
[0038] FIG. 4 is a layout diagram illustrating the pixel of the embodiment shown in FIG. 2 . Referring to FIG. 4 , the pixel includes a red sub pixel 120 R, a green sub pixel 120 G, and a blue sub pixel 1206 .
[0039] Each of the red sub pixel 120 R, the green sub pixel 120 G, and the blue sub pixel 1206 includes a transistor Tr and a storage capacitor Cst. The red sub pixel 120 R, the green sub pixel 120 G, and the blue sub pixel 1206 are coupled to the scan line Sn and the data line Dm, and are coupled to first pixel power source lines, e.g., a first pixel power source line ELVDDR for supplying the first pixel power source ELVDD to the red sub pixel 120 R, a first pixel power source line ELVDDG for supplying the first pixel power source ELVDD to the green sub pixel 120 G, and a first pixel power source line ELVDDB for supplying the first pixel power source ELVDD to the blue sub pixel 120 B.
[0040] At this time, as illustrated in FIGS. 3A and 3B , since the voltage drop and the current error rate generated by the first pixel power source line ELVDDB coupled to the blue sub pixel 120 B are largest, and since the voltage drop and the current error rate generated by the first pixel power source line ELVDDG coupled to the green sub pixel 120 G are smallest, the width of the first pixel power source line ELVDDB coupled to the blue sub pixel 120 B is largest, and the width of the first pixel power source line ELVDDG coupled to the green sub pixel 120 G is smallest.
[0041] As described above, when the width of the first pixel power source lines is determined in accordance with the voltage drops and current error ratios of the respective sub pixels to which the first pixel power source lines are coupled, the sum of the widths of all of the first pixel power source lines is smaller than if the width of all of the first pixel power source lines were determined in accordance with only the sub pixel whose efficiency is lowest.
[0042] While the present invention has been described in connection with certain exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, and equivalents thereof.
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An organic light emitting display is capable of reducing variation in power transmitted to pixels to reduce or prevent non-uniformity of brightness from being generated. The organic light emitting display includes a pixel including a red sub pixel, a green sub pixel, and a blue sub pixel and first pixel power source lines for supplying a first pixel power from a first pixel power source to the red sub pixel, the green sub pixel, and the blue sub pixel, wherein the first pixel power source lines coupled to at least two different color sub pixels of the red, green and blue sub pixels have different widths. The first pixel power source lines have widths that may correspond to a voltage drop of the first pixel power source or may correspond to deterioration of the respective sub pixels to which they are coupled.
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TECHNICAL FIELD
[0001] The present invention relates to a method and an apparatus for sensing and indicating of permanent state deviations via detection of temporary, inner material oscillations in real time in parts of importance for hardware design and construction such as, for example, in prototype testing, in existing production equipment within industry, and/or monitoring and thereby maintaining previously constructed infrastructure.
BACKGROUND ART
[0002] Recent years' developments within the area of microelectronics, above all the evolution of increasingly powerful memories for computers has entailed that transducers or sensors of different types occurring on the market such as accelerometers, flexural/deformation indicators, indicators for acoustic emission and so on which are intended for measuring magnitudes of importance to the dimensioning of products in design have proved to be excessively complex in their construction and, as a result, excessively space-consuming and costly for application to the extent which modern hardware design increasingly demands and which, in particular, modern software permits.
BRIEF SUMMARY OF THE INVENTION
[0003] One major object of the present invention is, therefore, to realise a transducer element or sensor and arrangement thereof which, in principle, are extremely simple and thereby so space-saving in their construction that previously inconceivable transducer- or sensor configurations may be realised, at the same time as the opportunity is afforded of measurement with considerably greater sensitivity and accuracy within broader ranges than has hitherto been possible, and moreover the measurement of previously almost undetectable magnitudes has been made possible. A further object of the present invention is to realise a sensor arrangement which has a so slight inherent mass that the magnitude which it has for its object to detect cannot be affected thereby.
[0004] The above outlined objects will be attained by a method and an apparatus wherein the apparatus consists of one or more at least about 20 μm thick amorphous or nanocrystalline band elements of high permeability and relatively high magnetostriction being applied to the pertinent part, the band elements being, for attaining a desirable material structure, treated by magnetic heat treatment, the band elements being at least partly surrounded by multi-turn coils, such atomic movements as occur in an optional such state deviation being transmitted to the band element/elements either giving rise to a clearly measurable and detectable magnetic flow change (dB/dt) in the coil in proportion to said atomic movements, or to a similarly measurable and detectable inductance change in the coil/coils.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0005] The present invention will now be described in greater detail hereinbelow, with reference to the accompanying Drawings. In the accompanying Drawings:
[0006] FIG. 1 shows a sensor for acoustic emission photographed on a millimetre paper;
[0007] FIG. 2 is a schematic diagram of a sensor for detecting acoustic emission;
[0008] FIG. 3 shows the output signal as a function of load in positive and negative stretching for measurement of inductance change;
[0009] FIG. 4 shows a time signal from each respective transducer P 1 _ 1 (a. top), P 1 _ 2 (b. centre) and P 1 _ 3 (c. bottom);
[0010] FIG. 5 shows the frequency spectra over the output signals on breaking of glass for P 1 _ 1 , P 1 _ 2 and P 1 _ 3 (a. top, b. centre and c. bottom, respectively);
[0011] FIG. 6 is a schematic diagram of a possible realisation of an accelerometer which is based on amorphous material;
[0012] FIG. 7 shows the connection of the accelerometer and the principle of processing of signals therefrom;
[0013] FIG. 8 shows an impulse response for the accelerometer where the signal on the Y axis is the output signal in (mV) and the X axis is the time axis;
[0014] FIG. 9 shows the results of an accelerometer measurement at 1.7 Hz;
[0015] FIG. 10 shows the results of a measurement carried out at 3.0 Hz;
[0016] FIG. 11 shows the results of a measurement carried out at 4.4 Hz;
[0017] FIG. 12 shows the result of a measurement carried out at 10.94 Hz;
[0018] FIG. 13 shows a relative frequency response for a reference accelerometer and produced accelerometer type;
[0019] FIG. 14 is a schematic diagram of a possible realisation of an accelerometer or AE sensor (AE≈acoustic emission) based on amorphous material; and
[0020] FIG. 15 shows the output signal of the AE sensor in transient exiting.
DETAILED DESCRIPTION
[0000] Application as Glass Breakage Sensor
[0000] Functional Principle
[0021] The transducer or indicator consists of an amorphous ferromagnetic material which possesses the property that it may be given extremely high permeability, 5,000<μ<200,000, at the same time as it has, for certain alloy compositions, a relatively high magnetostriction, 5<λ sat <40 ppm. Taken as a whole, this gives a material with a very high magneto-elastic relationship and Is therefore extremely suitable as sensor material.
[0022] By employing a band approx. 3*10 mm which is cut from a sheet of amorphous material of a thickness of 22 μm and thereafter glued on an optional material, stretching in the material can be detected. The amorphous material may be given different properties by cutting it in different directions in relation to the rolling direction, in the present case use has been made of longitudinally and transversely of the rolling direction.
[0023] The material parameters may also be modified by heat treating the material in magnetic fields in temperatures close to but below the crystallisation temperature. In the case of breaking glass and general acoustic emission, the magnetic flow change is detected in that a multi-turn coil is wound around the band, see FIG. 1 and FIG. 2 .
[0000] Theory
[0024] In order to detect high frequency signals, it is advantageous and simple merely to detect the flow change and assume that it is proportional to the size of the deformation to the band. This implies that a magnetically well-defined initial state must be achieved, since an unmagnetised band gives no flow change in stretch change.
[0025] In order to attain a magnetised basic state, in principle the earth magnetic state is sufficient of 30-60 μT (20-40 A/m), but on the other hand it is unpractical to need to monitor the direction and size of the earth magnetic field when an indicator is to be mounted and calibrated.
[0026] There are two ways of attaining a satisfactory initial state:
Lightly magnetic encapsulation and direct current through the pickup coil.
[0028] Lightly magnetic encapsulation and bias magnetisation with permanent magnet.
[0029] The size of the field should be such that the magnetisation will be 0.2-0.7 T, which implies that the magnetising field in the band should be of the order of magnitude of 2-56 A/m. The size of the field may generally be calculated from the formula
H = B μ 0 · μ
where H is the magnetising field, B is the magnetic flow density, the permeability for free space μ 0 =4π· 10 −7 Vs/Am and the relative permeability μ for, in this case, the amorphous band.
[0030] The measurement signal is obtained by detecting the flow change in the band because of stretching/compression. For the linear case, the following connected equation should describe the function:
Δ B=d·Δσ+μ 0 ·μ·ΔH
[0031] Where σ describes mechanical stress and d is the magneto-elastic relationship coefficient. The prefix Δ describes the change from the original value. The material parameter d may be approximated by taking maximum magnetostriction at constant mechanical stress, Δσ=0, divided by magnetising field in magnetic saturation, i.e.
λ max H max = d
since
Δλ = Δ σ . E H + d · Δ H
which, with λ max =35·10 −6 and H max =200 A/m, gives the relationship factor d=1.75·10 −7 m/A, a very high value for all types of magneto elastic relationship.
[0032] The output signal which may be expected is proportional to the flow change and the mechanical stress
U ( t ) = N · A · ⅆ B ⅆ t
where N is the number of turns in the pickup coil and A is the cross sectional area of the amorphous band. By the assumption that ΔH=0, the following equations apply:
{ Δσ = Δλ · E H Δ B = d · Δσ
where E H is the modulus of elasticity in constant magnetising field. The transition to the frequency plane and the utilisation of the above equations give:
U ^ = N · A · ω · d · Δ λ ^ · E H
where ω is the angular frequency in rows/sec. The circumflex indicates that the amplitude value is intended. With the assumption that the modulus of elasticity is of the order of magnitude of 100 GPa, the stretching in the sensor at 100,000 kHz should be of the order of magnitude of 0.0025 ppm for the case P 1 _ 2 , see FIG. 4 and FIG. 5 centre.
Measurement Results
[0033] Initial experiments with sensors glued to a glass slide show that vibrations in the frequency range 40 kHz-1 MHz can be detected.
[0034] The following comparative tests have been carried out:
TABLE 1 description of indicator Orientation of Number Static unloaded Sensor band turns Comments permeability [mH] P1_1 Transverse 280 Thick glue joint 158 P1_2 Transverse 280 60 P1_3 Longitudinal 280 Thick plastic 32 encapsulation
[0035] The test was carried out in that the corner of the glass slide was broken off and the output signal registered with an amplification of approx. 100 times.
[0036] FIG. 3 shows the inductance change in different stretching for the sensors P 1 _, P 1 _ 2 and P 1 _ 3 . Here it is clearly apparent that P 1 _ 1 and P 1 _ 2 , which have bands cut out in the transverse direction, have the highest magneto-elastic relationship. These two samples also display a considerably higher permeability. This is also shown in glass breaking experiments where the signal levels in similar excitation will be higher for P 1 _ 1 and P 1 _ 2 . P 1 _ 2 displays a considerably more broad band signal spectrum compared with P 1 _ 1 and P 1 _ 3 . This may probably be explained by the larger glue quantities, see table 1.
[0000] Application in a Developed First Prototype of General Accelerometer with Real Static Measurement
[0000] Functional Principle
[0037] The transducer or indicator consists of an amorphous ferromagnetic material which possesses the property that it can be given extremely high permeability, 5,000<μ<200,000, at the same time as, for certain alloy compositions, it has a relatively high magnetostriction, 5<μλ sat <40 ppm. Taken as a whole, this gives a material with a very high magneto-elastic relationship and is, therefore, extremely suitable as sensor material. The transducer or indicator is composed of two amorphous bands of a size of 3·16·0.022 mm. The bands are glued to a fixing block, see FIG. 1 . At the fixing block, a coil is wound around each band. The coils are connected in a half bridge, see FIG. 2 . By connecting the coils in such a manner that a similar change in both bands does not give a signal, a high degree of insensitivity to temperature and other symmetric disruptions may be achieved. On flexing of the “beam” which consists of the two amorphous bands and an interjacent plastic band, a stretching in the one band will be obtained at the same time as a compression in the other band. The output signal from the coils will then be the opposite, i.e. an increase of inductance (permeability) on stretching and a reduction in compression.
[0038] The reaction mass (see FIG. 14 ), which is located in the end of the flexural beam gives a flexing moment which is proportional to the acceleration, the length of the beam and the mass. This naturally gives the possibility of adapting the accelerometer to almost any maximum acceleration whatever. The frequency performance is substantially determined by the rigidity of the beam and the mass of the reaction mass.
[0000] Theory
[0039] Since this transducer or indicator is to have real static measurement, the measurement principle cannot be based on induced tensions as a result of flow changes. In this case, it is necessary that the relative permeability of the band is measured using a carrier wave which should have a frequency roughly 10 times higher than the expected band width of the accelerometer.
[0040] For the linear case, the following linked equation should describe the function:
Δ B=d·Δσ+μ 0 ·μ·ΔH
where H is the magnetising field, B is the magnetic flow density, the permeability for free space μ 0 =4π·10 −7 Vs/Am and the relative permeability μ for, in this case, the amorphous band.
[0041] Further, σ stands for mechanical tension and d is the magneto-elastic relationship coefficient. The prefix Δ designates change from the original value. The material parameter d may be approximated by taking maximum magnetostriction at constant mechanical stress, Δσ=0, divided by magnetising field at magnetic saturation, i.e.
λ max H max = d
Since
Δλ = Δσ E H + d · Δ H
which, with λ max =35·10 −6 and H max =200 A/m, gives the relationship factor d=1.75·10 −7 m/A, a very high value for all types of magneto-elastic relationship. The measurement magnitude which is of interest here is hence the permeability as a function of stretching. By assuming that a well defined magnetic state has been able to be achieved, i.e. constant and known magnetising field, the change in magnetic flow density can, with a revision of the above equations, be designated as:
Δ B=d·E H ··Δλ
[0042] Hence, the change in magnetic flow density is proportional to the stretching in the band with the proportional constant d·E H. which, with E H ·=100 GPa, will be approximately 1.75·10 4 T.
[0043] Assume that the coils are connected in a half bridge and that we have a stretching of 10 ppm in the one band and a compression of 10 ppm in the other band. Since the H field may be assumed to be constant and that the change in the B field is proportional to the change in permeability and naturally also to the inductance in the coils, this implies that the output signal from the balanced bridge will be
Δ U= 1.75·10 4 ·2·10·10 −6 ·=0.35V
[0044] This is an output signal which is so powerful that it does not need to be amplified.
[0000] Measurement Results
[0045] Each coil has 800 turns, which gives an inductance of 8.2 mH. The half bridge is supplied with a sinusoidal voltage of an amplitude of 4.4 V and 19.3 kHz. Since the coils are connected in series, this implies that the bridge impedance may be kept in the order of magnitude of 10 kΩ, which is a good adaptation to be driven by operational amplifier.
[0046] For calibration of the transducers, use is made of the earth's force of gravity of 9.81 G. This gives a sensitivity of 35 mV/G. The transducers appear to be saturated at approx. 1 V, which implies that the linear area is approx. ±0.5 C which is equivalent to ±14 G. The resonance frequency, which may be calculated as:
f res = k m . · 2 π
has, by studying an impulse response, been measured up to approx. 80 Hz, see FIG. 3 .
Measurements in Accelerometer Test Equipment
[0047] In order to examine linearity, and to some degree frequency performance, measurements were carried out in the accelerometer test equipment.
[0048] A feature common to FIG. 4 , FIG. 5 , FIG. 6 and FIG. 7 is that a curve with relatively large output signal variations shows the output signal from the reference accelerometer, another curve with as good as equally large output signal variations shows the signal from the prototype accelerometer, while the almost solid line continuous curve shows the analytically simulated acceleration which should be exactly right. The scale on the axes is for the y axis acceleration in G and for the x axis time in seconds. Approximately 1.5 periods have been presented throughout.
[0049] By comparing the output signal of the accelerometers and relating them to the simulated acceleration, a frequency response can be evolved, see FIG. 8 .
[0050] The developed accelerometer displays good linearity up to the expected linearity limit of 14 G. There is no reason to assume any form of frequency dependence until the frequencies begin to approach the resonance frequency at 80 Hz. The decline at 11 Hz in FIG. 8 may be explained by the fact that saturation has been reached.
[0000] Application in Developed First Prototype of Sensor for Acoustic Emission
[0000] Functional Principle
[0051] The indicator or transducer consists of an amorphous ferromagnetic material which has the property that it may be given extremely high permeability, 5,000<μ<200,000, at the same time as, for certain alloy compositions, it has a relatively high magnetostriction, 5<λ sat <40 ppm. Taken as a whole, this gives a material with a very high magneto-elastic relationship and, as a result, is excellently suitable as sensor material. The indicator or transducer is composed of an amorphous band of a size of 3·18·0.022 mm. The band is wound two turns with an insulating plastic band in between. It is vitally important that the different strata of the band do not have electric contact with each other, since the band would then function as a short-circuited secondary winding. The resulting active cylinder is glued on the measurement object with a thin glue joint and to the bottom of a bowl-shaped plastic bobbin on the other side. On the bottom of the plastic bobbin, there is secured a reaction mass, while a 1,000 turn coil is wound on its side surface. This transducer principle is best suited for detecting dynamic cycles, since there is only one coil. By using two coils coupled in a half bridge (presupposes that the coils operate differently, i.e. that for positive acceleration one coil gives a positive output signal while the other gives a correspondingly negative signal), the advantages will be afforded that the effects of all currents (air-born electromagnetic waves etc.) and variations caused by external, global phenomena (heat, magnetic field, etc.) which occur symmetrically in relation to the coils will be reduced/eliminated.
[0052] The reaction mass (see FIG. 14 ) which is secured on the bottom of the plastic bobbin gives a reaction force on the active cylinder which is proportional to the acceleration and the mass. This naturally affords the possibility of adapting the accelerometer to almost any maximum acceleration and resonance frequency whatever. The frequency performance is determined substantially by the rigidity of the cylinder, as well as the mass of the reaction mass.
[0000] Theory
[0053] In order to detect high-frequency signals, it is advantageous and simple merely to detect the flow change and assume that it is proportional to the size of the deformation of the band. This implies that a magnetically well-defined initial state must be attained since an unmagnetised band gives no flow change in stretch change. In order to achieve a magnetised basic state, the earth magnetic field of 30-60 μT (20-40 A/m) is in principle sufficient, but on the other hand it is unpractical to need to monitor the direction and size of the earth magnetic field when a transducer or indicator is to be mounted and calibrated. There are two methods of attaining a good initial state:
1. Lightly magnetic encapsulation and direct current through the pickup coil. 2. Lightly magnetic encapsulation and bias magnetisation with a permanent magnet.
[0056] The size of the field should be such that the magnetisation will be 0.2-0.7 T, which implies that the magnetising field in the band should be of the order of magnitude of 2-56 A/m. The size of the field can generally be calculated from the formula
H = B μ 0 · μ
where H is the magnetising field, B is the magnetic flow density, the permeability for free space μ 0 =4π10 −7 Vs/Am and the relative permeability μ for, in this case, the amorphous band. By detecting the flow change in the band because of stretching/compression, the measurement signal will be obtained. For the linear case, the following linked equation should describe the function:
Δ B=d·Δσ+μ 0 μ·ΔH
[0057] Where σ designates mechanical stress and d is the magneto-elastic relationship coefficient. The prefix Δ designates change from the original value. The material parameter d can be approximated by taking maximum magnetostriction in constant mechanical stress, Δσ=0, divided by magnetising field at magnetic saturation, i.e.
λ max H max = d
since
Δλ = Δσ E H + d · Δ H
which, with λ max =35·10 −6 and H max =200 A/m, gives the relationship factor d=1.75·10 −7 m/A, a very high value for all type of magneto-elastic relationship. The output signal which may be expected is proportional to the flow change and the mechanical stress
U ( t ) = N · A · ⅆ B ⅆ t
where N is the number of turns in the pickup coil and A is the cross sectional area of the amorphous band. By the assumption that ΔH=0, the following equations apply:
{ Δσ = Δλ · E H Δ B = d · Δσ
where E H is the modulus of elasticity at constant magnetising field. Transition to the frequency plane and the utilisation of the above equations give:
U ^ = N · A · ω · d · Δ λ ^ · E H
where ω is the angular frequency in rows/sec. The circumflex indicates that it is the amplitude value which is intended.
Measurement Results
[0058] The coil which is measured has 650 turns, which gives an inductance of 3.2 mH. The resonance frequency may be calculated as:
f res = k m · 1 2 π
which, with the assumption that the modulus of elasticity is 100 GPa, the height of the active cylinder is 3 mm and the cross sectional area 2·3·π·0.022 mm 2 and the reaction mass is 4 gram, gives a resonance frequency of approx. 10 kHz. FIG. 2 shows a 50 times amplified output signal from the transducer when this has been mounted on a large iron blank and excited with a hammer blow.
[0059] A frequency analysis in the time series in FIG. 15 shows that signals up to approx. 5 kHz occur broadband, thereafter there is a distinct peak at 8 kHz and one at 60 kHz. It appears probable that the 8 kHz signal is the transducer resonance, while the 60 kHz signal is that which is traditionally called acoustic emission, i.e. transient release of energy in, for example, material deformation. The broadband signal content below 5 kHz consists of vibrations on the test body.
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The disclosure relates to a method and an apparatus for sensing and indicating permanent state deviations via detection of temporary inner material oscillations in real time in parts of importance for hardware design and construction, within existing production equipment, e.g. machinery, and/or monitoring of previously built-up infrastructure. One or more at least approximately 20 μm thick amorphous or nanocrystalline band elements with high permeability and relatively high magnetostriction are applied to a pertinent part, the band element or elements, respectively, being at least partially surrounded by a multi-turn coil, such atomic movements (oscillations) as occur in any optional such state deviation in the part being transferred to the band element/elements. The deviation either gives rise to a clearly measurable and detectable magnetic flow change (dB/dt) in the coil in proportion to said atomic movements, or to a similarly measurable and detectable inductance change in the coil/coils.
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CROSS-REFERENCE TO PROVISIONAL APPLICATION
The subject-matter of this invention is substantially as described in the same inventor's U.S. Provisional Application for U.S. patent No. 60/066,410, filing date: Nov. 24, 1997, entitled SUBMERGED DISPENSER FOR LOW-RATE DOSING OF A POOL, the disclosure content of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
In general, the invention relates to a mechanically deformable container type dispenser for submerged discharge of a quantity of liquid from the dispenser into liquid surroundings. More particularly, the dispenser is a type wherein the wall structure of an orificed container is comprised by a flaccid membrane, with which opposed end effectors at the ends thereof are combined in a manner whereby said end effectors constitute means for applying tension to the wall structure in order to actuate dispenser operation.
All embodiments of the invention are capable of operation unattended at a submerged site in a surrounding liquid of a first composition, releasing thereinto--at a low rate of discharge--a liquid of a second composition.
To clarify by example what is meant by `low rate`, an approximately palm-sized unit embodying the invention has been used to discharge two hundred and fifty (250) milliliters of liquid over a period of about five hundred (500) hours--nearly three weeks--thus averaging a discharge of only about 0.5 milliliters per hour. After opening a previously closed orifice in this small unit, the user simply allows the unit, which is appropriately weighted, to sink into the liquid body which will receive the `dose` of liquid automatically discharged from such a pre-filled packet-like product.
There are numerous purposes to which embodiments of the invention may be applied with advantage, in preference to a considerable diversity of known types of dispensers which also possess utility for unattended submerged discharge of a liquid at a low rate. Some devices for submerged dispensing are known wherein the liquid specifically to be discharged is displaced from a container by allowing a different liquid thereinto, drawn either from the surroundings or from a separate container elevated higher than the immediate liquid surroundings of the dispenser container, in order to develop an excess of hydrostatic pressure. Such approaches are limited to a somewhat narrow range of applications, however, because pre-discharge admixture of some displacement liquids and some dispensed liquids is highly unfavourable to maintaining constant compositional qualities of the latter, for the comparatively long period of time entailed by a low discharge rate. Furthermore, in view that the dispenser containers for carrying out such approches are typically rigidly constructed, ie. with rigid wall structure, such dispensers occupy as much submerged volume after discharging their contents as before, and this can be undesirable when unobstructed space within the liquid surroundings is at a premium.
The invention is excellently suited to replenishment or preservation of a chemical constituent which is intended to be maintained at a certain concentration in a liquid body that may be subjected to some foreseeable type of depletion process. Depletion processes which the invention is useful to counteract may include any of the following: evaporative loss of volatile constituents; alteration of constituents due to chemical reaction; precipitative deposition of solutes; nutritive consumption of constituents by biological organisms; and removal by mechanical means of constituents which adhere to surfaces of articles dipped into and retracted from a liquid body.
Although the genesis of the invention in its earliest embodiments was in the context of swimming pool treatment means to assure a desired quality of pool water, and to reduce swimming pool operating costs, it should be noted that most if not all of the foregoing depletion processes may in many instances be normally incurred in settings of use wherein a particularly constituted and/or treated liquid body is employed for productive purposes in such fields of enterprise as the following: chemical processing in general; liquid waste treatment; biotechnology (including fermentation of beverages and culture of anti-biotic medicines); aquaria; mariculture; agriculture (including paddy cultivation, and hydroponics); floriculture; decorative garden ponds; animal husbandry; and textile processing (dip dyeing).
Swimming pool and therapeutic spa treatments employing the invention have to date been more thoroughly investigated from a marketing standpoint, but any one or more of the foregoing diverse types of enterprises may well ultimately consume a larger number of tension-actuated submerged dispensers constructed in accordance with the invention. For example, needed nutritional supplements for cattle and hogs are very conveniently provided by means of tension-actuated dispensers submerged in drinking troughs or in-the-ground livestock drinking reservoirs (`waterholes`), and it seems reasonable to suppose that the number of such troughs and waterholes, on a worldwide basis, far exceeds the total number of swimming pools and spas.
SUMMARY OF THE INVENTION
General objects like economical manufacturing and convenience of use are as desirable in the case of this invention as with any well-designed new article intended for commerce, but apparatus reliability is an object of special pertinence with respect to the present invention, inasmuch as (a.) without requiring control means remote from the liquid surroundings, a submerged liquid-dispensing apparatus really is not as accessible for making post-installation adjustments, as an unsubmerged apparatus would be; (b.) a low rate of discharge over an extended period of time naturally entails more time during which a variety of events in the surroundings could conceivably interfere with dispenser functioning; and, (c.), more generally, because the appeal of this type dispenser to users so largely depends on its being simply droppable into the operational environment with worry-free assurance it will perform its intended function unattended.
A second object of special pertinence is versatility of application. In view of the diversity of liquids which are usefully discharged into liquid surroundings, as suggested above in connection with identifying typical purposes to which the invention is suited, it is especially desirable to specify dispenser actuation means in such a way as to accomodate discharged liquids having specific gravities either above, below, or the same, as that of any surrounding liquid which is to receive the discharged liquid in a given case.
The sought-for qualities of reliability and versatility have been found to be best procured by employing a flaccid membrane for the wall structure of an orificed, shape-deformable, submerged container having end-effectors at opposite ends thereof, such that said end-effectors constitute means for applying tension to the wall structure, stressing it in order to actuate dispenser operation by causing the container wall to progressively flatten against a quantity of liquid in the container which slowly diminishes as a stream of the discharged liquid escapes through a suitably sized orifice in the container. A float is particularly effective as a upwardly pulling end-effector, whereas a weight is particularly effective as a downwardly pulling end-effector. Depending on the specific gravity of the liquid to be discharged, relative to that of the surrounding liquid, there may simply be a use of contained liquid itself to serve as an end-effector, in view of the buoyancy or alternatively weight thereof. In some cases fixturing means or a frame can supply a tensioning point which is pulled against.
In the interest of greater clarity with regard to the versatility that is attained in accordance with the invention, it seems apropos here to recall that in the incorporated-by-reference related application (ie. the provisional application), FIGS. 3a-3c depicted an embodiment specifically for dispensing a liquid of lesser density than the surroundings, therefore requiring only a lowermost end-effector comprising a weight. To enable a similar embodiment to dispense a liquid of greater density than the surroundings, it is evident that an uppermost end-effector comprising a float could be added opposite the weight. That a float as uppermost end-effector has been contemplated and disclosed in the provisional application is shown by reference to FIG. 2b therein. Similarly, in order to enable an embodiment like the one shown in FIGS. 4a-4c of the provisional application to dispense a liquid of lesser density than the surroundings, a lowermost end-effector comprising a weight could be added. That use of a weight as an end-effector has been contemplated and disclosed in the provisional application is shown by reference to FIGS. 3a-3c therein. Again similarly, to the embodiments depicted in FIG. 1a and FIG. 2a of the provisional application, a float as an uppermost end-effector could be added, and to the embodiments depicted in FIG. 1b and FIG. 2b of the provisional application, a lowermost end-effector comprising a weight could be added. It is readily apparent also that opposed pairs of uppermost and lowermost end-effectors attached to a tension-actuated, shape-deformable, submerged container will provide a capability for dispensing a liquid irrespective of its relative density with regard to the surroundings.
Bearing these matters of clarification (without introducing any new subject-matter) in mind, it is seen that the invention is indeed versatile.
Tension by means of pulling forces applied from the ends of a deformable container, and the fact that the container has a suitably sized orifice in it for escape of a stream of the contents as the container tends to be flattened, provide a highly reliable principle of operation.
Details of structures and arrangement, plus recommended manners of manufacturing submerged dispensers embodying the invention, and suggestions how to deploy such dispensers to convenient advantage, are addressed below with reference to the figures of drawing next identified.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1a illustrates an embodiment wherein the opposed end-effectors are a suction cup-type fixture and a float.
FIG. 1b illustrates an embodiment wherein the opposed end-effectors are a suction cup-type fixture and a weight.
FIG. 2a shows an embodiment wherein the opposed end-effectors are a float and an embedded stake.
FIG. 2b shows an embodiment wherein the opposed end-effectors are a weight and a floating stake.
FIGS. 3a-3c illustrate an embodiment at three intervals in the process of tensed container wall structure being flattened between float and weight end-effectors.
FIGS. 4a-4c illustrate an embodiment at three intervals in the process of tensed container wall structure being flattened between weight and frame type end-effectors.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1a, float 8 is an uppermost end-effector which pulls upwardly on deformable container 10 against the opposed resistance provided by fixturing means 14 secured to the glass wall of an aquarium tank by suction cup 21. The result of such pulling is to strain the wall membrane of container 10, tending to flatten the container and thereby pressurizing the container content 16, thus forcing a continuous thin stream of liquid (or suspension) 16 out into surrounding liquid 18 through orifice 12. If liquid 16 in this instance is assumed to be of lesser density than liquid 18, then the float 8 could be omitted, for the buoyancy of the content itself of container 10 would then serve functionally as an upwardly pulling end-effector.
With reference to FIG. 1b, weight 9 is a lowermost end-effector which pulls downwardly on deformable container 10 against the opposed resistance provided (again) by fixturing means 14 secured to the glass wall of an aquarium tank by suction cup 21. The result of such pulling is the same as in the previous figure, but here, if liquid 16 in this instance is assumed to be of greater density than liquid 18, then weight 9 could be omitted, for the weight differential of the dispensed liquid 16 would then make it serve as a downwardly pulling end-effector.
The invention, however, would not, if the free end-effectors shown in FIGS. 1a and 1b, respectively were omitted, discharge a liquid of specific density exactly equal to that of the liquid surrounding. It is easy to see that in such a case either version, as shown, would suffice. These two versions, incidentally, are easily provided as a single commercial product, by simply making the weight and the float detachable and interchangeable, and of course optional in both cases, in view that a given fishtank liquid treatment chemical may in fact be heavy enough or light enough that the container will discharge its contents (after filling, say by means of a syringe), without an externally mounted free end-effector at all, since the dispenser content would then amount to an internally provided source of container-tensing power. A further point to note is that the rate of discharge of a liquid that can be discharged without a weight or float can be modified by using one or the other: a weight in conjunction with a heavy dispensed liquid will cause a faster discharge, and a float with a lighter liquid will do so also.
With reference next to FIGS. 2a and 2b, the principle of operation and essential interrelation of elements are the same as in the first example. Here the environment of use is a natural pond, into the earthen bottom of which a fixturing means 14 comprising a wooden stake can be embedded as shown in FIG. 2a, in which case a float type end-effector 8 is again appropriately used when the liquid to be discharged is not sufficiently differentiated by a lower density from that of the surroundings to obtain the desired discharge. In FIG. 2b, on the other hand, a weight 9 is shown working in opposition to the buoyant force provided by a wooden stake in a non-embedded orientation. Such a variant would be easier to check on and retrieve, if that were desired. Again, exactly as above and for the same reasons, the float 8 and the weight 9 are optional, unless that is, a liquid of the same density as the surrounding liquid is to be dispensed. Sans float, an apparatus as in FIG. 2a would be excellent for releasing a low density film-forming chemical so as to coat the surface of a reservoir in order to prevent excessive evaporative loss therefrom of water. The dispensed liquid from the apparatus as shown in FIG. 2b, but sans the weight, alternatively could be a heavy bromine compound for disinfecting a contaminated reservoir or pond.
While the first two sets of figures illustrating embodiments of the invention above featured overall structures which, with the exception of alternative liquid contents, are the same both for upwardly and downwardly directed flows of discharging contents, although the structures are in the appropriate cases inverted and slightly differently sited, the following third and fourth examples are provided in contemplation that it is nothing unusual to supply dispensers equipped with installation means suited to just one particular intended direction of flow.
With reference to FIGS. 3a-3c depicting the same embodiment at three intervals in time, as container 10 progressively flattens, the site-holding function is by means of the weight 9. Orifice 12 is built into the top of container 10, above which, preferably, an optional float 8 is detachably secured by attachment means whereby the upwardly pulling force of the float contributes to tensing the membraneous container wall. As already noted above, a dispensed liquid of lower density relative to that of the surroundings will by itself produce a buoyancy force and will interiorly push upwardly against the top of the container, in that manner tensing its wall structure, and the purpose of the float therefore is merely to increase the available net upwardly pulling container-tensing force. In order to prevent either kind of source of buoyancy from raising the whole dispenser to the surface of the liquid surroundings, of course, the mass provided by weight 9 must be appropriately proportioned--taking into consideration both the buoyancy of a float 8 and the relative density of the dispensed liquid.
Pertaining next to the embodiment of the invention shown in FIGS. 4a-c, wherein container 10, assumably filled with a dispensable liquid of higher specific gravity than that of surrounding liquid, hangs suspended from the site-holding fixturing means comprised by legged frame 14. The point of attachment of the container with this frame is the tensioning point pulled upon by membraneous wall structure of the container, by means of weight 9.
Any dispensably flowable substance which may be both heavy and somewhat viscous, the definition of "liquid" herein encompassing even syrupy and pasty compounds, such as a crack-sealing compound or glue, can be steadily discharged from an embodiment of this last exemplified type. Again, as in above cases, a free end-effector, whether a float or (as here) a weight, is best regarded as an option which is useful when development of a larger force tending to flatten the container by expressing the content therefrom is needed.
It will be readily understood by now that every embodiment of the disclosed invention operates in accordance with the same actuation concept as in the case of other embodiments, namely: that the volume of a flaccid container initially filled with a liquid to be dispensed will diminish as the membraneous container wall is tensed between opposed tensioning points, at least one of which must be associated with structure which is free to move in a direction away from the opposite point. The illustrated example of an embodiment with both a float and a weight, where the weight is well away from the bottom of the use surroundings, as shown in FIG. 2b, functions no differently with respect to the foregoing concept of actuation than any other version of the invention, say for example: the embodiment shown in FIGS. 3a-c.
Issues regarding certain constructional features will next be addressed, emphasizing particularly a distinction between essential and non-essential features pertaining to the various physical elements of any embodiment of the invention.
An orifice in the container is essential to dispensing, not only in the immediately obvious sense applicable to all containers of fluids whatever their nature, if the content is to be removed, but also in the sense that escape of liquid permits tensioning of container wall structure to change the shape of the container, and to cause its ever-diminishing volumetric capacity. One may contrast this circumstance to a similar flaccid-walled container holding a gas instead of a liquid, such as a weather balloon, in which case no orifice would be required in order to reduce the volume actually occupied by the gas, since gases are compressible, whereas with a liquid-filled, closed, flaccid-walled container having a tensioned wall, the shape thereof and volume of content will remain substantially constant irrespective of the magnitude of tension force. Thus it is the cooperation of an orifice allowing the liquid content to escape, and of a tensioned container wall structure, not the tensioning by itself, which in the invention make the process of pressurization of the content synchronous with reduction of the volume of contained liquid.
Relatedly it follows that it is not orifice size by itself which limits the rate of discharge of the content from any embodiment of the invention, such rate being a function of the proportioning of both orifice size and of amount of tension applied to the membraneous wall of the container. To make the point clear, it is possible to have a larger orifice and a lesser tension force operative in combination to produce a lower rate of discharge than produced by a somewhat smaller orifice and a greater tension force. For practical reasons, such as potential entry into a comparatively large orifice of fast-moving foreign material, especially when pressurization may be fairly low and unreliable to keep particles having significant momentum out, it is generally preferable to employ a smaller rather than a larger orifice, thus necessitating attention to means for increasing tensioning force.
Orifice location is another matter, not pertaining essentially to device actuation. Having the orifice built into the top of a container discharging a buoyant liquid content takes advantage of the tendency of the liquid to move upwardly and so can contribute to effective discharge, and similarly, the tendency of a liquid content which is heavier than the liquid of the surroundings to sag within a flaccid container can also be taken advantage of by an underside location of the orifice. These choices are appropriately preferred when it is desired to direct the discharge toward a certain area thus receiving it more promptly; however, location of the orifice is not normally essential to discharge occurring per se, since the tensioning of the container does not depend on orifice location, which might in fact be anywhere on the container, providing the requirement to completely void the container can be met. Progressive flattening of some embodiments of the invention, when dispensing liquids which tend to rise or sag to one end because of differentiation of specific gravity from the surroundings, could in some cases unevenly close the sides of a container progressively together, more toward one end than toward the other, as discharge proceeds, and therefore one does need to avoid any prospect of a side flattening against the interior of an orifice in a manner sealing it closed and thus perhaps trapping an undischarged quantity of contained liquid above or below a side-located orifice. This would not be a problem likely to occur in the case of dispensing a liquid of the same density as liquid of the surroundings, or with an embodiment having both upper and lower ends free to move, as when a container is tensed between a float and a weight as in FIG. 2b. The distribution of tension in such a case is more ideally from both ends pulling against one another, as distinct from embodiments wherein one free end-effector pulls against the resistance afforded by an anchored or fixtured type opposite end-effector. Therefore, it will be understood that an embodiment such as that shown in FIG. 2b, especially if used to dispense a liquid which does not tend to rise or sag within the container, lends itself to easier provision of a side-located orifice (not shown) instead of at an end of the container. Interestingly, the embodiment shown in FIGS. 3a-c, if it were used with a dispensed liquid heavier than the liquid of the surrounding, as conceivably it could be, could be feasibly equipped with a side-located orifice (not shown), and assurance against the sealing closed of the orifice by uneven container flattening could be gained by providing little enough of extra weight in the optional weight shown attached to the bottom of the container, so that the reduction of net weight of the submerged device due to discharge would at an appropriate moment cause it to rise from contact with the bottom or floor of the liquid surroundings. Similarly, a careful scaling of relative proportions of buoyancy in the float and weight of dispensable liquid could provide a device not needing an attached weight, which would act in the same way, rising as container content is discharged (not shown). Such and other non-illustrated variants can be developed within the scope of the invention with ease, once its principles are grasped as herein taught.
Essential to effective practice of the invention is understanding of the character of container shape-deformation and of the provision of a membrane type wall structure for the container. The material of the membrane has been described throughout the above discourse using the term `flaccid`, and for greater clarity it is now stated that this means that the material has a low bending modulus in thin construction but simultaneously is of high tensile strength and low elongation. Generally, a sheet of flaccid material as herein understood is easily folded, creased, or crumpled, by application of small magnitude forces, but is not easily stretched to dimensions much greater than as fabricated. The actuation concept of tensing the container to discharge its content through an orifice at a substantially steady and preferably slow rate would not be well served by use of rubber or similar material of high elongation with elastic recovery of changed dimensions. Such material would not be desirable for the type of submerged discharge contemplated, due to the highly progressive weakening of force causing the discharge in such a pre-expanded rubber bladder case, which would make it inherently impossible to obtain a fairly steady discharge over a long duration of time, unless simultaneously there were some means for changing the orifice size, say by enlarging it as available force diminishes, which is a highly undesirable complication of apparatus. The easy way to distinguish a variable-volume container made of high elongation wall material, on the one hand, and a variable-volume container made of low elongation wall material (as with the invention), on the other hand, is to note that the surface area of the wall structure is substantially unchanged in the latter case. That a continuous surface of a given constant area may enclose different volumes depending on the shapes to which the surface is contoured, closed upon itself, or in other words `bent`, is of course well established. The nature of deformation of the shape of a container constructed of thin low elongation material involves a change of surfacial contouring which is quite different from dimensial stretching of high elongation rubbery sheet material.
Typical materials which are well suited for use in fabricating the container element of any embodiment of the invention include polyvinyl chloride and polypropylene films. These and similar polymeric films are sufficiently liquid-impermeable and mechanically sound, and are easily cut into shaped gores which are sealable at the edges thereof to form excellent containers, the minimum number of gores needed being two. To fabricate a container, alternatively, the same polymeric substances may be blown as tubular film, or may be rotationally molded, and in all cases it is not difficult to form suitable orifices built into the container using wellknown techniques.
With regard to an optional detachable float and/or weight, such may be separately fabricated from the container and then attached to it by known means. In the case of a weight, a convenient option not illustrated in the figures is to emplace a strip of metal in a partly fabricated container before sealing its edges all around the gores comprising it. Also, it is readily understood that a built-in rather than attached float would simply be a matter of providing sufficient excess container material to seal about a pocketlike area permanently containing air.
At the point of manufacturing of products which constitute pre-filled dispensers, for supply to purchasers with the desired dispensable liquid already in each product unit, the liquid can be easily introduced to the container element by means of pumping through tubes or hollow needles momentarily inserted into apertures in container wall portions or edges which are subsequently sealed. Such apertures may or not be the discharge orifices themselves.
It has been suggested already in the SUMMARY above that use of the invention should normally involve no more imposition upon the user other than that pre-use orifice closure means be removed, followed immediately by placing the dispenser into the liquid surroundings where it typically will function unattended with great reliability for the length of time for which it is designed to discharge its content. One method of opening an orifice which is convenient to users is to cut across a marked line on the container, such cutting to remove the sealed portion of container wall edge structure adjacent a built-in channel comprising the orifice.
When the palm-sized packet-like product mentioned in the BACKGROUND is finally devoid of its content, it is flat and takes up little space, thus a large number of such units used successively over a long period of time can be allowed to accumulate at the bottom of a pool, if desired, before someday collecting them for recycling (also facilitated by the flatness).
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A tension-actuated submerged dispenser for discharging a liquid of one composition into liquid surroundings constituted by a liquid of a different constitution is useful for unattended employment to maintain a certain quality of composition in the surroundings. On the other hand, the quality of composition of liquid in the dispenser can be jeopardized if liquid from outside the container is allowed in, as has been the case with some earlier known submerged dispensers which employed a displacement liquid. In order to develop the necessary pressure to express a liquid through an orifice in a submerged container into which no such displacement liquid is allowed entry, a system of actuating a reduction of enclosed volume by means of tensing a container between opposed end-effectors has been developed. The source of pulling force can be either an externally attached weight or float, or a dispensed liquid which is differentiated as to specific gravity from that of the liquid surroundings.
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CROSS-REFERENCE TO RELATED APPLICATION
This patent claims priority to U.S. Provisional Patent Application Ser. No. 61/839,980, filed Jun. 27, 2013, which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
This disclosure relates to devises and techniques for removing water from flexible covers for tanks, including covers for swimming pools.
BACKGROUND
Flexible, water impermeable swimming pool covers and similar covers for other tanks, pools and the like provide safe and effective covers. However, rain water often collects on such covers and can damage the cover and present a drowning hazard, particular for children and animals, because of water that pools on top of the cover. Accordingly, it is often desirable to remove such water that has collected on a cover or within a vault or other structure within which such a cover may be stored. Pumps for such water removal are available, but they must be placed on the cover by a user and removed before the cover is closed, which may be neither easy to remember nor to do, particularly, for instance, if it is raining.
SUMMARY
The terms “invention,” “the invention,” “this invention,” “the present invention” and “disclosure” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.
A water removal pump or pump inlet device may be automatically deployed when a cover is deployed across a pool or tank by friction between the device and the cover causing a portion of the device to travel, in some instances at the end of a pivoting arm, out to a central region within the cover where water may accumulate. Water, temperature and other sensors may be used together with appropriate control devices to enhance operation of such water removal devices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially schematized plan view of a water removal apparatus of this disclosure.
FIG. 2 is an isometric view of one embodiment of a water removal apparatus of this disclosure.
FIG. 3 is an enlarged exploded isometric view of the pump head portion of the apparatus shown in FIG. 2 .
FIG. 4 is an enlarged isometric view of a knuckle hinge assembly shown in FIG. 2 .
FIG. 5 is an enlarged exploded isometric view of the pivot apparatus shown in FIG. 2 .
FIG. 6 is an enlarged exploded isometric view of an optional docking station attached to the pump head in FIG. 2 .
FIG. 7 is an enlarged isometric view of the pump and pivot portions of the water removal device of FIG. 2 .
FIG. 8 is an isometric view of another embodiment of a water removal apparatus of this disclosure.
FIG. 9 is a partially schematized plan view of an alternative water removal apparatus of this disclosure.
DETAILED DESCRIPTION
FIG. 1 illustrates an exemplary swimming pool 12 having a cover 14 with a cover leading edge 16 shown not quite fully deployed, so that water 20 may be seen in the pool near the bottom of FIG. 1 . When the cover 14 is retracted, it may be stored under a vault 18 . The schematized water removal apparatus 10 depicted in FIG. 1 includes a generally rigid arm 22 attached at one end to a pivot structure 24 and having a pump head structure 26 attached to the other end of arm 22 . A knuckle joint 28 allows the pump head 26 to move vertically as may be necessary when water on cover 14 has formed a depression in cover 14 . A pump (not shown in FIG. 1 ), typically in the vicinity of the pivot structure 24 draws water from the pump head through the arm 22 and discharges it into a drain 30 . The pump may be actuated or turned on, and turned off, by control circuitry 108 ( FIG. 1 ).
Pump head 26 automatically moves between its stored position within the vault 18 and its deployed position near the middle of cover 14 as cover 14 is stored or deployed. Such movement may be powered, power-assisted or solely as a result of friction between cover 14 and one or more wheels 32 mounted on pump head 26 and in contact with cover 14 . Such wheel or wheels 32 located at an appropriate angle such that contact with the cover exerts force on the pump head 26 causing it to move in the same general direction as the cover 14 is moving. This causes the pump head 26 to pivot out of the vault 18 when cover 14 is being deployed on the pool 12 and back into the vault 18 when the cover 14 is being stored. The most force will be exerted on pump head 26 by one or more wheels 32 when the axis of rotation of wheel 32 is parallel to, or at a fairly small fraction of ninety degrees)(90° relative to, the direction of movement of cover 14 . As the axis of rotation of the wheel(s) comes close to or is fully transverse (i.e., at ninety degrees))(90° to the direction of movement of cover 14 , the wheels will just rotate freely and exert little force on pump head 26 .
A second drain inlet 102 located within vault 18 may be coupled by a pipe 106 to a valve 104 also controlled by control 108 when desired to withdraw water that has accumulated within the vault 18 and discharge it into drain 30 . Among other alternatives, valve 104 and the pump may be actuated in response to a signal from water a sensor 100 within vault 18 . A valve may also be positioned between pump head 26 and the pump and controlled manually or by control 108 .
Another embodiment of a automatically deploying water removal apparatus of this disclosure is depicted as apparatus 34 in FIG. 2 . Pump head 36 portion of apparatus 34 in FIG. 2 is depicted in an exploded isometric view in FIG. 3 . As shown in FIG. 3 , top head and bottom head castings 46 and 48 hold a nozzle assembly 54 that attaches to tubing end 58 that communicates through tubing 60 and with pump 42 (visible in FIG. 2 ). Top and bottom head castings 46 and 48 also trap axles 50 of two pairs of wheels 52 , as may be appreciated by FIG. 3 . The head castings 46 and 48 also hold a sensor 56 which may include a water sensor, a temperature sensor and possibly other sensors such as a motion detector. Sensor 56 is attached to a control located, for instance and among other alternatives, within an alternating current (ac) to direct current (dc) converter and control box 108 (near pump 42 in FIGS. 2 and 7 ), through cable 66 that runs outside of tubing 60 but inside of pipe arm 64 . Pipe arm 64 may be a rigid material such as a metal or rigid plastic tube or pipe that encircles the tubing 60 . Alternatively, a flexible tube 60 and any cables could be secured with straps or the like to a rigid rod as an alternative to a rigid tube or pipe. Pipe arm 64 may not be needed if the tubing 60 itself is sufficiently rigid.
As can be seen in FIGS. 2 and 3 , the pairs of wheels 52 have axles 50 mounted at a significant angle to each other. This facilitates the exertion of appropriate forces on pump head 36 by contact with cover 14 at different points in the travel of pump head 36 and during different directions of cover travel (opening or closing).
Nozzle assembly 54 may also include a water filter through which the water being removed is drawn. Pump head 36 is attached to arm 40 by means of tubing 60 and pipe arm 64 , as well as knuckle assemblies 62 adjacent to pump head 36 and intermediate pump head 36 and pivot structure 38 . The knuckle assemblies 62 , as is illustrated in FIG. 4 allow fluid-tight fluid communication between tube 60 on opposite ends of the knuckle 62 while permitting articulation in a vertical plane.
Water sensor functionality in sensor 56 in pump head 36 can be used to turn on the pump 42 when water is present on the pool cover 14 and to turn the pump 42 off when no more water is sensed on the cover. A water sensor with or near pump 42 may also be desirable to sense the absence of water while water is still present on cover 14 because, for instance, the filter in nozzle assembly 54 has become clogged. This may permit control circuitry to switch pump 42 off so that it will not be damaged by running “dry.” Furthermore, a water sensor 100 in FIG. 1 can be used by control circuitry in ac to dc converter and control box 108 to control valves (such as valve 104 ) so that water is removed from within vault 18 or some other location from which water removal is desirable.
As may be appreciated by reference to FIGS. 5 and 7 , pivot structure 38 attaches to arm 40 (shown in FIG. 2 ) by capturing a portion 68 of pipe arm 64 (shown in FIGS. 2 and 7 ) between two pivot bearings 70 that rotate within an upper bearing plate 72 and a lower bearing plate 74 . As depicted in FIGS. 5 and 7 , bearing plate 74 is adapted for mounting to structure not shown by passing bolts or other appropriate fasteners (not shown) through flanges 75 and into such structure. Flexible tubing (not shown) communicates between the tubing within pivot bearings 70 and pump 42 inlet 109 so that water can be drawn through the pivot. Cable 66 communicates with control circuitry within an ac to dc convertor and control box 108 . Tubing 78 may be an alternative drain line for draining an area within the vault (as depicted schematically in FIG. 1 .).
In an alternative embodiment depicting a water removal apparatus 120 in FIG. 8 , the same pump head 36 is used as in FIG. 2 , but a different but similar pivot structure 122 is utilized together with an ac pump 124 and a controller 126 . (No docking station is depicted in FIG. 8 .) Flexible tubing 128 may be used to accommodate the rotation of the arm 130 about pivot structure 122 . A water detection sensor 132 just “upstream” from pump 124 can communicate the presence or absence of water to control the pump 124 to prevent damage to it from running “dry.”
An optional docking station 80 visible in FIG. 2 is further illustrated in FIG. 6 . In docking station 80 , a mounting dock 94 (that may be molded of plastic, among other alternatives) is secured to a mounting bracket 96 with plates 98 , and bracket 96 may be attached to structure not shown with bolts or other fasteners, not shown, passing through flanges 97 and into that structure.
Top unlock pivot 86 and bottom unlock pivot 88 are mounted on mounting dock 94 and can rotate slightly about a bolt 81 . Coiled compression springs 90 secured in openings 92 (only one opening is visible in FIG. 6 ) in mounting dock 94 biases pivots 86 and 88 in a counter clockwise direction as viewed from the top of FIG. 6 . Pivots 86 and 88 have recesses 84 for receiving pins 82 on the top and bottom head castings 46 and 48 (pins 82 may be seen on the top head casting 46 in FIG. 3 ). When pins 82 are in recesses 84 , pump head 36 is secured in its docked position (as depicted in FIG. 2 ).
Pressure exerted on arm 95 by, for instance, as a pool owner rotates pivots 86 and 88 out of contact with pins 82 when pump head 36 and arm 40 are to be released and pivoted out to their deployed position with pump head 36 in a central region of pool cover 14 as is depicted in FIG. 1 .
Arm 22 or 26 could also be biased toward its deployed position by a spring or other force-exerting component to facilitate deployment of arm 22 or 26 when the cover 14 is deployed. While friction between a retracting cover 14 and the wheels 52 may not cause such a spring-loaded arm to retract or to retract fully, contact between the pool cover edge 16 and pump head 26 or 36 should nevertheless drive the pump head and attached arm into their stored position.
Friction between moving pool cover 14 as it is deployed and wheels 52 causes the desired pivoting action driving pump head 26 or 36 out to its deployed position. Friction exerted in the opposite direction when pool cover 14 is closed likewise tend to urge pump head 26 or 36 and arm 22 or 64 to a stored position, typically within vault 18 . If such friction is inadequate to fully store the water removal apparatus, contact between pool cover edge 16 and pump head 26 or 36 , as the case may be, will forced the pump head and attached arm into their closed positions.
While the wheels 32 or 52 depicted in FIGS. 2, 3 and 7 are not powered and simply rotate as result of contact with the pool cover against which they rest, in alternative embodiments, the wheels 32 or 52 could be powered to assist in deployment as described above or to enable deployment or storage of the pump head to occur without or separately from cover movement. Movement of arm 22 or 64 between stored and deployed positions could also be achieved or facilitated by force exerted on the arm 22 or 64 by an appropriate electrical or hydraulic rotary motor or one or more hydraulically actuated piston(s), among other alternatives.
In addition to the water sensor 56 visible in FIG. 3 , which is associated with pump head 36 , a water sensor 100 (shown in FIG. 1 ) may be located in a location within vault 18 (shown in FIG. 1 ) where water accumulates, and a water inlet 102 (shown in FIG. 1 ) communicating with a valve 104 (shown in FIG. 1 ) through a pipe 106 (shown in FIG. 1 ) may be used to remove such water within the vault by controlling valve 104 and the pump to draw water from inlet 102 , when desired, rather than from pump head 36 . Additionally, a water sensor may be located proximate the pivot structure 24 or 38 or integrated with the pump 42 to sense the absence of water because the filter as part of nozzle assembly 54 has become clogged, all the water has been removed from pool cover 14 , or for any other reason so that pump 42 can be shut off.
Other sensors can also be used such as a sensor detecting motion of pump head 26 or 36 consistent with a person or animal having fallen onto the pool cover.
A temperature sensor as part of sensor 56 (shown in FIG. 3 ) or located elsewhere may be coupled to the control 108 (shown in FIG. 1 ) to prevent pump operation below certain temperatures at which the water may be frozen to prevent damaging operation of the pump.
Alternative structures and components are possible such as embodiments of this disclosure in which the water pump is integrated with the pump head 26 or 36 or is in some other location, rather than being located proximate the pivot structure 24 and 38 , as depicted in the Figures. As reflected in the different embodiments described above, one pump 42 uses a direct current (dc) motor and the other pump 124 uses an alternating current (ac) motor. Different types of, and differently powered, pumps can also be used.
Illustrating another embodiment, FIG. 9 is a schematized plan view of pool 12 (also shown in FIG. 1 ) having cover 14 and cover edge 16 shown almost fully deployed over the water 20 . In this embodiment, pump head 130 does not pivot on the end of a rigid pipe or other structure, and, as a result, no long, rigid pipes, rods or other potentially difficult-to-ship components are needed. Instead, pump head 130 is in communication with a pump 132 (that discharges into a drain 131 ) by a flexible pipe or hose 134 . Pump head 130 is tethered to a reel 136 within vault area 138 by a rope, cable, line or cord 140 that limits pump head 130 travel beyond approximately the middle of the pool cover. Pump head 130 travels along with the pool cover 14 during pool cover deployment so that pump head 130 is in approximately the middle of the pool cover 14 when the cover is fully deployed, as is almost the case in FIG. 9 . During such deployment of the pool cover 14 and pump head 130 , cord 140 is permitted to spool out of reel 136 until pump head 130 reaches a predetermined distance away from the vault area 138 with the pump head approximately in the middle of pool cover 14 (or some other desired location). When pool cover 14 is retracted into vault area 138 in order to make pool 12 usable, pump head 130 likewise retracts into the vault area 138 , and cord 140 helps insure that pump head is appropriately positioned for proper deployment the next time the cover 14 is deployed.
Multiple reel 136 and retraction mechanisms are possible. For instance, reel 136 can be used solely for retracting cord 140 when pool cover 14 is stored, in which event, guided by cord 140 , pump head 130 moves back into the middle of vault area 138 as a result of friction between pump head 130 and cover 14 and as a result of contact between pump head 130 and cover leading edge 16 . In this case, reel 136 can simply contain a spring mechanism that retracts the cord 140 when the pump head 130 moves toward the vault area 138 .
Alternatively, reel 136 can contain a retraction mechanism powered and controlled by control box 142 to which reel 136 is attached by cable 144 . Such a retraction mechanism may cause cord 140 to be retracted into the reel 136 , thereby pulling pump head 130 back to the vault area 138 . In this alternative, the pump head 130 can be retracted separately while the cover 14 remains deployed.
In another alternative, cord 140 can include a power, sensor and/or control cable that provides power to pump head 130 so that a pump can be located in pump head 130 and data can be provided to the control box 142 from sensors in or on pump head 130 . In yet another alternative, one or all of such power, sensor and control cables may be positioned along with flexible pipe 134 or may travel separately to pump head 130 rather than along either of flexible pipe 134 or cord 140 .
In alternatives in which power is supplied to pump head 130 , pump head 130 can include a powered deployment mechanism, such as powered wheels, that can move pump head 130 out onto the cover 140 after cover 140 has already been deployed.
The sensors described above may be of any appropriate type for determining the conditions of interest, including without limitation electronic, magnetic, and electro-mechanic (e.g., float-type water) sensors. Such sensors and other system elements can be coupled to control circuitry through cables, but wireless coupling could also be employed, for instance, using existing wireless technology such as Wi-Fi, Bluetooth or infrared technology or using future wireless technologies.
Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and subcombinations are useful and may be employed without reference to other features and subcombinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the claims below.
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An automatically deployed water removal apparatus for use with a solid, flexible swimming pool cover to remove rainwater caught by the cover. In one embodiment, a head with a water inlet pivots from a stored position along the edge of a pool to a deployed position near the center of a deployed cover as the cover advances to its deployed, pool-covering position. In another embodiment, a water inlet is attached to and positioned in part by a tether cord that may be reeled out during cover deployment and reeled in during retraction of the cover.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a luminance gradation correcting apparatus for correcting a luminance gradation of a video signal.
[0003] 2. Description of Related Art
[0004] In recent years, in association with the increase in size of display apparatuses, there is an increasing need to have a luminance gradation correcting apparatus in order to allow images to be seen more clearly. In a luminance gradation correcting apparatus, usually, a luminance gradation of the video signal is corrected by supplying a video signal to a non-linear amplifier, so as to widen a luminance distribution to a whole extent of the dynamic range.
[0005] [0005]FIG. 1 shows a conventional luminance gradation correcting apparatus. The luminance gradation correcting apparatus comprises a histogram memory 1 , a maximum correction value calculating circuit 2 , and a lookup table memory 3 . A digital luminance signal is supplied as an input signal to the histogram memory 1 and lookup table memory 3 . The histogram memory 1 is a memory for obtaining a luminance distribution of the input luminance signal and has a memory area whose address is designated by each of a plurality of predetermined luminance levels. A frequency is stored in each memory area. That is, each time the luminance signal of one pixel is supplied, the frequency in the memory area of the histogram memory 1 corresponding to the luminance level is increased by 1. All storage contents in the histogram memory 1 are cleared to 0 every predetermined period (one vertical scan period or a period which is an integer multiple of one vertical scan period), so that a new luminance distribution is obtained.
[0006] The maximum correction value calculating circuit 2 comprises: a histogram accumulating circuit 2 a for sequentially accumulating data in the histogram memory 1 from the data of a low luminance; an accumulation histogram memory 2 b for storing a result of the accumulating circuit 2 a ; and a normalization arithmetic operating circuit 2 c for normalizing each data so that the maximum accumulation degree equals the maximum value of an output luminance signal based on the data stored in the accumulation histogram memory 2 b . The accumulation histogram memory 2 b has a memory area of a frequency which is address designated by each of the luminance levels of the luminance signal in a manner similar to the histogram memory 1 .
[0007] The lookup table memory 3 stores data obtained by normalizing the storage data in the accumulation histogram memory. An address in the lookup table memory 3 is designated according to the luminance level of the input luminance signal and the luminance level stored in the memory area of the designated address is outputted as a normalized level.
[0008] [0008]FIGS. 2A to 2 C show the luminance converting operation by the conventional luminance gradation correcting apparatus by way of waveforms. One of the addresses in the histogram memory 1 is designated every pixel of the input luminance signal. The value in the memory area of the designated address is increased by 1 . It is assumed that the frequency corresponding to the luminance level of the input luminance signal for a predetermined period is detected as shown in FIG. 2A. For the better understanding of the conversion operation, it is assumed that frequencies at luminance levels Y 150 , Y 160 , Y 170 , Y 180 , Y 190 , Y 200 , and Y 210 were detected in the histogram memory 1 . There are relations of Y 150 <Y 160 <Y 170 <Y 180 <Y 190 <Y 200 <and Y 210 . Assuming that the frequencies in the predetermined period are equal to 1, 3, 5, 7, 5, 3, and 1 for the luminance levels Y 150 , Y 160 , Y 170 , Y 180 , Y 190 , Y 200 , and Y 210 , the accumulation frequencies are equal to 1, 4, 9, 16, 21, 24, and 25 for the luminance levels Y 150 , Y 160 , Y 170 , Y 180 , Y 190 , Y 200 , and Y 210 . That is, as shown in FIG. 2B, as the luminance level increases, the accumulation frequency increases. A normalization coefficient is calculated by the normalization arithmetic operating circuit 2 c so that the maximum value of the accumulation frequency equals the maximum value of the output luminance level. The normalization coefficient is multiplied to each data in the histogram memory 1 and a multiplication result is stored into the corresponding memory area in the lookup table memory 3 . A relation between the input luminance level and the output luminance level of the lookup table memory 3 is as shown in FIG. 2C. By transmitting the input luminance signal through the lookup table memory 3 , the luminance signal is outputted whose gradation has been corrected.
[0009] However, as the image carried by a supplied video signal there is a cinesco size image or the like in which an actual image portion is narrow in the vertical direction. In the case of the conventional luminance gradation correcting apparatus, non-image portions (black belts) appear in the upper and lower portions as shown by hatched regions in FIG. 3 in the image mentioned above. If a detecting area of an accumulation histogram is an area surrounded by a dotted line A in FIG. 3 including the non-image portions, therefore, the accumulation histogram has such a characteristic as shown in FIG. 4. That is, the accumulation histogram has a problem that the frequency of the black level in the non-image portion is largely influenced by the frequency of the luminance level in the actual image portion and, if the gradation of the luminance level is corrected based on the accumulation histogram. Thus, there has been a problem of a black floating or the like in which a black level rises in the actual image portion.
OBJECTS AND SUMMARY OF THE INVENTION
[0010] It is, therefore, an object of the invention to provide a luminance gradation correcting apparatus which can properly correct a gradation of a luminance level even if a size of actual image portion of an image differs from a size of image shown by a video signal.
[0011] According to the invention, there is provided a luminance gradation correcting apparatus comprising: a masking part for allowing only a luminance signal of a pixel in a predetermined detecting range in the vertical direction in an image shown by an input luminance signal to pass; a histogram memory for forming frequency data at each luminance level of the luminance signal outputted from the masking part for every predetermined period and storing it; a correcting part for correcting the luminance level of the input luminance signal based on the frequency data in the histogram memory; and a detecting range setting part for obtaining an accumulation value of the frequency data regarding the luminance signal in which the luminance level lies within a range from a zero level to a non-image display color level in the input luminance signal and setting the predetermined detecting range based on the accumulation value.
[0012] According to the luminance gradation correcting apparatus of the invention, since the predetermined detecting range in the vertical direction in the image shown by the input luminance signal is set in accordance with the size of actual image portion of the image, the gradation of the luminance level of the input luminance signal can be properly corrected without being influenced by the luminance level of the non-image portions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block diagram showing a conventional luminance gradation correcting apparatus;
[0014] [0014]FIGS. 2A to 2 C are characteristics graphs for explaining an example of the operation of the apparatus of FIG. 1;
[0015] [0015]FIG. 3 is a diagram showing a display example of an image in which an actual image portion is narrow in the vertical direction;
[0016] [0016]FIG. 4 is a graph showing an accumulation histogram of a luminance level of the image in FIG. 3;
[0017] [0017]FIG. 5 is a block diagram showing an embodiment of the invention;
[0018] [0018]FIG. 6 is a flowchart showing the operation of a detecting range forming circuit in an apparatus of FIG. 5;
[0019] [0019]FIG. 7 is a diagram showing the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline;
[0020] [0020]FIGS. 8A to 8 D are diagrams showing changes of the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline in the case where the image is changed from a 4:3 image to the image of a cinesco size by the apparatus of FIG. 5;
[0021] [0021]FIGS. 9A to 9 D are diagrams showing accumulation histograms in the case of detecting ranges in FIGS. 8A to 8 D;
[0022] [0022]FIG. 10 is a flowchart showing the other operation of the detecting range forming circuit;
[0023] [0023]FIG. 11 is a diagram showing threshold value Thrd setting characteristics corresponding to the number of vertical detecting range lines Vdetline;
[0024] [0024]FIG. 12 is a block diagram showing another embodiment of the invention;
[0025] [0025]FIG. 13 is a flowchart showing the operation of the detecting range forming circuit in an apparatus of FIG. 12; and
[0026] [0026]FIGS. 14A to 14 D are diagrams showing changes of the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline in the case where the image is changed from the 4:3 image to the image of a vista size by the apparatus of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] An embodiment of the invention will be described in detail hereinbelow with reference to the drawings.
[0028] [0028]FIG. 5 shows a luminance gradation correcting apparatus according to the invention. As shown in FIG. 5, the luminance gradation correcting apparatus comprises an A/D converter 11 , a sync separating circuit 12 , a detecting range forming circuit 13 , and a masking circuit 14 in addition to the conventional construction (histogram memory 1 , maximum correction value calculating circuit 2 , and lookup table memory 3 ) shown in FIG. 1. The A/D converter 11 converts an input video signal (composite signal) into a digital signal. The sync separating circuit 12 extracts a vertical sync signal and a horizontal sync signal of the input video signal and supplies them to the detecting range forming circuit 13 and masking circuit 14 .
[0029] The detecting range forming circuit 13 detects an image size of the input video signal in accordance with the contents in the accumulation histogram memory 2 b in the maximum correction value calculating circuit 2 and sets a detecting range of the video signal. The masking circuit 14 is connected to an output of each of the A/D converter 11 and detecting range forming circuit 13 and supplies a digital video signal in the detecting range set by the detecting range forming circuit 13 to the histogram memory 1 .
[0030] Since the histogram memory 1 , maximum correction value calculating circuit 2 , and lookup table memory 3 are the same as those shown in FIG. 1, their detailed description is omitted here.
[0031] Although not shown, in the case where the input video signal is a color video signal, for example, a Y-C separating circuit 11 is provided at the post stage of the A/D converter and a separated luminance signal is supplied to the masking circuit 14 .
[0032] As a size of actual image portion of the input video signal, it is assumed that there are a size of image of 4:3, vista size, and cinesco size.
[0033] In the case where the input video signal is a signal of the 4:3 image, its actual image is formed by 199 scanning lines in a range of the 39th to 237th lines. In the case where the input video signal is a signal of the image of the vista size, its actual image is formed by 167 scanning lines in a range of the 56th to 222th lines. In the case where the input video signal is a signal of the image of the cinesco size, its actual image is formed by 139 scanning lines in a range of the 70th to 208th lines.
[0034] In the embodiment, the actual image portion of the vista size is set to the detecting range for the 4:3 image and the vista size image, and the actual image portion of the cinesco size is set to the detecting range for the cinesco size image.
[0035] Subsequently, the operation of the detecting range forming circuit 13 will be described with reference to a flowchart of FIG. 6. When a result of the accumulating circuit 2 a is stored into the accumulation histogram memory 2 b every field of the input video signal, the detecting range forming circuit 13 detects an accumulation value Acm(b) of frequency data in a range of a luminance level from a zero level to a black belt display level (non-image display color level) (step S 1 ). That is, an accumulation frequency obtained by accumulating the number of times of appearance in which the luminance level of the video signal lies within a range from 0 to 255 is calculated by the histogram accumulating circuit 2 a every field and stored into the accumulation histogram memory 2 b. An accumulation frequency of the black belt display level in the range accumulation frequency of the luminance levels 0 to 255, therefore, is obtained as an accumulation value Acm(b).
[0036] The detecting range forming circuit 13 discriminates whether the accumulation value Acm(b) is larger than a threshold value Thrd or not (step S 2 ). If Acm(b)>Thrd, the detecting range is decreased by an amount corresponding to upper x (x is an integer of 1 or more) lines and lower x lines (step S 3 ). In step S 3 , a calculation to increase the number of vertical delay lines Vdlyline by x and decrease the number of vertical detecting range lines Vdetline by 2 x is executed. After the execution of step S 3 , the detecting range forming circuit 13 discriminates whether the number of vertical detecting range lines Vdetline as a result of the calculation is smaller than the number of base lines Cinline of the cinesco size image or not (step S 4 ). When Vdetline<Cinline, since the detecting range is narrower than the cinesco size image, the number of vertical delay lines Vdlyline is equalized to the number of base delay lines Cindly of the cinesco size image and the number of vertical detecting range lines Vdetline is equalized to the number of base lines Cinline (step S 5 ). When Vdetline=Cinline, the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline which were calculated in step S 3 are maintained as they are as numerical values of a new detecting range.
[0037] If Acm(b)=Thrd in step S 2 , the detecting range is increased by an amount corresponding to upper y (y is an integer of 1 or more) lines and lower y lines (step S 6 ). In step S 6 , a calculation to decrease the number of vertical delay lines Vdlyline by y and increase the number of vertical detecting range lines Vdetline by 2 y is executed. After the execution of step S 6 , the detecting range forming circuit 13 discriminates whether the number of vertical detecting range lines Vdetline as a calculation result is larger than the number of base lines Visline of the vista size image or not (step S 7 ). If Vdetline>Visline, since the detecting range is wider than the vista size, the number of vertical delay lines Vdlyline is equalized to the number of base delay lines Visdly of the vista size image and the number of vertical detecting range lines Vdetline is equalized to the number of base lines Visline (step S 8 ). If Vdetline=Visline, the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline which were calculated in step S 6 are maintained as they are as numerical values of a new detecting range.
[0038] The detecting range forming circuit 13 supplies the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline which were set as mentioned above as detecting range data to the masking circuit 14 (step S 9 ).
[0039] The masking circuit 14 generates the digital video signal supplied from the A/D converter 11 to the histogram memory 1 for a horizontal scan period corresponding to the number of vertical detecting range lines Vdetline after the elapse of a horizontal scan period corresponding to the number of vertical delay lines Vdlyline set in the detecting range forming circuit 13 in response to a vertical sync signal.
[0040] [0040]FIG. 7 shows the period of time corresponding to each of the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline in one field of the input video signal. In FIG. 7, the video signal is not supplied from the masking circuit 14 to the histogram memory 1 for the period of time corresponding to the number of vertical delay lines Vdlyline but the video signal is supplied from the masking circuit 14 to the histogram memory 1 for the period of time corresponding to the number of vertical detecting range lines Vdetline.
[0041] In the case where the input video signal is a signal of the 4:3 image, a detecting range for this image is set to the vista size (portion surrounded by a dotted line) as shown in FIG. 8A, and an accumulation histogram for each luminance level of the video signal of the 4:3 image shows characteristics as shown in FIG. 9A. The accumulation value Acm(b) of the accumulation histogram in FIG. 9A is equal to or smaller than the threshold value Thrd.
[0042] It is assumed that the image corresponding to the input video signal is changed from the 4:3 image to the cinesco size image as shown in FIG. 8B. Hatched portions in FIG. 8B are black belt portions associated by the cinesco size image. An accumulation histogram in the field at this time shows characteristics as shown in FIG. 9B. The accumulation value Acm(b) of the frequency data at the luminance level in a range from the zero level to the black belt display level increases. Since the accumulation value Acm(b) is larger than the threshold value Thrd, the detecting range is narrowed by an amount corresponding to upper x lines (for example, 2 lines) and lower x lines as shown by a dotted line in FIG. 8C. The accumulation value Acm(b), thus, decreases as shown in FIG. 9C.
[0043] In each of the subsequent fields, since the operation such that the detecting range is set to be narrowed by the amount corresponding to upper x lines of the image and lower x lines is repeated so long as Acm(b)>Thrd, the detecting range for the image is gradually narrowed and the accumulation value Acm(b) of the accumulation histogram gradually decreases. By the execution of steps S 4 and S 5 , thus, the detecting range becomes the cinesco size as shown in FIG. 8D, and the accumulation histogram for each luminance level of the video signal of the cinesco size image shows characteristics as shown in FIG. 9D.
[0044] In the luminance gradation correcting apparatus according to the invention, since the luminance data of the actual image portion in the image of one field is supplied to the histogram memory 1 , a frequency of the luminance of the black belt display level is not included in the data table showing the frequency data at each luminance level which is formed in the histogram memory 1 . The data table of the accumulation histogram, therefore, is formed in the accumulation histogram memory 2 b without accumulating the luminance frequencies of the black belt display level. Since the lookup table memory 3 stores the data obtained by normalizing the data stored in the accumulation histogram memory 2 b , the influence of the luminance in the black belt portions can be eliminated in the gradation correction of the luminance data. That is, even in the image of the cinesco size or the like having the black belts in the upper and lower portions of the display image, the gradation correction can be performed without causing the black floating in the actual image portion. For the video signals in which the sizes of the actual image portions such as cinesco size, vista size, and the like are different, a complicated circuit for detecting the sizes is unnecessary. Since the size in the vertical direction of the detecting range is gradually increased or decreased every field, a sudden change is not caused in a picture quality.
[0045] Although a construction such that a predetermined detecting range is increased or decreased by the same number of lines on the upper and lower sides has been shown in the embodiment (flowchart of FIG. 6), the number of lines which are increased or decreased on the upper side and that on the lower side can be made different.
[0046] Although the accumulation value Acm(b) is compared with the single threshold value Thrd to thereby discriminate the increase or decrease of the detecting range in the embodiment, two threshold values Thrd-d and Thrd-u can be also used. There is a relation of Thrd-d>Thrd-u and a difference between the threshold value Thrd-d and the threshold value Thrd-u is set to be larger than a change amount of the accumulation value Acm(b) due to the numbers of lines ( 2 y, 2 x ) to be increased or decreased at every field. For example, if x=y=2, Thrd-d=Thrd-u+5. When the two threshold values Thrd-d and Thrd-u are used, as shown in FIG. 10, after the execution of step S 1 , whether the accumulation value Acm(b) is larger than the threshold value Thrd-d or not is first discriminated (step S 2 a ). If Acm(b)>Thrd-d, step S 3 follows. If Acm(b)≦Thrd-d, whether the accumulation value Acm(b) is smaller than the threshold value Thrd-u or not is discriminated (step S 2 b ). If Acm(b)<Thrd-u, step S 6 follows. If Thrd-d ≧Acm(b)≧Thrd-u, the detecting range data (the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline) set in the previous field is supplied to the masking circuit 14 (step S 9 ). By the above operation, if the number of vertical detecting range lines Vdetline is decreased because a discrimination result in step S 2 a indicates that Acm(b)>Thrd in one field, the discrimination result in step S 2 b indicates Acm(b)<Thrd in the next field, so that the repetition of the increase and decrease of Vdetline of every field such that the number of vertical detecting range lines Vdetline is increased is eliminated. The more stable luminance gradation correction can be performed.
[0047] Further, although the numbers of lines ( 2 y , 2 x ) to be increased or decreased every field are set to the predetermined values in the above embodiment, the increase and decrease numbers of lines ( 2 y , 2 x ) can be also changed in accordance with the difference between the present number of vertical detecting range lines Vdetline and the number of base lines Cinline of the cinesco size image or the number of base lines Visline of the vista size image. For example, when the difference between the present number of vertical detecting range lines Vdetline and the number of base lines is equal to or larger than a predetermined value, the increase or decrease numbers of lines ( 2 y , 2 x ) can be increased. When it is smaller than the predetermined value, the increase or decrease numbers of lines ( 2 y , 2 x ) can be decreased.
[0048] Although the threshold value Thrd has been set to the predetermined value in the embodiment, the threshold value Thrd can be also changed in accordance with the present number of vertical detecting range lines Vdetline. For example, the threshold value Thrd can be also set like characteristics shown in FIG. 11. That is, if the detecting range (the number of vertical detecting range lines) is located near the cinesco size, the threshold value is set to the predetermined threshold value Thrd so as not to oscillate the detecting range and, after that, as the number of vertical detecting range lines increases, the threshold value Thrd is increased at an inclination smaller than an inclination of the accumulation value of the black belt portions of the cinesco size image. In the vista size image, consequently, when the detecting range is set to the range corresponding to the number of lines of the vista size image, if the signal at the black belt display level or lower exists in the image, a margin up to the number of lines is started to be reduced is improved.
[0049] [0049]FIG. 12 shows another embodiment of the invention. In this embodiment, the detecting range can be adjusted to three kinds of sizes of the 4:3 image, vista size, and cinesco size.
[0050] A construction of a luminance gradation correcting apparatus shown in FIG. 12 differs from the apparatus of FIG. 5 with respect to a point that the apparatus has a 4:3 image detecting circuit 15 . The 4:3 image detecting circuit 15 is connected to an output of the A/D converter 11 and detects that the image shown by the output digital video signal of the A/D converter 11 is the 4:3 image. In case of the 4:3 image, unlike the cinesco size image and vista size image, the whole luminance of the lines of a predetermined number (for example, 5) from the upper edge (the 39th scanning line) of the actual image range and the luminance of the lines of a predetermined number to the lower edge (the 237th scanning line) is not equal to or lower than the black belt display level. The 4:3 image detecting circuit 15 , therefore, determines that the image is the 4:3 image if the whole luminance of those lines is not equal to or lower than the black belt display level. The 4:3 image detecting circuit determines that the image is an image other than the 4:3 image if the whole luminance of those lines is equal to or lower than the black belt display level. A signal indicative of a detection result of the 4:3 image detecting circuit 15 is supplied to the detecting range forming circuit 13 .
[0051] The operation of the detecting range forming circuit 13 in case of the apparatus of FIG. 12 will now be described with reference to a flowchart of FIG. 13. When the result of the histogram accumulating circuit 2 a is stored into the accumulation histogram memory 2 b every field of the input video signal, the detecting range forming circuit 13 discriminates whether the input video signal is the signal of the 4:3 image or not in accordance with an output signal of the 4:3 image detecting circuit 15 (step S 11 ). If the input video signal is the signal of the 4:3 image, the detecting range is increased by an amount corresponding to upper z lines and lower z lines (step S 12 ). In step S 12 , a calculation so as to decrease the number of vertical delay lines Vdlyline by the amount corresponding to z lines and increase the number of vertical detecting range lines Vdetline by the amount corresponding to 2 z lines is executed. After the execution of step S 12 , the detecting range forming circuit 13 discriminates whether the number of vertical detecting range lines Vdetline as a calculation result is larger than the number of base lines Baseline of the 4:3 image or not (step S 13 ). When Vdetline>Baseline, since the detecting range is wider than the size of the 4:3 image, the number of vertical delay lines Vdlyline is equalized to the number of base delay lines Basedly of the 4:3 image and the number of vertical detecting range lines Vdetline is equalized to the number of base lines Baseline (step S 14 ). If Vdetline<Baseline, the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline which were calculated in step S 12 are maintained as they are as numerical values of a new detecting range.
[0052] The detecting range forming circuit 13 supplies the number of vertical delay lines Vdlyline and the number of vertical detecting range lines Vdetline which were set as mentioned above as detecting range data to the masking circuit 14 (step S 9 ).
[0053] If it is determined in step S 11 that the input video signal is a signal other than the 4:3 image signal, the detecting range forming circuit 13 discriminates whether the present number of vertical detecting range lines Vdetline is larger than the number of base lines Visline of the vista size image or not (step S 15 ). If Vdetline>Visline, the detecting range is decreased by an amount corresponding to upper a (a is an integer of 1 or more) lines and lower a lines (step S 16 ). In step S 16 , a calculation so as to increase the number of vertical delay lines Vdlyline by the amount corresponding to a lines and decrease the number of vertical detecting range lines Vdetline by the amount corresponding to 2 a lines is executed. After the execution of step S 16 , the detecting range forming circuit 13 advances to step S 9 .
[0054] If Vdetline<Visline is determined in step S 15 , the detecting range forming circuit 13 executes the operations in steps S 1 to S 9 shown in FIG. 6 and forms detecting range data corresponding to the vista size image or cinesco size image.
[0055] When the input video signal is a signal of the 4:3 image, a detecting range for this image is as shown by a dotted line in FIG. 14A. The number of vertical detecting range lines Vdetline of the 4:3 image is equal to the number of base lines Baseline.
[0056] It is now assumed that the image of the input video signal is changed from the 4:3 image to a vista size image as shown in FIG. 14B. The whole luminance of the lines of a predetermined number from the 39th scanning line in the field at this time and the luminance of the lines of a predetermined number up to the 237th scanning line is equal to or lower than the black belt display level. The operations in steps S 15 and S 16 are repeated and the detecting range of the image, that is, the number of vertical detecting range lines Vdetline is gradually decreased as shown in FIG. 14C. If Vdetline<Visline is determined in step S 15 , the detecting range finally becomes a range of the vista size shown by a dotted line as shown in FIG. 14D and the number of vertical detecting range lines Vdetline is equal to the number of base lines Visline through the operations in steps S 1 to S 8 .
[0057] Although the non-image display color level as a luminance level of the non-image portion of the image has been disclosed as a black belt display level in the embodiments, since the non-image portion is not limited to black, naturally, the non-image display color level can be also set to a luminance level of another display color.
[0058] As mentioned above, according to the invention, the predetermined detecting range in the vertical direction in the image shown by the input luminance signal is set in accordance with the size of actual image portion of the image. By this configuration, the gradation correction of the luminance level of the input luminance signal can be properly performed without being influenced by the luminance level of the non-image portions of the luminance signal.
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A luminance gradation correcting apparatus which can properly correct the gradation of a luminance level even if a size of actual image portion of an image differs from a size of image. The apparatus has: a masking part for allowing only a luminance signal of a pixel in a predetermined detecting range in the vertical direction in an image shown by an input luminance signal to pass; a histogram memory for forming frequency data at each luminance level of the luminance signal outputted from the masking part at every predetermined period and storing it; a correcting part for correcting the luminance level of the input luminance signal based on the frequency data in the histogram memory; and a detecting range setting part for obtaining an accumulation value of the frequency data with respect to the luminance signal in a portion of the luminance level in a range from the zero level to the non-image display color level in the input luminance signal and setting the predetermined detecting range based on the accumulation value.
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FIELD OF THE INVENTION
The present invention relates generally to a walk-behind self-propelled broom sweeper with independent direct hydraulic drives for the wheels and the broom.
BACKGROUND OF THE INVENTION
The present invention is directed to a walk-behind rotary sweeper that is unique in the industry in that it uses a direct drive for the drive wheels and the rotary broom, unlike the present practice in the industry where belt/chain, gear axle, open gear, belt drive, etc. are used, requiring relatively more maintenance. Furthermore, the present invention includes a quick change broom drive, whereas the industry uses belt, chain, sprockets, belt, etc., which would generally require more time to remove when replacing the broom wafers. In addition, the present invention is directed to a walk-behind rotary sweeper with direct, spring return valve handle controls, while the industry uses levers and cables that are relatively imprecise. The present invention is also directed to a rotary sweeper with variable wheel speed, while the industry does not incorporate such feature.
Therefore, there is a need for a walk-behind rotary sweeper with the above features that are not presently available in the industry.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a rotary sweeper that has a direct drive for the wheel drive and the broom drive, without using intermediate power transmissions such as chains, belts, sprockets, pulleys, etc.
It is another object of the present invention to provide a rotary sweeper with variable wheel speed.
It is still another object of the present invention to provide a rotary sweeper that is all hydraulic driven.
It is another object of the present invention to provide a rotary sweeper that has independent drives for the wheels and the broom.
It is yet another object of the present invention to provide a rotary sweeper that has an automatic return-to-neutral controls for wheel and broom drives and an automatic the reverse hydraulic lock on the drive wheel.
It is still another object of the present invention to provide a rotary sweeper that has hydraulic posi-traction and rachet wheels for easy turning.
It is another object of the present invention to provide a rotary sweeper that sweeps either straight ahead, to the left or to the right, by merely repositioning a simple spring loaded pin.
It is yet another object of the present invention to provide a rotary sweeper that provides relatively high tractive ability due to the machine weighing at least 450 lbs. and use of 16" diameter wheels.
It is still another object of the present invention to provide a rotary sweeper with relatively precise broom down pressure control.
It is an object of the present invention to provide a rotary sweeper that permits the right or left end of the broom as viewed from the rear or front of the machine to be adjusted up or down for positive broom bristle contact with the surface all across the broom, even if the broom wafers had worn unevenly, and/or to provide more sweeping down pressure at one end than the other end as desired.
It is another object of the present invention to provide a rotary sweeper that provides a relatively easy and quick way to remove the broom and replace worn broom wafers.
It is still another object of the present invention to provide a rotary sweeper that is modular in construction such that the broom attachment can relatively easily be removed and replaced with another attachment.
These and other objects of the present invention will become apparent from the following detailed description.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a front perspective view of a rotary sweeper in accordance with the present invention.
FIG. 2 is a side elevational view of the rotary sweeper of FIG. 1.
FIG. 3 is a top view of the rotary sweeper of FIG. 1.
FIG. 4 is a front elevational view of the rotary sweeper of FIG. 1.
FIG. 5 is a perspective view of a wheel drive used in the rotary sweeper of FIG. 1.
FIG. 6 is a perspective view of a unitary main frame used in thee rotary sweeper of FIG. 1.
FIG. 7 is side cross-sectional view of FIG. 6.
FIG. 8 is an exploded view of a rotary broom used in the rotary sweeper of FIG. 1.
FIG. 8(A) is a view taken along line 8(A)--8(A) in FIG. 8, showing a square sleeve adapted to receive a corresponding square shaft of the drive motor of the rotary broom.
FIG. 9 is a schematic diagram of a hydraulic circuit used in the rotary sweeper of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
A walk-behind self-propelled rotary sweeper R in accordance with the present invention is disclosed in FIG. 1. The rotary sweeper R comprises a power unit 2 and a broom attachment 4, as best shown in FIG. 1.
The power unit 2 includes a main frame 6 with a base portion 8 and a T-handle portion 10. The base portion 8 is supported above the ground by a pair of drive wheels 12. An internal combustion engine 14 is supported on the base portion 8. A hydraulic oil tank 16 is integrated into the rear portion of the base portion 8, as best shown in FIGS. 6 and 7. A hollow tube 18 that communicates at one end with the tank 16 and at the other end with a filler cap 20 advantageously provides means for replenishing the hydraulic oil in the tank 16.
The T-handle portion 10 has a platform 22 connected at the upper end of the hollow tube 18 and provides support for the filler tube 20 and an air pre-cleaner 24. A hose 26 connects the air pre-cleaner 24 to an air inlet filter housing 28 of the engine 14.
A hydraulic pump 30 is advantageously directly coupled to the output shaft of the engine 14. A relief valve 32 is secured to the base portion 8. A forward/reverse valve 34 for the drive wheels 12 is secured to the hollow tube 18. A broom rotation valve 36 and an oil filter assembly 38 are secured to the hollow tube 18.
An opening 39 communicates with the inside of the hollow tube 18 for connecting to the oil filter 38 thereby to provide a return path for the oil to the storage tank 16.
Handgrips 40 and 42 that are operably connected to valve control rods 40 and 46, respectively, advantageously provide positive control to the valves 34 and 36, respectively, as best shown in FIGS. 1 and 3. A handgrip 48 that is operably connected to the valve control rod 44 provides for setting the valve 34 to either a forward or reverse mode, as best shown in FIG. 3. The use of the control rods 40 and 46, instead of cables, pulleys or linkages, advantageously provides for positive and reliable control of the valves.
A U-shaped broom pivot bracket 50 that is secured to the front end of the base portion 8 provides the attachment means for the broom attachment 4. The bracket 50 pivotally secures a broom mount 52 with a vertical pin 54 such that the broom mount 52 is pivotable about a vertical axis. The broom mount 52 has a pivot bracket 56 with a hole that cooperates with the pin 54. The pivot bracket 56 includes a set of holes 58 disposed on a radius from the pivot pin 56, each of which cooperates with a broom angle pin 60 to advantageously change the angle of the rotational axis of the broom attachment 4, either to the left or right, as indicated in phantom lines 59 and 61, respectively, relative to the forward direction of travel of the rotary sweeper R, as best shown in phantom lines in FIG. 3.
The broom pivot bracket 50 has a semi-circular arc slot 62 that cooperates with a horizontal pivot pin 64 to advantageously raise either end of the broom attachment 4, thereby to advantageously apply a differential down pressure on the ground surface, as best shown in phantom lines 63 and 65 in FIG. 4. A bolt 66 preferably locks the pivot bracket 50 at the desired angle.
The broom attachment 4 has a rotary broom 68 that comprises a plurality of alternating polypropelene and wire broom wafers 70, as best shown in FIGS. 1 and 8. The broom wafers 70 are supported by a broom core 72, which is in turn supported by the broom mount 52. The broom core 72 at one end has preferably a square sleeve 73 with a square opening 74 which receives in loose interference fit a square shaft 76 that is connected to the broom drive motor 78. The square shaft 76 and the square opening 74 advantageously permit a positive broom drive in an abrasive dirt laden operating environment without the need of lubrication, which could collect dirt and cause excessive wear.
A pair of caster assemblies 80 with slotted mounting brackets 82 advantageously provide a downward limit on the down pressure of the broom attachment 4. The caster assemblies 80 are secured to the broom mount 52.
The broom mount 52 comprises two parallel horizontal arms 84 and 86 secure to a horizontal support 88 forming a U-shape, as best shown in FIG. 3. The arms 84 and 86 advantageously provide support to the rotary broom 68. The arm 84 is advantageously removably secured to one end of the support 88 thereby to facilitate removal and replacement of the wafers 70. An end bearing 90, bearing spacer 91 and broom core cap plate 93 are likewise removably secured to the arm 86 such that the broom 68 can be released from the mount 52.
A broom hood 92 is removably secured to the arms 84 and 86. The hood 92 advantageously provides a shield for the operator from any flying debris during a sweeping operation.
The drive wheels 12 are propelled by a direct coupled hydraulic motor 94 with a through shaft with portions 96 and 98 that protrude beyond the motor housing, as best shown in FIG. 5. The shaft portions 96 and 98 are directly coupled to axles 100 and 102 which are then operably connected to wheel hub assemblies 104 and 106. The wheel hub assemblies 104 and 106 are secured to the respective wheels 12. The wheel hub assemblies 104 and 106 advantageously incorporate standard ratchet bearings (not shown) which lock up when the shaft portions 96 and 98 turn, advantageously providing a positive drive forward. The ratchet bearings are also designed to overrun the powerized axle when and if turning or steering of the rotary sweeper R is needed, thereby enabling easy steering of the machine. The axle 104 is supported by axle bearing 108. The ratchet bearings are available from Torrington Bearing (203-482-9511), Part No. RCB 162117. The hydraulic motor 94 and the axle bearing 108 are secured to the base portion 8 of the main frame 6.
The broom hydraulic motor 78 and the wheel drive motor 94 are powered through a hydraulic circuit 110, as best shown in FIG. 9. The hydraulic pump 30 pumps pressurized oil from the hydraulic tank 16 through a tank screen 112. The pressurized hydraulic oil flows through the relief valve 32 via hose 113 and to the drive wheel valve 34 through hose 114. If the handgrip 40 is pressed, then the hydraulic oil will flow from the valve 34 to the wheel drive motor 94 through hose 116. The hydraulic oil then flows back to the valve 34 through hose 118 and then to the valve 36 through hose 120. If the handgrip 42 is pressed, the pressurized oil then will flow to the broom motor 78 through hose 122. The hydraulic oil then returns to the hydraulic tank 16 through hoses 124 and 126 through the filter 38.
If the handgrips 40 and 42 are not pressed, the pressurized oil from the tank 16 simply flows through the valves 34 and 36, without being directed to the respective hydraulic motors 94 and 78. The handgrip 40 and 42 are biased in the un-pressed position so that the hydraulic motors 78 and 94 are advantageously idle and inoperative unless the operator deliberately decides to power them.
When the handgrips 40 and 42 are unpressed, the valves 34 and 36 are in bypass mode wherein the hydraulic oil from the pump 30 bypasses the drive motors 78 and 94. The shaft of the motor 94 is locked against rotation in the reverse direction when it is not turning in the forward direction, thereby locking the drive wheels 12 in place to prevent the machine from free-rolling in reverse without any assistance from the operator. This is very advantageous when the sweeper R is on an upgoing incline and the operator wishes to stop.
The hydraulic circuit 110 is a series circuit, such that oil flows from one component to another component sequentially.
If the valve 34 is set in the reverse mode, then the pressurized oil from the valve 34 to the motor 94 will flow in the reverse direction, thereby driving the drive motor 98 in the reverse direction, which releases the ratchet bearings and allows the machine to be moved reverse by hand.
The engine 14 is supported on an engine mount 128 that is removably secured to the base portion 8 of the main frame 6. The removability of the engine mount 128 advantageously provides for access to the drive motor 94 disposed within the base portion 8.
The base portion 8 of the main frame 6 comprises a pair of parallel spaced apart side plates 130 and 132 and secured together by horizontal plates 134, 138 and 142 and by vertical plates 136, 140 and 144, as best shown in FIGS. 6 and 7. The horizontal top plates 134 and 138 are advantageously disposed below the top edges 146 and 148 of the side plates 130 and 132. When the engine mount 128 is secured to the base porion 8, as best shown in FIG. 1, a gap is formed between the bottom surface of the engine mount 128 and the horizontal plates 138 and 134 to advantageously provide a passageway for the hoses 116 and 118 for the drive wheel motor 94 and the hoses 122 and 124 for the broom motor 78.
A person of ordinary skill in the art will therefore appreciate that the main frame 6 is a rigid and compact structure for providing an integrated support frame for the various components of the power unit 2.
While the present invention is disclosed with a sweeper attachment, it should be understood that other attachments that can be used with the power unit 2.
Operation
In operation, the rotary sweeper R is operated by turning on the engine 14 to pressurize the hydraulic circuit 110. If the operator decides to sweep with the axis of rotation of the rotary broom 68 transverse to the direction of travel of the rotary sweeper R, then the angle pin 60 is disposed through one of the holes 58 which is centrally positioned. If the operator wishes to angle the rotary broom either to the left or to the right, as generally shown by the phantom lines 59 and 61 in FIG. 3, then the angle pin 60 is positioned in one of the outer holes 58. The pin 60 is advantageously biased by spring 152 in the downward direction to prevent the pin from accidentally disengaging from the bracket 56.
If the operator decides to operate the rotary broom 68 in an inclined positions, as generally indicated by the phantom lines 63 and 65 in FIG. 4, the bolt 66 is loosened and the rotary broom is rotated about the pin 64 until the desire position is obtained, after which the bolt 66 is tightened. The casters 80 may be adjusted by loosening the mounting bolts 154 and adjusting vertically the respective slotted mounting brackets 82, after which the mounting bolts 154 are tightened.
To start sweeping, the operator would be positioned behind the handle portion 10. The operator then checks the handgrip 48 to ensure that it is positioned such that the wheel drive valve 34 is in the forward mode. The handgrips 40 and 42 are then squeezed toward the operator, thereby permitting the hydraulic fluid to flow to the respective drive motors 94 and 78 and causing the drive wheels 12 to turn in the forward direction and the rotary broom in the counter-clockwise direction, as viewed in FIG. 2. Thus, the wheels 12 and the broom 68 rotate in opposite directions, advantageously providing stability during operation. The operator may vary the speed of the drive wheels 12 by varying the gripping pressure on the handgrip 40.
If the operator decides to stop the rotary sweeper R, the operator merely releases the grip on the handgrips 40 and 42, which causes the handgrips to return to their original biased position, wherein the valves 34 and 36 return to their bypass or normal positions, cutting off the flow of hydraulic fluid to the motors 94 and 78. At this point, the wheels 12 are locked in place against reverse rotation by the shaft of motor 94 and will therefore not free-roll in the reverse direction.
If the operator wishes to sweep in place, the handgrip 42 would be squeezed, while keeping the handgrip 40 in its normal position. This causes the hydraulic fluid to flow to the drive motor 78 that drives the rotary broom 68, without activating the drive motor 94 for the drive wheels 12.
If the operator wishes to move the machine backwards, the handgrip 48 would be pulled backwards such that the valve 34 is positioned in the reverse mode, thereby automatically causing hydraulic fluid to flow to the motor 94, which would then turn in the reverse direction to over-ride the ratchet bearing.
To adjust the down pressure on the rotary broom 68, the casters 80 are adjusted vertically as discussed above.
To replace the broom 68, the operator merely removes the arm 84 from the support 88 and pulls the square shaft 76 from the square sleeve 73, as best shown in FIG. 8. The bolts (not shown) securing bearing 90 are removed from the other end of the broom core 72, thereby freeing the broom 68 from its mount 52. The broom core cap plate 75 is slipped off from the end of core 72, allowing the broom wafers 70 to be removed and replaced at that end.
To replace the broom attachment 4 with another attachment, the mount 52 is disengaged from the bracket 50 by removing the pins 54 and 60. The drive motor 78 is also removed from the arm 84 by removing its mounting bolts (not shown) and withdrawing the shaft 76 from the sleeve 73. The other attachment is then ready to be hooked up.
While this invention has been described as having preferred design, it is understood that it is capable of further modification, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims.
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A walk-behind self-propelled device comprises a main frame including a base portion and a handle portion; a pair of wheels secured to the base portion for engaging the ground surface; an engine mounted on the base portion; a hydraulic pump carried by the base portion and operably connected to the engine; a first hydraulic motor directly coupled to the wheels and operably connected to the hydraulic pump; an attachment secured to the base portion; a second hydraulic motor directly coupled to the attachment and operably connected to the hydraulic pump; and first and second valves for controlling the first and second hydraulic motors, respectively. Each of the first and second valves has a bypass position whereby hydraulic fluid bypasses the first and second hydraulic motors. First and second handgrips are provided for operating the first and second valves, respectively. Each of the first and second handgrips includes a non-operative position corresponding with the first and second valves being in the bypass positions and the handgrips are normally biased in the non-operative positions.
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BACKGROUND
This disclosure relates to the field of visual displays. In particular, it relates to visual displays including two-particle electrophoretic systems having a controlled response to tribo-electric charging effects. More particularly, this disclosure relates to large area visual displays including two-particle electrophoretic systems having a controlled response to tribo-electric charging effects.
Paper has traditionally been a preferred medium for the presentation and display of text and images. Paper has several characteristics that make it a desirable display medium, including the fact that it is lightweight, thin, portable, flexible, foldable, high-contrast, low-cost, relatively permanent, and readily configured into a myriad of shapes. It can maintain its displayed images without using any electricity. Paper can also be read in ambient light and can be written or marked upon with a pen, pencil, paintbrush, or any number of other implements, including a computer printer.
Unfortunately, paper is not well suited for large-area or real-time display purposes. Real-time imagery from computer, video, or other sources cannot be displayed directly with paper, but must be displayed by other means, such as by a cathode-ray tube (CRT) display or a liquid-crystal display (LCD). However, real-time display media lack many of the desirable qualities of paper, such as stable retention of the displayed image in the absence of an electric power source.
Electric paper combines the desirable qualities of paper with those of real-time display media. Like ordinary paper, electric paper can be written and erased, can be read in ambient light and can retain imposed information in the absence of an electric field or other external retaining force. Also like ordinary paper, electric paper can be made in the form of a light-weight, flexible, durable sheet that can be folded or rolled into a tubular form about any axis and placed into a shirt or coat pocket, and then later retrieved, re-straightened, and read without loss of information. Yet unlike ordinary paper, electric paper can be used to display full-motion and other real-time imagery as well as still images and text. Thus, electric paper can be used in a computer system display screen or a television.
Traditionally, electronic displays such as liquid crystal displays have been made by sandwiching an optoelectrically active material between two pieces of glass. In many cases, each piece of glass has an etched, clear electrode structure formed using indium tin oxide (ITO). A first electrode structure controls all the segments of the display that may be addressed, that is, changed from one visual state to another. A second electrode, sometimes called a counterelectrode, addresses all display segments as one large electrode, and is generally designed not to overlap any of the rear electrode wire connections that are not desired in the final image. Alternatively, the second electrode is also patterned to control specific segments of the display. In these displays, unaddressed areas of the display have a defined appearance.
Electrophoretic displays offer many advantages compared to liquid crystal displays. Electrophoretic display media are generally characterized by the movement of particles through an applied electric field. Encapsulated electrophoretic displays also enable the display to be printed. These properties allow encapsulated electrophoretic display media to be used in many applications for which traditional electronic displays are not suitable, such as flexible displays. Additionally, electrophoretic displays typically have attributes of good brightness, wide viewing angles, high reflectivity, state bistability, and low power consumption when compared with liquid crystal displays. However, problems with the image quality, specifically the contrast, to date has been less than optimal. Contrast is defined as the ratio of the white state to the dark state reflectance of the display. Contrast enables the eye to easily distinguish between light and dark.
The gyricon, also called the twisting-ball display, rotary ball display, particle display, dipolar particle light valve, etc., provides a technology for making electric paper and electrophoretic displays. A gyricon display is a display that can be altered or addressed. A gyricon display is made up of a multiplicity of optically anisotropic balls which can be selectively rotated to present a desired surface to an observer.
The optical anisotropy of the gyricon balls is provided by dividing the surface of each gyricon ball into two or more portions. One portion of the surface of each gyricon ball has a first light reflectance or color. At least one other portion of the surface of the gyricon ball has a different color or a different light reflectance. For example, a gyricon ball can have two distinct hemispheres, one black and the other white. Additionally, each hemisphere can have a distinct electrical characteristic, such as, for example, a zeta potential with respect to a dielectric fluid. Accordingly, the gyricon balls are electrically as well as optically anisotropic. It is conventionally known that when particles are dispersed in a dielectric liquid, the particles acquire an electric charge related to the zeta potential of their surface coating.
The black-and-white gyricon balls are embedded in a sheet of optically transparent material, such as an elastomer layer, that contains a multiplicity of spheroidal cavities. Each of the spheroidal cavities is permeated by a transparent dielectric fluid, such as a plasticizer. The fluid-filled cavities accommodate the gyricon balls, one gyricon ball per cavity, to prevent the balls from migrating within the sheet. Each cavity is slightly larger than the size of the gyricon ball so that each gyricon ball can rotate or move slightly within its cavity.
A gyricon ball can be selectively rotated within its respective fluid-filled cavity by applying an electric field, so that either the black or white hemisphere of the gyricon ball is exposed to an observer viewing the surface of the sheet. By applying an electric field in two dimensions, for example, using a matrix addressing scheme, the black and white sides of the balls can be caused to appear as the image elements, e.g., pixels or subpixels, of a displayed image.
Conventional gyricon displays are described further in U.S. Pat. Nos. 4,126,854; 4,143,103; 5,389,945 and 5,739,801 to Sheridon, the disclosures of which are incorporated herein in their entirety. Gyricon displays can be made that have many of the desirable qualities of paper, such as flexibility and stable retention of a displayed image in the absence of power, that are not found in CRTs, LCDs, or other conventional display media. Gyricon displays can also be made that are not paper-like, for example, in the form of rigid display screens for flat-panel displays.
However, electronic papers such as gyricon displays are not necessarily compatable with low resolution applications and large area, outdoor electronic signage. In order to achieve a gyricon contrast ratio of about 8 and a white reflectivity of from 20–22% up to 28% requires the gyricon beads have a 90–95% perfect bichromality, the distinct equatorial separation of black and white hemisphere. In addition, the color axis and dipole moment axis of the beads must be aligned, and all the beads must complete their rotation. In addition, the layer of spherical capsules in which the beads are located is a major contributor to optical reflectivity, but hexagonal close packed spheres only occupies 90.7% of this layer. Gyricon devices are usually made into a multilayer configuration to enhance optical performance. For high-brightness large-area visual displays, 100% coverage of reflective surface is desired. These requirements pose significant challenges in low resolution applications and large area electronic signage.
One example of electrophoretic displays being developed to address the challenges of low resolution applications and large-area electronic signage involves an electrophoretic ink that uses spherical cells or microcapsules filled with black and white particles. The particles can be manipulated to position themselves on the top or the bottom of the microcapsule or cell to generate black or white surface visibility to an observer. Specifically, the particles are oriented or translated by placing an electric field across the cell. The electric field typically includes a direct current field, which may be provided by at least one pair of electrodes disposed adjacent to a display comprising the cell. Once set for a black state or a white state, the display maintains its color until a different configuration is forced through the application of a subsequent electrical field.
Such two-particle electrophoretic capsule systems, which have a contrast ratio of about 10 and a whiteness of more than 35%, are commercially available. However, these products are limited to small area displays, such as a personal digital assistants (PDAs) or handheld E-book, because a uniform close-pack coating of spherical capsules over large area is difficult to achieve where spherical capsules are deformed into a closed packed layer. Also, the electrophoretic ink systems cannot tolerate outdoor environmental conditions.
Such electrophoretic displays are disclosed, for example, in U.S. Patent Application Publication US 2004/0119680 to Daniel et al., which describes the switching of a two-particle electrophoretic display comprising two-particle electrophoretic ink consisting of a first particle species of a first color (e.g. white) and a second particle species of a second color (e.g. black) suspended in a clear medium. The disclosure of Daniel is incorporated herein in its entirety. The different colored particles of Daniel carry opposite charges, and the charged particles are moved by DC current application to change the electrophoretic display.
These two-particle electrophoretic systems are well recognized as providing good black and white electronic displays, but are currently limited by difficulties in making large area display media.
Thus, there remains a need for electrophoretic displays having good optical performance at high and low resolutions. There also remains a need for electrophoretic displays that can be used for large area and/or outdoor visual displays.
SUMMARY
This disclosure provides improved two-particle electrophoretic display systems. In particular, this disclosure provides a two-particle electrophoretic system for visual displays, along with methods and materials for use in such systems.
Electrophoretic displays, in embodiments, include one or more thin media sheets, one or more pairs of electrodes and one or more sources of electrical charge. The thin media sheets are made from polymeric materials and include one or more cavity that contains two species of oppositely charged particles. These species differ from each other in charge as well as in at least one other physical characteristic, such as optical characteristics.
Additional embodiments are directed to processes for preparing thin media sheets for use in electrophoretic displays, such as those discussed above. These processes include steps of separately preparing first and second species of oppositely charged particles, preparing composite particles including a sacrificial material and the first and second species of charged particles, encapsulating one or more of the composite particles in a transparent material, preparing a thin film of the transparent material and encapsulated composite particles, and removing the sacrificial material to form cavities in the transparent thin film.
In addition, disclosed embodiments are directed to methods of electrophoretic display, in which electrophoretic displays are provided and electrical charges or voltages are applied to affect at least one optical characteristic of the electrophoretic display. In such methods, the electrophoretic display includes one or more sources of electrical charge, one or more pairs of electrodes and one or more thin media sheets.
These and other features and advantages of various exemplary embodiments of materials, devices, systems and/or methods according to this disclosure are described in, or are apparent from, the following detailed description of the various exemplary embodiments of the methods and systems according to this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The exemplary embodiments of the invention will be described in detail, with reference to the following figures in which:
FIGS. 1A–1C are schematic drawings representing processes for preparing exemplary embodiments of electrophoretic display capsules;
FIGS. 2A–2C are schematic drawings representing the processes for preparing exemplary embodiments of electrophoretic display systems;
FIGS. 3A–3D are schematic cross-sectional views of exemplary embodiments of electrophoretic display systems; and
FIGS. 4A–4C are photomicrographs of an exemplary embodiment of an electrophoretic display having 150–180 μm composite spheres.
DETAILED DESCRIPTION OF EMBODIMENTS
Preferred embodiments will be described in detail below with reference to drawings in some cases. In the drawings, the same reference numerals and signs are used to designate the same or corresponding parts, and repeated descriptions are avoided.
This disclosure relates to improved encapsulated electrophoretic displays and, more particularly, to the colored states and resultant contrast of such displays. Generally, an encapsulated electrophoretic display includes two species of particles that either absorb or scatter light.
This disclosure also relates to a new approach for creating large-area visual displays having high brightness and low-cost fabrication. This approach can be extended to high resolution electronic paper. In particular, a novel process for fabricating a large-area two-particle electrophoretic media is provided. In this process, two species of small charged particles are prepared and incorporated into a sacrificial material to create composite particles. The composite particles are then encapsulated in a polymeric material that is then formed into a sheet. The polymer sheet is treated to remove the sacrificial material, resulting in a polymeric sheet that includes cavities containing the charged particles.
The electrophoretic display systems of this disclosure include two species of charged particles. The two species of charged particles differ from each other in charge and in terms of at least one other physical characteristic, such as color, fluorescence, phosphorescence, retroreflectivity, etc., that distinguishes one species of particles from the other species and provides the basis for their separation. For example, the two species of charged particles are colored differently and have different surface charges. The two species of charged particles of embodiments are small particles that are generally about 50 μm or less in diameter. The two species carry opposite charges; that is, one species of charged particles carries a positive charge and the other carries a negative charge. The two species of charged particles can be separately prepared by any suitable process, such as a mechanical spinning process. These charged particles are not particularly limited in shape. In exemplary embodiments, the small charged particles are spherical, but may be any desired shape or configuration, such as cylinders, prisms or the like.
As shown in FIGS. 1A–1C , two exemplary species of charged particles are produced by mechanical spinning of the components of each species, black 1 and white 2 , in a monochrome spinner 3 . One particle species 4 having a black color and one particle species having a white color 5 are individually obtained. In some embodiments, the black colored particles 4 carry a positive charge, while the white colored particles 5 carry a negative charge. The particle size can range from about 0.1 μm to about 50 μm.
The composition of the two species of small charged particles is also not particularly limited. In embodiments, the small charged particles include at least a hardenable material, a charge additive, and a colorant that may be the same as or different from the charge additive.
Of the above components, the two species may include the same or different hardenable material. Hardenable materials that may be used in embodiments include glass, silicon resins, high-temperature melting waxes, UV curable resins, thermocurable resins, hot-melt resins, and mixtures thereof.
Thus, in embodiments, the hardenable material of a species of charged particles may be one or more resin selected from the group consisting of thermoset resins, curable resins, thermoplastic resins and mixtures thereof. Non-limiting examples of suitable resins include epoxy resins, poly-functional epoxy resins, polyol resins, polycarboxylic acid resins, poly (vinylidene fluoride) resins, polyester resins, carboxy-functional polyester resins, hydroxy-functional polyester resins, acrylic resins, functional acrylic resins, polyamide resins, polyolefin resins, plasticized PVC, polyester and poly (vinylidene fluoride), ionomers, styrene, copolymers comprising styrene and an acrylic ester and mixtures thereof.
In embodiments, the hardenable material of a species of charged particles may be one or more high-temperature melting waxes selected from the group consisting of natural vegetable waxes, natural animal waxes, mineral waxes, synthetic waxes and functionalized waxes. The high-temperature melting waxes of embodiments have a melting point in a range of from about 70° C. to about 300° C.; in certain embodiments, the high-temperature melting waxes may have a melting point in a range of from about 90° C. to about 180° C. Examples of high-temperature melting natural vegetable waxes include, for example, carnauba wax, candelilla wax, Japan wax, and bayberry wax. Examples of high-temperature melting natural animal waxes include, for example, beeswax, punic wax, lanolin, lac wax, shellac wax, and spermaceti wax. High-temperature melting mineral waxes include, for example, paraffin wax, microcrystalline wax, montan wax, ozokerite wax, ceresin wax, petrolatum wax, and petroleum wax. High-temperature melting synthetic waxes include, for example, Fischer-Tropsch wax, acrylate wax, fatty acid amide wax, silicone wax, polytetrafluoroethylene wax, polyethylene wax, and polypropylene wax, and mixtures thereof. Preferably, the hardenable material is a linear polyethylene wax, such as POLYWAX® 2000 (available from Baker Petrolite), which has a molecular weight of about 2000.
The charge additive of embodiments is a component that is charged or capable of acquiring a charge. The two species of charged particles generally include different charge additives, so that the two species of charged particles carry opposite charges. In embodiments in which the charge additive is a component capable of aquiring a charge, the particle charge is generated by triboelectric charging during the mechanical spinning step that produces the particles. In embodiments, the charge additive is used in suitable effective amounts. In embodiments, the charge additive is used in amounts from about 0.1 to about 15 percent by weight of the charged particle. In embodiments, the charge additive is used in amounts from about 1 to about 15 percent by weight of the charged particle, preferably, in amounts from about 1 to about 3 percent by weight of the charged particle. Suitable charge additives in embodiments include, for example, alkyl pyridinium halides; bisulfates; positive charge enhancing additives, such as the BONTRON series of charge controlling agents (available from Orient Chemical Industries, Ltd.) and the COPY CHARGE series of charge controlling agents (available from Clariant AG Corporation); and negative charge enhancing additives, such as, for example, aluminum complexes, and other charge additives known in the art or later discovered or developed.
The two species of charged particles also each include, in embodiments, at least one colorant. The colorant of each species is generally different from the colorant of the other species. In various embodiments, a colorant may be included in a suitable amount, to achieve a desired color strength. In embodiments, the at least one colorant is included in an amount of from about 1 to about 40 percent by weight of the charged particle, preferably in an amount of from about 10 to about 30 percent by weight of the charged particle.
Colorants that may be incorporated into embodiments include pigments, dyes, mixtures of pigments, mixtures of dyes and mixtures of pigments with dyes, and the like. In general, one species of charged particles will include a black colorant and the other species will include a white colorant. However, various known white, black, cyan, magenta, yellow, red, green, brown, or blue colorants, or mixtures thereof may be incorporated into the two species of charged particles of embodiments. The colorant may have, in embodiments, a mean colorant size in a range of from about 50 to about 3000 nm, preferably in a range of from about 100 to 2000 nm. Examples of white colorants that may be used in electrophoretic displays according to embodiments include titanium oxide, aluminum oxide, and silicon oxide. Examples of black colorants that may be used in electrophoretic displays according to embodiments include absorptive materials, such as carbon black or colored pigments used in paints and ink.
The two species of charged particles are mechanically incorporated into a sacrificial material to create composite particles. As shown in FIGS. 1A–1C , one particle species 4 having a black color, one particle species having a white color 5 and a sacrificial material 7 are combined to produce composite particles.
The composite particles may have any desired shape. In embodiments, the composite particles may be spherical 8 , discoid 9 or cylindrical 10 . In FIGS. 1A and 1B , the sacrificial material and the two exemplary species of charged particles are combined by mechanical spinning of the components in a monochrome spinner 6 to produce spherical and discoid composite particles, respectively. In FIG. 1C , cylindrical composite particles are produced by mixing the sacrificial material and the two exemplary species of charged particles and either extruding or injection molding the mixture. Spherical or discoid composite particles of embodiments may have diameters in a range of from about 100 μm to about 200 μm. Cylindrical composite particles of embodiments may have any desired length, such as from about 0.5 to about 100 cm, preferably from about 1 to about 20 cm; such cylindrical composite particles may have diameters in a range of from about 100 μm to about 200 μm. In particular embodiments, the diameters of spherical, discoid or cylindrical composite particles may be in a range of from about 150 μm to about 200 μm.
The sacrificial material used in embodiments is limited only in its ability to diffuse through the transparent polymeric material, described below. In embodiments, the sacrificial material may be one or more low-temperature melting waxes selected from the group consisting of natural vegetable waxes, natural animal waxes, mineral waxes, synthetic waxes and functionalized waxes. The low-temperature melting waxes of embodiments have a melting point in a range of from about 45° C. to about 95° C.; in certain embodiments, the low-temperature melting waxes may have a melting point in a range of from about 65° C. to about 85° C. Examples of low-temperature melting natural vegetable waxes include, for example, Japan wax, and bayberry wax. Examples of low-temperature melting natural animal waxes include, for example, beeswax, punic wax, lanolin, lac wax, shellac wax, and spermaceti wax. Low-temperature melting mineral waxes include, for example, paraffin wax, microcrystalline wax, montan wax, ozokerite wax, ceresin wax, petrolatum wax, and petroleum wax. Low-temperature melting synthetic waxes include, for example, Fischer-Tropsch wax, acrylate wax, fatty acid amide wax, silicone wax, polytetrafluoroethylene wax, polyethylene wax, and polypropylene wax, and mixtures thereof. Preferably, the sacrificial material is a linear polyethylene wax, such as POLYWAX® 400 (available from Baker Petrolite), which has a molecular weight of about 400.
The composite particles are encapsulated inside the transparent polymeric material to form a thin media sheet 11 . The composite particles act as a template to create a cavity inside the transparent polymer. After the polymeric material has cured to form a thin media sheet, the sacrificial material is removed from the encapsulated composite particles. After the removal of the sacrificial polymer, the electrophoretic particles are free to move inside the cavity. Removal of the sacrificial material may be accomplished by any suitable means. In embodiments, the sacrificial material is diffused through the cured polymeric material. For example, the thin media sheet may be heated and/or treated to cause the sacrificial material to diffuse through polymeric material.
The number of composite particles included in a thin media layer is not particularly limited. In embodiments, composite particles are packed into a close arrangement and are individually encapsulated by the polymeric material. In particular, a closely packed layer of composite particles, the top or display layer, is created, optionally with additional layers of composite particles, as shown in FIGS. 2A–2C . FIGS. 2A and 2B show schematic side views of the formation of exemplary polymeric sheets 12 and 13 incorporating two layers of spherical or discoid composite particles, respectively. FIG. 2C shows a schematic oblique-side view of the formation of an exemplary polymeric sheet 14 incorporating a single layer of cylindrical composite particles.
Depending on the shape of the composite particles, the display layer of composite particles may cover more than about 90% of a reflective surface of the polymeric layer. In particular, closely packed cylindrical composite particles can achieve coverage of up to about 100% of a reflective surface of the polymeric layer.
The polymeric material used in embodiments to form the polymeric sheet is not particularly limited. In embodiments, the polymeric material includes one or more polymeric material selected from elastomeric materials, such as silicones, including room-temperature vulcanized silicones; thermally or UV-curable polyurethane resins; thermally or UV-curable epoxy resins; and one or more curing agents.
Once the composite particles have been arranged in the polymeric material, the polymeric material is cured to form a thin media sheet. Curing may be accomplished by any suitable method, such as thermal curing, UV curing, moisture curing, electron-beam curing, and gamma-radiation curing.
An encapsulated electrophoretic display can be constructed so that the optical state of the display is stable for some length of time. When the display has two states that are stable in this manner, the display is said to be bistable. Bistable displays are displays in which any optical (colored) state remains fixed once the addressing voltage is removed. For the purpose of embodiments using black and white species of charged particles, the bistable states represent white states and black states. Since the two species of charged particles in embodiments are oppositely charged, each species moves inside the cavity in a direction opposite to the other species, according to an externally applied voltage or electric field to form white and black states that are bistable and reflective. In the absence of an electric field, the particles are substantially immobile. The driving voltage can be as low as 100V.
FIGS. 3A–3D schematically illustrate bistable white and black states in various exemplary embodiments. FIG. 3A shows a display including spherical cavities; FIG. 3B shows a display including discoid cavities; and FIGS. 3C and 3D show side and oblique-side views of displays including cylindrical cavities. In these Figures, bistable white and black states are produced by the application of a voltage to the electrophoretic thin media sheets containing positively charged black particles 4 and negatively charged white particles 5 .
The different shapes of composite particles provide advantages. Non-spherical, discoid-shape cavities can be used to provide devices that can achieve higher brightness than those including corresponding spherical cavities, because the two species of charged particles can be distributed more evenly along the reflective surface and provided better optical performance. In addition, a thinner device, which may be operated with a lower driving voltage, can be made using discoid particles.
Electrophoretic display devices according to embodiments include the above described electrophoretic thin media sheet, at least one pair of electrodes 17 , and at least one voltage source, such as, for example, a voltage source that provides an AC (alternating current) field or a DC (direct current) field.
The devices according to this disclosure provide multiple advantages over conventional gyricon devices and known two-particle display systems.
The two-particle display systems disclosed herein can be used to obtain large-area electrophoretic devices with whitenesses of up to about 28%, as compared to the 20–25% whitenesses that can be achieved with gyricon devices. In addition, devices according to this disclosure can achieve contrast ratios of about 10.
In addition, the two particle display systems disclosed herein avoid the problems associated with the bichromal beads of gyricon processes. If even one parameter is not properly set, the bichromality of gyricon beads will be very poor, resulting in poor optical performance. However, because the disclosed species are individually monochromatic, extensive time and effort to optimize and maintain the properties of black and white wax melts, such as temperature, viscosity, feed rate, disc rotation speed, chamber temperature, etc. need not be expended. The monochromatic species of this disclosure eliminate the problems of bichromality by separately formulating each species of charged particles.
Further, because the individual species of charged particles are separately formed, the material compositions of each can be individually studied, recycled and modified to obtain specific properties, such as viscosity, whiteness, blackness, charging, etc. In contrast, any change in the formulation of one side of a gyricon bichromal ball affects the bead making process and the rotational dynamic of the whole bead. In addition, bichromal beads that do not meet the required specifications cannot be recycled, resulting in wasted materials.
An additional advantage of the above-disclosed two-particle electrophoretic systems is that large-area visual displays may be prepared. Such displays may be prepared in unit dimensions of up to about 14–24 inches in width and up to about 50 to about 100 feet in length.
The above-described materials are known to be stable under environmental stresses, including prolonged outdoor use and exposure to the elements. Thus, embodiments of visual displays according to this disclosure may be used for outdoor E-signs.
EXAMPLES
Example 1
Preparation of Black Charged Particles
A pigmented wax comprising 20 percent by weight of a black pigment, FERRO F-6331 (a commercially available black metallic oxide from Ferro Corporation), 0.3 percent by weight of IGEPAL DM970 (a commercially available nonionic surfactant from Sigma-Aldrich) and 79.7 percent by weight of POLYWAX 2000 (a commercially available linear polyethylene wax having a molecular weight of about 2000 from Baker Petrolite) was prepared using an extruder. This wax was melted at 150° C. and mechanically stirred for 2 hours at 1200–1500 rpm in a beaker to achieve good dispersion. The hot wax melt was then fed into a benchtop monochrome spinner as shown in FIG. 1 . The disc of the spinner was set to 5930 rpm, and the shroud and nozzle temperatures were 170° C. and 125° C., respectively. Small black monochrome spheres having diameters of less than 50 μm were sieved and collected. The black particles were positively charged.
Example 2
Preparation of White Charged Particles
A pigmented wax comprising 30 percent by weight of a DUPONT R104 (a commercially available white titanium oxide pigment, TiO 2 , commercially available from DuPont) and 70 percent by weight of POLYWAX 2000 was prepared using an extruder. This wax was melted at 150° C. and mechanically stirred for 2 hours at 1200–1500 rpm in a beaker to achieve good dispersion. The hot wax melt was then fed into a benchtop monochrome spinner as shown in FIG. 1 . The disc of the spinner was set to 5930 rpm, and the shroud and nozzle temperatures were 170° C. and 125° C., respectively. Small white monochrome spheres having diameters of less than 50 μm were sieved and collected. The white particles were negatively charged.
Example 3
Preparation of Spherical Composite Particles
10 grams of the black particles of Example 1 and 10 grams of white particles of Example 2 were mixed well and placed into an oven at 90° C., and 25 grams of POLYWAX 400 (a commercially available linear polyethylene wax having a molecular weight of about 400 from Baker Petrolite) was separately melted inside the 90° C. oven. After two hours, the particles were added to the wax melt and stirred well. This mixture was kept at 90° C. and fed into a benchtop monochrome spinner as shown in FIG. 1 . A strong cold air stream was purged inside the spinner to prevent the composite particle from touching the chamber wall. The disc of the spinner was set to 3700 rpm, the shroud and nozzle temperatures were 95° C. and 77° C., respectively. The spherical composite particles were collected and sieved. FIG. 4A is an optical micrograph of the composite particles, which had diameters in a range of 150 to 180 nm.
Example 4
Encapsulation of Spherical Composite Particles
6 grams of the spherical composite particles of Example 3 were mixed well with 6.6 grams of a silicone elastomer resub (commercially available from Dow Corning as SYLGARD 184 elastomeric kit in a ratio of 1/10 curing agent/resin). The mixture was degassed for 10–15 minutes, and a thin media layer of the mixture was coated onto a Mylar substrate using a doctor blade. The thin media layer was cured in a 60° C. oven for 12 hours to produce a thin media sheet. The final thickness was 330–360 μm.
Example 5
Extraction of Low-Temperature Melting Wax from Thin Media Sheet
A 2″×2″ section of the thin media sheet of Example 4 was soaked in 150 ml of ISOPAR G (a commercially available isoparaffinic solvent from ExxonMobil), and then ultrasonicated for 30 minutes. The solvent was removed, 150 ml of fresh ISOPAR G was added, and the section was further sonicated for 60 minutes at 40° C. This step was repeated once to remove the POLYWAX 400. The thin media section was prepared for testing by washing and soaking the section in ISOPAR G.
Example 6
Device Fabrication
The thin media section sample of Example 5 was sandwiched between two ITO glass plates, and a square-wave voltage was applied across the media. The black and white state were photographed and are shown in FIGS. 4B and 4C . The contrast ratio of these images, and thus this device, is about 1.5 from 150 to 200 V.
Example 7
Device Fabrication
A 10″×10″ thin media section sample was prepared as described above with respect to the 2″×2″ sample of Example 6. Optical characterization was performed, and a contrast ratio of about 1.5 to about 2.0 was observed.
Example 8
Preparation of Discoid Composite Particles
10 grams of the black particles of Example 1 and 10 grams of white particles of Example 2 were mixed well and placed into an oven at 90° C., and 25 grams of POLYWAX 400 was separately melted inside the 90° C. oven. After two hours, the particles were added to the wax melt and stirred well. This mixture was kept at 90° C. and feed into a benchtop monochrome spinner as shown in FIG. 1 . A strong cold air stream was purged inside the spinner to prevent the composite particle from touching the chamber wall. A non-stick surface, e.g. teflon sheet, is inserted between the spinning disc and chamber wall. The disc of the spinner was set to 3700 rpm, the shroud and nozzle temperatures were 95° C. and 77° C., respectively. The hot wax droplets hit the Teflon sheet, coalesced and solidified into a discoid shape. These discoids are collected and sieved into different sizes.
Example 9
Encapsulation of Discoid Composite Particles
6 grams of the discoid composite particles of Example 8 were mixed well with 6.6 grams of SYLGARD 184. The mixture was degassed for 10–15 minutes, and a thin media layer of the mixture was coated onto a Mylar substrate using a doctor blade. The thin media layer was cured at 60° C. oven for 12 hours to produce a thin media sheet. The final thickness was 330–360 μm.
Example 10
Extraction of Low-Temperature Melting Wax from Thin Media Sheet
A 2″×2″ section of the thin media sheet of Example 9 was soaked in 150 ml of ISOPAR G, and then ultrasonicated for 30 minutes. The solvent was removed, 150 ml of fresh ISOPAR G was added, and the section was further sonicated for 60 minutes at 40° C. This step was repeated once to remove the POLYWAX 400. The thin media section was prepared for testing by washing and soaking the section in ISOPAR G.
Example 11
Device Fabrication
The thin media section sample of Example 10 was sandwiched between two ITO glass plates, and a square-wave voltage was applied across the media. The contrast ratio of these images, and thus this device, is about 1.5 from 150 to 200 V.
Example 12
Device Fabrication
A 10″×10″ thin media section sample was prepared as described above with respect to the 2″×2″ sample of Example 11. Optical characterization was performed.
Example 13
Preparation of Cylindrical Composite Particles
10 grams of the black particles of Example 1 and 10 grams of white particles of Example 2 were mixed well and placed into an oven at 90° C., and 25 grams of POLYWAX 400 was separately melted inside the 90° C. oven. After two hours, the particles were added to the wax melt and stirred well. This mixture was extruded into a fiber with a diameter of 100–200 μm. The composite fibers were collected and cut into appropriate lengths by tungsten carbide cutter (laser cutting may also be used to obtain appropriately sized fibers).
Example 14
Encapsulation of Cylindrical Composite Particles
6 grams of the cylindrical composite fibers of Example 13 were mixed well with 6.6 grams of SYLGARD 184. The mixture was degassed for 10–15 minutes, and a thin media layer of the mixture was coated onto a Mylar substrate using a doctor blade. The thin media layer was cured at 40–60° C. oven for 12 hours to produce a thin media sheet. The final thickness was 330–360 μm.
Example 15
Extraction of Low-Temperature Melting Wax from Thin Media Sheet
A 2″×2″ section of the thin media sheet of Example 14 was soaked in 150 ml of ISOPAR G, and then ultrasonicated for 30 minutes. The solvent was removed, 150 ml of fresh ISOPAR G was added, and the section was further sonicated for 60 minutes at 40° C. This step was repeated once to remove the POLYWAX 400. The thin media section was prepared for testing by washing and soaking the section in ISOPAR G.
Example 16
Device Fabrication
The thin media section sample of Example 15 was sandwiched between two ITO glass plates, and a square-wave voltage was applied across the media. The contrast ratio of these images, and thus this device, is about 1.5 from 150 to 200 V.
Example 17
Device Fabrication
A 10″×10″ thin media section sample was prepared as described above with respect to the 2″×2″ sample of Example 16. Optical characterization was performed.
It will be appreciated that various of the above-discussed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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An electrophoretic display includes a transparent polymeric film including at least one cavity including a first particle species and a second particle species. Application of an electrical field causes the first particle species and the second particle species to separate from one another, and align on opposite sides of the cavity. Subsequent electric field applications cause migration of the first and second particle species, affecting a color state of the display. The electrophoretic display may be fabricated from multiple display cells arranged on a substrate.
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FIELD OF THE INVENTION
[0001] The invention relates to a cosmetics unit, in particular in the form of a mascara unit.
BACKGROUND OF THE INVENTION
[0002] Cosmetics units of this type typically comprise a storage container containing the cosmetic. An applicator typically dips into this storage container and thus, also into the cosmetic. Most frequently this applicator is attached to the cap of the cosmetics unit by a shaft. As a rule the applicator dips into the supply of the cosmetic if and so long as it is in its storage position.
[0003] In order to apply cosmetic using the applicator, the applicator is drawn through a wiper which is typically located in the neck or the mouth of the cosmetics container. In the process, the applicator is relieved of a good portion of the cosmetic that it has stored between its bristles, fingers or other application organs due to having been dipped into the cosmetics supply. Such a wiping action is obligatory, because otherwise the applicator would, as a rule, remain charged with the cosmetic in too great an extent to be able to accomplish a neat application of cosmetics therewith.
[0004] How strong the wiping action is that the respective wiper exhibits is determined in the factory by the manufacturer of the cosmetics unit. Apart from the properties of the cosmetic mass (viscosity etc.), the decisive parameters are in this case particularly the mass storage capacity of the covering of the applicator and, of course, the design of the wiper.
[0005] The difficulty or challenge lies in designing the wiping action precisely in such a way that the wiping result of the wiper finds as broad an acceptance as possible amongst the users. Even if that should be accomplished, it is, however, in many cases unsatisfactory that the wiping action of a normal wiper cannot be readily adapted to the momentary need of the respective user, which may change from case to case.
[0006] It has therefore already been proposed to use adjustable wipers in which the user—for example by rotating the wiper into a certain position—is able to vary the diameter of the wiper lips that cause the actual wiping action. However, such adjustable wipers have drawbacks. On the one hand, they are, as a rule, of a multi-part construction and therefore expensive, on the other hand, they may become stuck over time, particularly if the wiper is not adjusted for a longer period of time. Furthermore, many of the adjustable wipers are continuously adjustable and therefore demand that, having purchased the product, one first becomes acquainted with the possibilities of the adjustable wiper in order to establish which of the many adjustment positions approximately ensures a wiping effect that corresponds to one's own need, and how the wiping action changes if the adjustable wiper is readjusted in one or the other direction as intended.
[0007] Therefore, it is an object of the invention to specify a cosmetics unit which, in a simple and inexpensive manner, enables wiping off the cosmetics applicator in different degrees as required.
SUMMARY OF THE INVENTION
[0008] According to the invention, a cosmetics unit, in particular a mascara unit, is thus provided, comprising a storage container for storing the cosmetic to be applied, an applicator which in its stowed position preferably dips into the cosmetic, and a wiper device which wipes off a portion of the cosmetic picked up by the applicator during dipping, wherein the wiper device consists of several wipers that produce a different wiping action and through which the applicator can be passed alternatively.
[0009] Being passed through alternatively means, in the broadest sense of the invention, that the applicator needs only to be passed through any one of the different wipers in order to pull it out from the cosmetics supply. In this case, the user can choose, when resealing the cosmetics container, through which of the wipers she returns the applicator into its stowed position.
[0010] In most cases (that is, preferably), the user has to pass the applicator through a predetermined one of the different wipers in order to return it into its stowed position. In that case, the applicator can only be passed through the other wipers in order to change its charge, but not in order to finally reseal the cosmetics unit.
[0011] The advantage of the further wiping option(s) in that case lies in that the user, after withdrawing the applicator through the first wiper that is to be used primarily, is able to decide, based on the visual impression of the charge of the applicator, to again pass the applicator through another wiper, which has a different, preferably stronger wiping action, in a next step prior to the actual application.
[0012] In particular, it is also possible that the user, after withdrawing the applicator, first applies a certain amount of the cosmetics mass and only later, when the mass application has been provisionally completed, pulls the applicator through another wiper, which due to its design relieves the applicator of the cosmetic still remaining thereon to such an extent that it can now be used as a comb, for example, for separating or shaping the eyelashes.
[0013] Preferably, the several wipers are each rigid wipers whose wiping actions cannot be modified and whose wiping actions are different from one another, preferably by the wiper lips of the individual wipers that produce the actual wiping action respectively having a different clear diameter. Such a design facilitates handling because the user is able to achieve different wiping results in a convenient manner without having to consider the function of the wiper(s) in detail.
[0014] Preferably, the several wipers are formed in a single integral wiper body, which is very advantageous with regard to production and costs (disposable articles). Alternatively, however, different wipers can be inserted in openings provided therefor.
[0015] In a particularly preferred exemplary embodiment, the integral wiper body circumferentially delimits an antechamber into which several wipers lead with their, relative to the wiper lip, distal ends. Such an inner chamber prevents splashing when the applicator is pulled out through the wiper. Furthermore, such an antechamber facilitates reliable sealing, also with respect to the wiper openings, which are not penetrated by an applicator stem in the closing position, therefore have a large free cross section, and as such thus tend to leak the cosmetic.
[0016] Preferably, the wiper body has an increased wall thickness in the area where it delimits the antechamber. This aids its sealing function, but as a rule also facilitates its reliable attachment in the mouth of the storage container.
[0017] Ideally, the wiper body, in the area in which it delimits the antechamber, forms a sealing seat against which a counter-sealing surface associated with the cap can be brought to rest in a sealing manner. Particularly preferred is the design of this sealing seat as a conical or wedge-shaped sealing seat with a sealing surface that is inclined by an angle W of 0.5° to 7° relative to the longitudinal axis L of the container.
[0018] Protection is sought also for a multiple wiper for insertion into a cosmetics unit as such, consisting of a preferably integral wiper body with several wipers that produce a different wiping action and that are suitable and intended for alternatively passing through an applicator.
[0019] Further advantages, optional embodiments and mechanisms of action of the invention become apparent from the exemplary embodiment for the invention described in more detail with reference to the Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 shows a sectional view of a cosmetics unit according to the invention.
[0021] FIG. 2 shows a lateral view of a cosmetics unit according to the invention.
[0022] FIG. 3 shows a top view of a multiple wiper according to the invention.
[0023] FIG. 4 shows a lateral view of a multiple wiper according to the invention, seen from its broad side.
[0024] FIG. 5 shows a lateral view of a multiple wiper according to the invention, seen from its narrow side.
[0025] FIG. 6 shows a section through a multiple wiper according to the invention, parallel to the broad side of the multiple wiper through its center.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] As can be seen rather well in FIGS. 1 and 2 , the cosmetics unit 1 according to the invention consists of a storage container 2 and a cap 3 . The cosmetics unit 1 in this case is a so-called sales unit, i.e. not a container for laboratory purposes, but a disposable container of appealing but inexpensive design, preferably of plastic with a wall thickness of between 0.3 and 1.5 mm.
[0027] As a rule the cap 3 , once it is in its closed position, will not be rotatable relative to the storage container 2 , but is stationarily latched onto or placed on the storage container 2 in order to seal it, and preferably fixated by additional retaining clips 14 or retaining means.
[0028] A stem 4 whose distal end, i.e. the end thereof facing away from the cap, carries an applicator 5 is attached to said cap. For this purpose, the stem, on the side thereof facing away from the applicator, expediently comprises a cup-like molded-on part, by which it is connected to, preferably latched onto or glued to, a shell 13 with which it forms the cap 3 .
[0029] A wiper body 7 is inserted and latched into the opening 6 of the storage container.
[0030] For this purpose, both the edge of the opening 6 as well as the wiper body 7 are each provided at least with a corresponding latching organ and a corresponding latching recess.
[0031] In this case the wiper body 7 is configured as an integral plastic piece forming three individual wipers of a preferably conventional type which are disposed next to one another along a line B-B, i.e., whose longitudinal wiper axes 8 that form the respective center of the wiper all intersect the line B-B.
[0032] The three wipers differ only or substantially by the diameter of their wiping lip that is effective in wiping. However, the wiper opening can also have different geometries. As a rule, the wiper, which can be seen in FIG. 3 and is to be used primarily because it enables the applicator to be pushed into the cosmetics unit, will comprise a wiper lip whose clear diameter is the largest. The two other wipers, which are preferably disposed to the left and right of the wiper to be used primarily, which is in this case attached in the middle, each comprise a wiper lip whose clear diameter is slightly smaller. It has thus proved beneficial to provide the middle wiper with a radius R 1 that determines its clear diameter, and the one of the adjacent wipers with a corresponding radius R 2 , which is at least 5%, better at least 7.5%, smaller than the radius R 1 , and the other one of the adjacent wipers with a corresponding radius R 3 , which is at least 10%, better at least 15%, smaller than the radius R 1 . However, it is also possible to use wipers with different geometries of the wiper opening.
[0033] For this purpose, the opening 6 of the storage container has a clear cross section which is larger than the clear cross section of the rest of the storage container adjacent to the opening 6 . The reason for this will be explained in more detail below.
[0034] The storage container is not completely round but, at least in the region of its opening 6 , has a cross section which in a first direction Ri 1 is longer by the factor 1.5, better even by at least the factor 1.75, than in a second direction Ri 2 perpendicular thereto. The side of the cap 3 cooperating with the opening 6 of the storage container is designed accordingly.
[0035] Towards its side facing away from the opening 6 , the cross section of the storage container 2 preferably tapers in such a way that the storage container becomes slimmer in the direction of its side facing away from the opening 6 , as was already mentioned above.
[0036] In this case, the storage container 2 preferably tapers in such a way that it is only through the wiper to be used primarily, which in this case is the middle one of the three, that the applicator can be pushed into the storage container 2 so deeply that the cap 3 can be brought into its closing position. Ideally the applicator can be pushed into the storage container only so far, through the two further wipers disposed to the left and the right of the middle wiper, that it passes the respective further wiper completely but then collides with the wall of the storage container, and is therefore prevented from further movement in a haptically perceptible manner before it dips into the stored cosmetic. Such an embodiment is expedient because it is thereby avoided that the applicator, which is moved through the further wiper in order to wipe it off to a greater extent, inadvertently dips back into the cosmetic mass, which would perhaps affect the desired stronger wiping action.
[0037] As can be seen rather well in FIG. 6 , the wiper body 7 consists of an integral plastic piece. Sometimes, two, or in this case even three, wipers of a conventional construction are formed in this integral plastic piece. The wiper body is preferably manufactured in an injection-molding process, ideally from a single plastic material in a single process step. A preferred material for such a wiper body is, for example, the type of plastic sold under the brand name GRILFLEX®.
[0038] As can be seen, the integral wiper body forms an antechamber 9 delimited by its wall in the circumferential direction. Several wipers lead into this antechamber 9 with their distal ends, i.e. the ends facing away from the respective wiper lip 10 . This antechamber collects the cosmetic mass which may possibly splash out when the applicator is withdrawn from the respective wiper, for example by individual bristles snapping into their unbiased positions once they have passed the narrow cross section of the respective wiper and are abruptly no longer subjected to a bending stress.
[0039] Moreover, this antechamber also serves for providing a sealing surface into which a corresponding counterpart of the cap or of the cup-like molded-on part forming a component of the cap can be pressed, in order thus to be biased against the wall of the antechamber in such a manner that a tight connection is produced, at least between the wiper and the cap or its cup-like molded-on part. For this purpose, the inner surface of the wall of the antechamber 9 is expediently slightly inclined by the angle W, for example by 0.3°-5°, see FIG. 6 . As soon as the counter-surface of the cap or of the cup-like molded-on part of the cap is also equipped with a corresponding slight inclination, the final result is a conical seal which seals even if the cap is pressed against the storage container only lightly, and which additionally facilitates the accurate placement of the cap onto the storage container.
[0040] In view of this, it is readily understandable why the wall of the wiper body 7 delimiting the antechamber is configured to be thicker, and why it is ensured that the section of the wall can be connected to the opening of the storage container as firmly as possible. The area sealing the cosmetics container has to be configured to be as dimensionally stable as possible so that a reliable tightness is provided even if the cosmetics container is exposed, for example, to bending or locally concentrated stresses during transport in a handbag.
[0041] As can be seen, said wipers respectively consist of a preferably circular-conical passage which respectively forms a wiper lip 10 on its side facing into the container. The wiper lip 10 can integrally consist of the same material as the wiper body 7 . Alternatively, modern two-component processes can be used in this case, i.e. of at least one of these wipers, the wiper lip, for example, can consist of a particularly soft or even rubber-elastic plastic that was molded on later.
[0042] Molding on such a wiper lip consisting of a particularly soft material may particularly make sense especially in the case of a multiple wiper as it is proposed herein—in order to render the wiping action of the wiper lip uniform and thus to counteract the tendency of the wiper lip to be more rigid in the wall area, which is particularly thick because it separates two adjacent wipers from each other, than in the area of the real outer wall of the respective wiper.
[0043] In the area of the antechamber 9 , the wiper body has an annular peripheral area in which its wall thickness is increased. This area has an increased deformation resistance and therefore serves for securely retaining the wiper body 7 in the opening 6 of the storage container 2 , see for example FIGS. 4-6 .
[0044] The wiper body 7 also additionally carries several retaining projections 11 preferably in this reinforced area, in such a way as can best be seen in the FIGS. 4 and 5 .
[0045] As can best be seen referring to the detail X of the FIG. 1 , these retaining projections 11 latch behind a projection of the wall that delimits the opening 6 of the storage container.
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The invention relates to a cosmetics unit, in particular a mascara unit, that includes a storage container for storing the cosmetic to be applied, an applicator which in its stowed position preferably dips into the cosmetic, and a wiper device which wipes off a portion of the cosmetic picked up by the applicator during dipping. The wiper device consists of several wipers that produce a different wiping action and through which the applicator can be passed alternatively.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Japanese Patent Application No. 2013-068088 filed Mar. 28, 2013, the content of which is hereby incorporated herein by reference.
BACKGROUND
The present disclosure relates to a sewing machine that includes a threading device.
A sewing machine that includes a threading device is known. The threading device includes a threading hook, a thread guide member, a drive mechanism, and an actuator. In a case where a threading key is pressed, the actuator drives the drive mechanism. When the drive mechanism is driven, the threading hook and the thread guide member are operated and an upper thread may be automatically threaded through an eye in a sewing needle.
SUMMARY
There are cases in which a relatively large accessory device (such as an upper feed device) is mounted on a presser bar of the above-described sewing machine and used. In such a case, when the threading device is operated, a distance between the threading hook and the accessory device may be extremely small. Therefore, the threading hook may come into contact with the accessory device. If the threading hook comes into contact with the accessory device, it is possible that the threading hook may be deformed.
Embodiments of the broad principles derived herein provide a sewing machine that is capable of reliably performing a threading operation in a state in which an accessory device is mounted on a presser bar, without contact between a threading hook and the accessory device even when a threading device is operated.
Embodiments provide a sewing machine that includes a needle bar, a presser bar, a threading device, a processor, and a memory. The needle bar is configured such that a sewing needle is attached thereto. The presser bar is configured such that an accessory device is mounted thereon. The threading device is configured to perform a threading operation in which an upper thread is passed through an eye of the sewing needle attached to the needle bar. The memory is configured to store computer-readable instructions. The computer-readable instructions cause the processor to perform processes that include determining whether a mounted device is a specific accessory device and causing the threading device to perform the threading operation in a case where it is determined that the mounted device is the specific accessory device and a specific condition is satisfied. The mounted device is an accessory device mounted on the presser bar;
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will be described below in detail with reference to the accompanying drawings in which:
FIG. 1 is a front view of a sewing machine;
FIG. 2 is a left side view of the sewing machine;
FIG. 3 is a perspective view of an upper feed device;
FIG. 4 is a front view of a cloth thickness detection mechanism;
FIG. 5 shows longitudinal sectional front views of a threading device in states in which a threading mechanism portion is in a withdrawn position, in a thread laying preparing position, and in a threading operation position;
FIG. 6 is a perspective view illustrating an operation of a threading hook in threading;
FIG. 7 is a perspective view illustrating an operation of the threading hook in threading;
FIG. 8 is a block diagram showing an electrical configuration of the sewing machine and the upper feed device;
FIG. 9 is a flowchart showing threading processing; and
FIG. 10 is an explanatory diagram of a screen displaying an error message.
DETAILED DESCRIPTION
Hereinafter, an embodiment of a sewing machine 101 will be explained.
Explanation of Sewing Machine 101
The external appearance of the sewing machine 101 will be explained with reference to FIG. 1 .
The sewing machine 101 includes a bed 111 , a pillar 112 , an arm 113 , and a head 114 . The bed 111 is a base portion of the sewing machine 101 . The bed 111 includes a flat surface on which a work cloth (not shown in the drawings) may be placed. The pillar 112 extends from the bed 111 . The arm 113 extends from the pillar 112 while facing the bed 111 . The head 114 is provided on a leading end of the arm 113 .
Directions relating to the sewing machine 101 according to the present embodiment will be defined. The direction in which the pillar 112 extends from the bed 111 is the upward direction of the sewing machine 101 and the direction opposite to the upward direction is the downward direction of the sewing machine 101 . The direction in which the arm 113 extends from the pillar 112 is the leftward direction of the sewing machine 101 and the direction opposite to the leftward direction is the rightward direction of the sewing machine 101 . The direction that is orthogonal to the left-right direction and the up-down direction of the sewing machine 101 is the front-rear direction of the sewing machine 101 . A face on which a threading switch 121 , which will be explained below, is arranged is the front face of the sewing machine 101 .
A vertically long rectangular liquid crystal display (LCD) 115 is provided on the front face of the pillar 112 . For example, keys to execute various functions necessary to a sewing operation, various messages, various patterns, etc. may be displayed on the LCD 115 .
A transparent touch panel 126 is provided on the top surface of the LCD 115 . As a result, it is possible to perform selection of a sewing pattern, various settings, or the like by performing a pressing operation, using a finger or a dedicated touch pen, on a position on the touch panel 126 that corresponds to one of the various keys etc. displayed on the LCD 115 .
The threading switch 121 and other operating switches are provided on a lower portion of the front face of the arm 113 .
An electrical connections of an upper feed device 104 and the sewing machine 101 will be explained with reference to FIG. 2 .
A presser bar 127 is disposed at the rear of a needle bar 6 . The upper feed device 104 may be detachably mounted on the lower end of the presser bar 127 . The upper feed device 104 may be disposed above the bed 111 . The upper feed device 104 is configured to feed the work cloth in cooperation with a feed dog (not shown in the drawings). Although not shown in the drawings, in addition to the above-described upper feed device 104 , a variety of devices, such as a cloth end cutting device (a side cutter) and a ruffler (a ruffler presser foot) that have known structures, may each be mounted on the sewing machine 101 as an accessory device.
An electric board 498 (refer to FIG. 3 ) is provided inside the upper feed device 104 . A connecting portion 152 is connected to the electric board 498 . The connecting portion 152 includes a lead wire 502 and a connector 503 . The lead wire 502 extends from the electric board 498 to the outside of the upper feed device 104 . The connector 503 is provided on the leading end of the lead wire 502 . The connector 503 may be connected to a connector 141 , which is provided on the head 114 of the sewing machine 101 . The connector 141 is electrically connected to a control portion 60 of the sewing machine 101 , which is shown in FIG. 7 . A motor 491 (refer to FIG. 3 ) is provided inside the upper feed device 104 . The motor 491 may be electrically connected to the control portion 60 of the sewing machine 101 via the electric board 498 , the lead wire 502 , and the connector 503 . In other words, the motor 491 and the control portion 60 of the sewing machine 101 may be electrically connected by the connecting portion 152 . A CPU 61 , which is shown in FIG. 7 , may control the motor 491 .
Explanation of Upper Feed Device 104
The upper feed device 104 will be explained with reference to FIG. 3 .
The upper feed device 104 may be mounted on and removed from the presser bar 127 . The upper feed device 104 includes a mounting portion 142 , a feed mechanism 143 , a drive mechanism 149 , the connecting portion 152 , and a presser foot 151 . The mounting portion 142 is a portion by which the upper feed device 104 is mounted on the presser bar 127 of the sewing machine 101 . The feed mechanism 143 is configured to feed the work cloth. The drive mechanism 149 is configured to drive the feed mechanism 143 . The connecting portion 152 may electrically connect the motor 491 , which is provided in the drive mechanism 149 , to the control portion 60 of the sewing machine 101 .
The mounting portion 142 and the presser foot 151 will be explained. The mounting portion 142 is provided above the feed mechanism 143 in the front end portion of the upper feed device 104 . The mounting portion 142 includes two holding portions 421 and 422 . The holding portions 421 and 422 may be mounted on and fixed to the presser bar 127 by a shoulder screw 423 . The shoulder screw 423 includes a head 425 , a shank 426 , and a threaded portion 424 . The outside diameter of the shank 426 is slightly smaller than the outside diameter of the head 425 . The outside diameter of the threaded portion 424 is slightly smaller than the outside diameter of the shank 426 . The holding portions 421 and 422 are provided on the front end of the upper feed device 104 . The holding portion 421 is provided above the holding portion 422 and is slightly separated from the holding portion 422 . Each of the holding portions 421 and 422 has a recessed portion that is recessed toward the left. The lower end portion of the presser bar 127 may be disposed in the recessed portions. A threaded hole (not shown in the drawings) is provided in the lower end portion of the presser bar 127 . The threaded hole extends through the presser bar 127 in the left-right direction. The threaded portion 424 may be screwed into the threaded hole. A slot (not shown in the drawings) is formed in the left side face of the head 425 . A tool may be fitted into the slot.
When the upper feed device 104 is mounted on the presser bar 127 , the user may adjust the position of the threaded portion 424 to the screw hole portion of the presser bar 127 . In this state, the user may rotate the head 425 using the user's fingers or fit the tool into the slot to rotate the head 425 . As a result of this, a right side surface of the shank 426 may come into contact with left side surfaces of the holding portions 421 and 422 . Further, if the shoulder screw 423 is rotated and tightened in this state, the holding portions 421 and 422 may be clamped between the shank 426 and the presser bar 127 . In this state, the holding portions 421 and 422 are fixed to the presser bar 127 . The upper feed device 104 may thus be mounted on the presser bar 127 .
A presser foot support portion 511 , which supports the presser foot 151 , is provided on the lower edge portion of the holding portion 422 . The presser foot support portion 511 straddles the front end portion of the feed mechanism 143 at the left and right. The presser foot support portion 511 extends obliquely downward and forward. The presser foot 151 is provided on the lower end of the presser foot support portion 511 . The belt positioning portion 512 is provided at the rear of the hole 513 of the presser foot 151 . The belt positioning portion 512 is a rectangular open portion that extends to the rear edge of the presser foot 151 . The front end portion of the belt 435 of the feed mechanism 143 may be disposed on the inner side of the belt positioning portion 512 . The front end portion of the belt 435 may feed the work cloth while pressing downward against the work cloth in the belt positioning portion 512 .
The upper feed device 104 may be mounted to the presser bar 127 by the mounting portion 142 . Therefore, when the presser bar 127 is moved upward, the upper feed device 104 is also moved upward and the presser foot 151 is also moved away from the work cloth. When the presser bar 127 is moved downward, the upper feed device 104 is also moved downward and the presser foot 151 also presses downward against the work cloth 100 .
Explanation of Cloth Thickness Detection Mechanism 180
The cloth thickness detection mechanism 180 will be explained with reference to FIG. 4 . The cloth thickness detection mechanism 180 is provided to the rear of the needle bar 6 . The cloth thickness detection mechanism 180 includes the presser bar 127 , the presser foot 151 , a presser bar bracket 85 , and a potentiometer 88 . The presser bar 127 is supported by a sewing machine frame such that the presser bar 127 may be moved up and down. The presser foot 151 is mounted on a lower end portion of the presser bar 127 . The presser bar bracket 85 is fixed to substantially the center, in the up-down direction, of the presser bar 127 . The potentiometer 88 is provided on the left side of the presser bar 127 .
The potentiometer 88 is a rotary potentiometer. The potentiometer 88 is configured to detect a position in height of the presser bar 127 . An arm 881 extends to the right from a rotating shaft of the potentiometer 88 . A protruding portion 851 protrudes to the left of the presser bar bracket 85 . The arm 881 is in contact with the top face side of the protruding portion 851 . The arm 881 is rotated in accordance with the up/down movement of the presser bar bracket 85 , and a resistance value of the potentiometer 88 changes. The control portion 60 detects the position of the presser bar 127 based on a voltage that corresponds to the resistance value of the potentiometer 88 .
Explanation of Threading Device 11
The threading device 11 and its peripheral portions will be explained with reference to FIG. 5 .
A needle bar base 9 extends in the up-down direction. The needle bar base 9 includes support pieces 92 and 93 . The support pieces 92 and 93 extend to the right. The support pieces 92 and 93 are disposed on an upper portion and a lower portion of the needle bar base 9 , respectively. The needle bar 6 is inserted through the support pieces 92 and 93 such that the needle bar 6 may be moved in the up-down direction, and is supported by the support pieces 92 and 93 . A needle bar bracket 24 is positioned between the support pieces 92 and 93 . The needle bar 6 is coupled to a needle bar drive mechanism by the needle bar bracket 24 , and is moved up and down at a specific stroke. When the sewing operation is stopped, the needle bar 6 is stopped at a specific raised position. A positioning member 25 is attached to an upper portion of a coupling portion between the needle bar 6 and the needle bar bracket 24 . The positioning member 25 includes a protruding piece 251 that protrudes to the left. A needle bar thread guide 26 is provided on the lower end of the needle bar 6 .
The threading device 11 is mounted on the needle bar base 9 . The threading device 11 is disposed to the left of the needle bar 6 . The threading device 11 includes a first threading shaft 27 , a second threading shaft 28 , a threading mechanism portion 29 , and a rotary mechanism 30 . The threading mechanism portion 29 includes a threading hook 31 (refer to FIG. 6 ), a thread guide member 32 , and a thread holding member 33 . The threading hook 31 and the thread guide member 32 are provided on the lower end of the first threading shaft 27 . The thread holding member 33 is provided on the lower end of the second threading shaft 28 . The rotary mechanism 30 is configured to rotate the first threading shaft 27 around the shaft center.
The first threading shaft 27 is disposed to the left of the needle bar 6 . The first threading shaft 27 extends in the up-down direction. The first threading shaft 27 is supported on the needle bar base 9 such that the first threading shaft 27 may be moved in the up-down direction and may be rotated. The second threading shaft 28 is disposed to the left of the first threading shaft 27 . The second threading shaft 28 is supported on the needle bar base 9 such that the second threading shaft 28 may be moved in the up-down direction. As will be explained in more detail below, the first and second threading shafts 27 and 28 are constantly urged upward with respect to the needle bar base 9 by a compression coil spring 42 . The first and second threading shafts 27 and 28 may be moved integrally in the up-down direction in a state in which positions of the upper ends of the first and second threading shafts 27 and 28 are aligned. A guide shaft 35 is fixed to the needle bar base 9 . The guide shaft 35 is disposed to the left of the second threading shaft 28 . The guide shaft 35 extends in the up-down direction. The guide shaft 35 guides a threading lever 40 .
The threading slider 36 is inserted through the upper ends of the first and second threading shafts 27 and 28 such that the threading slider 36 may be moved in the up-down direction. The threading slider 36 is disposed across both the first and second threading shafts 27 and 28 . The threading slider 36 includes a semi-circular wall portion that covers the left half of the upper portion of the first threading shaft 27 . A cam groove 361 extends in a diagonal direction from the wall portion. A sliding pin 37 , which extends horizontally, penetrates through the upper portion of the first threading shaft 27 . The sliding pin 37 is inserted through the cam groove 361 . The rotary mechanism 30 includes the sliding pin 37 and the cam groove 361 . A spring receiving pin 38 , which is positioned below the sliding pin 37 , is provided on the first threading shaft 27 . A compression coil spring 39 is provided between the spring receiving pin 38 and the lower end of the threading slider 36 .
The threading lever 40 and a lever plate 41 are fittingly inserted into the guide shaft 35 such that the threading lever 40 and the lever plate 41 may be moved in the up-down direction. The threading lever 40 and the lever plate 41 are used to move the first and second threading shafts 27 and 28 in the up-down direction. The threading lever 40 extends to the left. The threading lever 40 integrally includes a cylindrical portion 401 , which the guide shaft 35 is inserted through.
Two sliding ring portions 411 are provided on the lever plate 41 . The guide shaft 35 is inserted into the sliding ring portions 411 such that the guide shaft 35 may be moved in the up-down direction. The two sliding ring portions 411 are disposed on the lever plate 41 such that the two sliding ring portions 411 sandwich the cylindrical portion 401 of the threading lever 40 from above and below. Further, the lever plate 41 integrally includes a plate portion that extends to the right and an operation piece 412 that is positioned on the upper end of the plate portion. The operation piece 412 is configured to come into contact with and depress the top face of the threading slider 36 . The compression coil spring 42 is provided on the guide shaft 35 . The compression coil spring 42 constantly urges the threading lever 40 and the lever plate 41 upward.
The threading device 11 shown furthest to the left in FIG. 5 is in a state in which the force to depress the threading lever 40 downward is not acting on the threading lever 40 . In this state, due to the spring force of the compression coil spring 42 , the threading lever 40 and the lever plate 41 are positioned on the upper end of the guide shaft 35 . In the state in which the threading lever 40 and the lever plate 41 are positioned on the upper end of the guide shaft 35 , the threading slider 36 and the first and second threading shafts 27 and 28 are positioned at an uppermost position with respect to the needle bar base 9 . In the uppermost position, the threading mechanism portion 29 that is provided on the lower ends of the first and second threading shafts 27 and 28 is housed inside the head 114 , and this position is a withdrawn position.
When the force to depress the threading lever 40 downward acts on the threading lever 40 , the threading lever 40 , the first and second threading shafts 27 and 28 , and the threading mechanism portion 29 descend from the withdrawn position (refer to FIG. 5 ) by a distance D1. This position is a thread laying preparing position (refer to the threading device 11 in the center of FIG. 5 ). In the thread laying preparing position, the threading mechanism portion 29 is positioned at a height in the vicinity of a needle bracket 8 of the needle bar 6 that is in a needle up position above a needle. In the thread laying preparing position, a user may perform thread laying, which is an operation in preparation for threading an upper thread T.
When the force to depress the threading lever 40 downward further acts on the threading lever 40 , the threading lever 40 , the first and second threading shafts 27 and 28 , and the threading mechanism portion 29 are moved from the thread laying preparing position. Then, at a position at which the threading lever 40 , the first and second threading shafts 27 and 28 , and the threading mechanism portion 29 have been moved from the thread laying preparing position by a distance D2, the sliding pin 37 , which is provided on the first threading shaft 27 , engages with the protruding piece 251 of the positioning member 25 , which is provided on the needle bar 6 . When the sliding pin 37 engages with the protruding piece 251 , the downward movement of the first threading shaft 27 is regulated. This position is a threading operation position (refer to the threading device 11 furthest to the right in FIG. 5 ). In the threading operation position, the height position of the threading hook 31 is aligned with the height of an eye 71 of a sewing needle 7 . As a result, the threading operation becomes possible.
At the time of the threading operation, the threading lever 40 is further depressed by a distance D3 from the position to which the threading lever 40 has been moved by the distance D2. As a result of the downward movement of the threading lever 40 , the threading slider 36 is moved down via the lever plate 41 by the distance D3 with respect to the first and second threading shafts 27 and 28 against the spring force of the compression coil spring 39 . As a result of this, the sliding pin 37 of the first threading shaft 27 is relatively moved up in a diagonal direction inside the cam groove 361 of the threading slider 36 . When the sliding pin 37 , which is the rotary mechanism 30 , is moved up, the first threading shaft 27 and the threading hook 31 are rotated and the threading operation is performed.
When the depressing force on the threading lever 40 is released, by the spring force of the compression coil spring 39 , the threading lever 40 and the threading slider 36 are moved up by the distance D3 with respect to the first and second threading shafts 27 and 28 . When the threading slider 36 is moved up, the sliding pin 37 of the first threading shaft 27 is relatively moved down in a diagonal direction inside the cam groove 361 of the threading slider 36 . When the sliding pin 37 descends, the first threading shaft 27 and the threading hook 31 are rotated in a reverse direction. After that, the threading lever 40 is moved up by a distance (D2+D1), and the first and second threading shafts 27 and 28 and the threading mechanism portion 29 are moved up and return to the withdrawn position, as shown by the threading device 11 furthest to the left in FIG. 5 .
The threading mechanism portion 29 (refer to FIG. 5 ) will be explained with reference to FIG. 6 . The threading hook 31 , guide members 43 and 43 , and a thread holding wire 44 are provided on the lower end of the first threading shaft 27 (refer to FIG. 5 ). The threading hook 31 includes a hook portion 311 . The hook portion 311 is provided with a downward orientation on the leading end of the threading hook 31 . The threading hook 31 may be inserted through the eye 71 of the sewing needle 7 . The guide members 43 and 43 are positioned on both sides of the threading hook 31 . At the time of the threading operation, the thread guide member 32 , which is provided on the lower end of the first threading shaft 27 , is configured to hold the upper thread T in a horizontal state in front of the eye 71 of the sewing needle 7 , as shown in FIG. 6 .
An operation of the threading hook 31 will be explained. The threading mechanism portion 29 may be moved down to the threading operation position and the first threading shaft 27 may be rotated. When the first threading shaft 27 is rotated, the threading hook 31 is moved in the direction of an arrow A and passes through the eye 71 of the sewing needle 7 , as shown in FIG. 6 . Further, the threading hook 31 hooks the upper thread T that is being held by the thread guide member 32 using the hook portion 311 . After that, the first threading shaft 27 may be rotated in the reverse direction. When the first threading shaft 27 is rotated in the reverse direction, the threading hook 31 is moved in reverse in the direction of an arrow B and the upper thread T passes through the eye 71 along with the threading hook 31 , as shown in FIG. 7 . The threading is performed in this manner. For example, Japanese Laid-Open Patent Publication No. 2006-158412 discloses a structure and an operation of a threading mechanism portion, the relevant portions of which are incorporated by reference.
The sewing machine 101 includes an up-and-down moving mechanism (not shown in the drawings) that is configured to move the threading lever 40 in the up-down direction. The up-and-down moving mechanism is driven by a threading pulse motor 520 , which will be explained below. For example, Japanese Laid-Open Patent Publication No. 2009-165737 discloses a structure and an operation of an up-and-down moving mechanism, the relevant portions of which are incorporated by reference.
Electrical Configuration of Sewing Machine 101 and Upper Feed Device 104
An electrical configuration of the sewing machine 101 and the upper feed device 104 will be explained with reference to FIG. 8 . The control portion 60 of the sewing machine 101 includes the CPU 61 , a ROM 62 , a RAM 63 , and an input/output interface 65 . The CPU 61 , the ROM 62 , the RAM 63 , and the input/output interface 65 are electrically connected to each other by a bus 67 . The ROM 62 stores programs for the CPU 61 to execute processing, data, etc. Specifically, the ROM 62 stores a program to execute threading processing shown in FIG. 8 , a height table 621 , and a maximum cloth thickness table 622 . The height table 621 includes information in which detection values of the potentiometer 88 are associated with heights of the presser foot 151 . The maximum cloth thickness table 622 includes information in which types of accessory devices are associated with maximum cloth thickness values at which threading by the threading device 11 is possible. The RAM 63 stores various temporary data.
The threading switch 121 , the touch panel 126 , drive circuits 72 , 75 and 76 , the potentiometer 88 , and the connector 141 are electrically connected to the input/output interface 65 . The drive circuit 72 may drive a sewing machine motor 79 . The drive circuit 75 may drive the LCD 115 . The drive circuit 76 may drive the threading pulse motor 520 . The threading lever 40 is moved in the up-down direction by the rotation of the threading pulse motor 520 .
The connector 141 is connected to one end of the connecting portion 152 . The connecting portion 152 is electrically connected to a connector 504 . The connector 504 is electrically connected to a drive circuit 510 . The connector 504 and the drive circuit 510 are mounted on the electric board 498 , which is provided inside the upper feed device 104 . The drive circuit 510 is electrically connected to the motor 491 . The drive circuit 510 may drive the motor 491 . The CPU 61 controls the drive circuit 510 and may thus control the motor 491 .
When the upper feed device 104 is electrically connected to the CPU 61 of the sewing machine 101 via the connector 141 , a Low signal is input to the CPU 61 . When the upper feed device 104 is not electrically connected to the CPU 61 , a High signal is input to the CPU 61 . By detecting the Low signal or the High signal, the CPU 61 can detect whether or not the motor 491 and the control portion 60 of the sewing machine 101 are electrically connected.
Threading Processing
The threading processing will be explained with reference to FIG. 9 . The threading processing is executed by the CPU 61 of the sewing machine 101 in accordance with the program stored in the ROM 62 . The threading processing may be executed, for example, when the user presses the threading switch 121 . Each of the steps shown in the flowchart indicates the processing of the CPU 61 .
At step S 12 , the CPU 61 outputs a control signal that instructs the potentiometer 88 to detect the thickness of the work cloth. When the potentiometer 88 receives the control signal from the CPU 61 , the potentiometer 88 detects the thickness of the work cloth. More specifically, the CPU 61 detects a height of the presser foot 151 (a cloth thickness) that corresponds to a detection voltage, based on the height table 621 that is stored in the ROM 62 . The RAM 63 stores the height of the presser foot 151 (the cloth thickness) in response to a control signal from the CPU 61 .
At step S 14 , the CPU 61 determines whether or not a specific accessory device is mounted on the presser bar 127 . The specific accessory device may be, for example, the upper feed device 104 . More specifically, the CPU 61 may detect the Low signal from the upper feed device 104 via the connector 141 . When the upper feed device 104 is not electrically connected to the CPU 61 , the CPU 61 may detect the High signal. When the CPU 61 detects the Low signal (yes at step S 14 ), the CPU 61 advances the processing to step S 15 . When the CPU 61 detects the High signal (no at step S 14 ), the CPU 61 advances the processing to step S 25 .
At step S 15 , the CPU 61 determines whether or not the cloth thickness detected at step S 12 is larger than a maximum cloth thickness value that corresponds to a type of the accessory device and at which the threading is possible. More specifically, the CPU 61 reads the cloth thickness stored in the RAM 63 at step S 12 . Further, the CPU 61 reads the maximum cloth thickness table 622 stored in the ROM 62 . The CPU 61 determines whether or not the cloth thickness stored in the RAM 63 is larger than the maximum cloth thickness value stored in the ROM 62 . The maximum cloth thickness value may be, for example, a maximum value at which threading is possible when the upper feed device 104 is mounted on the presser bar 127 . The maximum cloth thickness value may be, for example, 2.5 mm. When the CPU 61 determines that the detected cloth thickness is larger than the maximum cloth thickness value (yes at step S 15 ), the CPU 61 advances the processing to step S 16 . When the CPU 61 determines that the detected cloth thickness is not larger than the maximum cloth thickness value (no at step S 15 ), the CPU 61 advances the processing to step S 25 .
At step S 16 , the CPU 61 prohibits execution of the threading operation by the threading device 11 . More specifically, the CPU 61 does not drive the threading pulse motor 520 . When the CPU 61 does not drive the threading pulse motor 520 , the threading mechanism portion 29 is in the withdrawn position shown in FIG. 5 due to the spring force of the compression coil spring 42 .
At step S 17 , the CPU 61 performs notification that it is not possible to perform the threading operation by the threading device 11 . More specifically, the CPU 61 causes the LCD 115 to display an error message 261 shown in FIG. 10 . The error message 261 may be, for example, a message instructing the user to remove the work cloth. Specifically, the CPU 61 outputs a control signal to the LCD 115 in order to display the error message 261 . The LCD 115 displays the error message 261 in response to the control signal received from the CPU 61 . More specifically, the CPU 61 reads image information representing the error message 261 from the ROM 62 and transmits an image signal to the LCD 115 .
The user may see the error message 261 displayed on the LCD 115 , and may remove the work cloth. At step S 19 , in a similar manner to the processing at step S 12 , the CPU 61 outputs a control signal that instructs the potentiometer 88 to detect the thickness of the work cloth.
At step S 21 , in a similar manner to the processing at step S 15 , the CPU 61 determines whether or not the cloth thickness detected at step S 19 is larger than the maximum cloth thickness value that corresponds to the type of the accessory device and at which the threading is possible. If, for example, the user has not yet removed the work cloth, the CPU 61 determines that the cloth thickness is larger than the maximum cloth thickness value (yes at step S 21 ) and returns the processing to step S 16 . On the other hand, for example, when the user has removed the work cloth, the CPU 61 determines that the cloth thickness is not larger than the maximum cloth thickness value (no at step S 21 ) and advances the processing to step S 23 .
At step S 23 , the CPU 61 cancels the error. Specifically, the CPU 61 deletes the display of the error message 261 , and outputs a control signal to the LCD 115 to display a menu screen. The LCD 115 displays the menu screen in response to the control signal from the CPU 61 . More specifically, the CPU 61 reads image information representing the menu screen from the ROM 62 and transmits an image signal to the LCD 115 .
At step S 25 , the CPU 61 outputs a control signal to the threading pulse motor 520 to perform the threading operation, as explained with reference to FIGS. 5 to 7 . More specifically, the threading pulse motor 520 rotates by a specific amount in response to the control signal from the CPU 61 . When the threading pulse motor 520 rotates, the threading lever 40 is depressed. When the threading lever 40 is depressed, the threading mechanism portion 29 is moved down from the withdrawn position to the threading operation position. The first threading shaft 27 and the threading hook 31 are rotated by the rotary mechanism 30 and the threading operation is performed. After that, the threading pulse motor 520 is rotated in the reverse direction, thus returns the threading mechanism portion 29 to the withdrawn position. After ending the processing at step S 25 , the CPU 61 ends the threading processing.
Effects of Present Embodiment
When the CPU 61 determines that the cloth thickness detected at step S 15 is larger than the maximum cloth thickness value that corresponds to the type of the accessory device and at which the threading is possible, the CPU 61 prohibits the execution of the threading operation. Thus, it is possible to reliably avoid the threading hook 31 from coming into contact with the presser foot support portion 511 of the upper feed device 104 .
At step S 17 , the LCD 115 displays the error message 261 instructing the user to remove the work cloth. By displaying the error message 261 on the LCD 115 , the user can know that it is necessary to remove the work cloth in order to perform the threading operation.
Modified Examples
Hereinafter, modifications that can be added to the above-described embodiment will be exemplified.
In the present embodiment, the explanation is made in which the specific accessory device is the upper feed device 104 . However, the specific accessory device is not limited to the upper feed device 104 and may be another accessory device or various presser members for which there is a possibility of contact with the threading hook 31 .
In a case where there are a plurality of types of the specific accessory device or the presser member, the following control may be performed. At step S 14 of the threading processing shown in FIG. 9 , the CPU 61 may identify the accessory device or the presser member that is mounted on the presser bar 127 . More specifically, a camera may be provided on the head 114 of the sewing machine 101 . The camera may perform image capture of the accessory device or the presser member. The CPU 61 may identify the type of the accessory device or the presser member by a known pattern matching method using the captured image. The ROM 62 may store the maximum cloth thickness table 622 in which the accessory device or the presser member is associated with the maximum cloth thickness value. At step S 15 , the CPU 61 may read the maximum cloth thickness table 622 and may determine whether or not the cloth thickness is larger than the maximum cloth thickness value that corresponds to the type of the accessory device or presser member identified at step S 14 .
In the present embodiment, in order to perform notification that the threading operation by the threading device 11 is not possible, the CPU 61 displays the error message 261 on the LCD 115 . However, the sewing machine 101 may be provided with a speaker or a buzzer and may output an error sound.
The above-described program may be recorded on a computer-readable storage medium, such as a hard disk, a flexible disk, a CD-ROM, or a DVD, and may be executed by being read from the storage medium by a computer. The program may be a transmission medium that can be distributed via a network such as the Internet.
In the present embodiment, the processing to determine whether or not the accessory device mounted on the presser bar 127 is the specific accessory device, the processing to determine whether or not the detected cloth thickness is larger than the maximum cloth thickness value, the processing to prohibit the execution of the threading operation, and the processing to notify that the execution of the threading operation is not possible are performed by software executed by the CPU 61 , but each of the above processing may be performed by hardware.
The apparatus and methods described above with reference to the various embodiments are merely examples. It goes without saying that they are not confined to the depicted embodiments. While various features have been described in conjunction with the examples outlined above, various alternatives, modifications, variations, and/or improvements of those features and/or examples may be possible. Accordingly, the examples, as set forth above, are intended to be illustrative. Various changes may be made without departing from the broad spirit and scope of the underlying principles.
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A sewing machine includes a needle bar, a presser bar, a threading device, a processor, and a memory. The needle bar is configured such that a sewing needle is attached thereto. The presser bar is configured such that an accessory device is mounted thereon. The threading device is configured to perform a threading operation in which an upper thread is passed through an eye of the sewing needle attached to the needle bar. The memory is configured to store computer-readable instructions. The computer-readable instructions cause the processor to perform processes that include determining whether a mounted device is a specific accessory device and causing the threading device to perform the threading operation in a case where it is determined that the mounted device is the specific accessory device and a specific condition is satisfied. The mounted device is an accessory device mounted on the presser bar.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to syringes which have a variety of uses, a very common one being the use of the syringe to inject a preselected medication into a human. Syringes are used both in a professional setting such as at a hospital, clinic, or offices of doctors or other medical professionals, and also by individual users, e.g., a diabetic requiring frequent injections of insulin, this latter use being typically at the individual user's place of residence.
[0003] 2. Description of the Prior Art
[0004] The safe storage of syringes is extremely important; this is especially the case for a “used” syringe which may, after the needle thereof is removed from the tissue into which it had penetrated, be contaminated with a possible deadly bacteria or virus. For a number of years, partly because of an awareness of the possible transmittal of diseases such as hepatitis and AIDS, various boxes and other containers have been developed and provided for the professional settings safe storage of used syringes. Such containers are sometimes referred to as “sharps-boxes”. A typical sharps-box would be a container securely attached to the wall within the professional setting, with a locked cover or the like, and with an opening permitting sequential insertion of used syringes into the box. From time to time, trained staff empty the used syringes into, hopefully, a safe disposal means for handling medical waste.
[0005] Individual users, on the other hand, have not typically had such “safe” storage arrangements. A more typical arrangement for an individual user would be to insert a used syringe into the mouth of an empty one-gallon plastic jug which, in practice, could hold a significant number of used syringes before it got full or otherwise required disposal. There are obvious risks associated with this type of storage. The user could inadvertently tip over the jug or otherwise cause one or more used syringes to come out of the container and into potential contact with the user and/or other people in that vicinity. Alternately, the user might put the filled or partly filled jug into the trash disposal system, which would create potential risk to others in society.
[0006] The individual user of syringes typically purchases syringes at a retail outlet such as a drug store, or other retailing establishment. Syringes are frequently vended in flat-like packets containing a preselected number of syringes, e.g., ten; sometimes the syringes are vended individually in single or, more typically, in bulk quantities. The user transports the unused syringes to his or her place of residence.
SUMMARY OF THE INVENTION
[0007] The present invention provides a multifunctional box for facilitating (i) the safe transport of the box and a plurality of unused syringes therein to a syringe user, (ii) the safe sequential dispensing of said unused syringes from said box, and (iii) the safe sequential feeding of used syringes into the box for safe storage therein. A typical usage of the invention would be for an individual to purchase the box (filled with unused syringes, either individual or in packets) at a vending establishment, to transport the box to his or her place of residence where the unused syringes would be withdrawn from the box as needed and the used syringes would be sequentially fed or inserted back into the box but, importantly, the used syringes would be hygienically separated from the unused syringes remaining in the box.
[0008] More specifically, the invention provides a multifunctional box comprising a container having an open top, a bottom, and a plurality of sides integral therewith defining a preselected volume for storing a preselected number of unused syringes. The syringes may be individualized or may be in packets containing a preselected number, e.g., ten. The container additionally has an exit opening adjacent to the bottom thereof, the opening being sized to permit sequential withdrawal therethrough of unused syringes.
[0009] The invention further provides a dividing tray having a bottom and a plurality of sides so as to provide a form of subcontainer. The tray is sized to fit in close but unrestricted relationship the sides of the main container. The tray is adapted to be rested upon and supported by either unused syringes positioned below, or by the bottom of the container. That is, the tray is adapted to be supported with the bottom thereof on top of a plurality of unused syringes in the container. Because the tray is not restricted from movement within the container, as unused syringes are withdrawn from the container through the aforesaid exit opening, the tray moves under the influence of gravity vertically downward towards the bottom of the container. The clearance between the sides of the container and the tray are selected to preclude the passage therebetween of a used syringe.
[0010] The invention additionally provides a cover adapted to be attached to and locked to the open top of the container. Additionally, a used syringe feed means or mechanism is positioned within and supported by the cover, and has at least one used syringe receiving means having a first preselected position for receiving a used syringe, and then being moveable, e.g., rotated to a second preselected position for feeding used syringes into the tray for safe storage therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is an isometric view of a first embodiment of my invention showing the top, a side, and an end thereof.
[0012] [0012]FIG. 1A is a partial view of the container shown in FIG. 1, depicting an alternate usage, i.e., having individual unused syringes removed from the exit opening as contrasted with the FIG. 1 depiction of a packet of unused syringes being removed from the exit opening.
[0013] [0013]FIG. 2 is cross-sectional view of the apparatus shown in FIG. 1, as viewed along section lines 2 - 2 thereof and as viewed along section lines 2 - 2 of FIG. 3.
[0014] [0014]FIG. 3 is a cross-sectional view of the apparatus shown in FIG. 1, as viewed along section lines 3 - 3 thereof and as viewed along section lines 3 - 3 of FIG. 2.
[0015] [0015]FIG. 4 is a cross-sectional view of the apparatus shown in FIG. 1, as viewed along section lines 4 - 4 thereof and as viewed along section lines 4 - 4 of FIG. 3.
[0016] [0016]FIG. 5 is a view, partly in section, of a second embodiment of the cover as viewed along section lines 5 - 5 of FIG. 6.
[0017] [0017]FIG. 6 is a cross-sectional view of the apparatus shown in FIG. 5, as viewed along section lines 6 - 6 thereof.
[0018] [0018]FIG. 7 is an isometric view of the used syringe feed means depicted in FIGS. 5 and 6.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring to FIG. 1, a multifunctional box AA comprises in part a container 10 shown in greater detail in FIGS. 2, 3, and 4 . The container 10 has an open top 10 OT, a bottom 10 B, and a plurality of sides 10 ′, 10 ″, 10 ′″, and 10 IV. As shown, the sides 10 ′ and 10 ′″ are of greater width than the sides 10 ″ and 10 IV. The sides of the container are preselected so as to efficiently accommodate a plurality of unused syringes S, such as is depicted in FIG. 1A, or a plurality of packets of unused syringes P, such as is shown in FIG. 1. Thus, sides 10 ′ and 10 ′″ are sufficiently long so as to accommodate the longitudinal length of the syringe S, FIG. 1A showing a plurality of unused syringes S being arranged lying in close side-by-side parallel relationship. Further, the sides 10 ″ and 10 IV are sufficiently wide in the transverse sense so as to permit the storage of a plurality of packets P stacked at the point of manufacture in side-by-side stacked relationship as is shown in FIG. 2. As can be noted in FIGS. 1 and 2, side 10 ″ of container 10 does not quite extend to the bottom 10 B; it terminates at 10 X to thus define an exit opening EO for the selective removal of packets P of syringes or individual unused syringes S by the user of box AA. Packets of syringes are typically sold by retail establishments to individual users, either as individual packets or in a larger container having a plurality of packets. The present invention contemplates that the individual user would purchase the entire container AA prefilled prior to purchase with either packets or individual unused syringes.
[0020] The multifunctional box of the invention includes a cup-like dividing tray 20 , shown clearly in FIGS. 2 and 3, having a bottom 20 B and a plurality of sides 20 ′, 20 ″, 20 ′″ and 20 IV, the bottom and sides being sized to fit in close but unrestricted relationship with the sides of the container 10 . The tray's initial position is shown in FIGS. 2 and 3, up at the top of the container 10 and adapted to be resting upon either a plurality of stacked packets, or a plurality of unused syringes, depending upon which choice is made by the purchaser. As individual packets P or individual syringes S are withdrawn from the exit opening EO, the tray 20 , under the influence of gravity, will move downwardly or towards the bottom 10 B of the container, and also carrying used syringes therewith, as will be explained below. The tray has the potential to descend all the way, to be proximate to the bottom of the container 10 to a position depicted in phantom in FIG. 3, wherein the bottom 20 B of the tray is abutted against abutments 20 S and 20 S′ which are shoulders on the insides of sides 10 IV and 10 ″ of the container.
[0021] The sides 20 ′ and 20 ′″ extend from the bottom 20 B to the top 20 T of the tray 20 as is clearly shown in FIG. 3. The other sides, 20 ″ and 20 IV are provided with semicircular cutouts 20 AA and 20 BB respectively, as is shown in FIGS. 2 and 3. The cutouts 20 AA and 20 BB are provided so as to accommodate the used syringe feed means to be described below.
[0022] The multifunctional box AA further includes a cover 30 adapted to be attached to and locked to the open top 10 OT of the container 10 . More specifically, the cover 30 is shown as an inverted elongated cup having sides 30 ′, 30 ″, 30 ′″ and 30 IV sized to fit over and be attached to the open top 10 OT of the container 10 . The attaching and locking means is shown as an outwardly extending shoulder 10 S at the outer periphery of the top of container 10 , and tapered inwardly toward the top as is shown in FIGS. 2 and 3. A tapered inner surface 30 S on the inside lower periphery of cover 30 is sized to complement the tapered surface 10 S of the container. As indicated, the cover and the container are sized so as to fit snugly together and to be locked in place by a bottom latch 30 S′ which is integral with cover 30 so as to lock the cover to the container.
[0023] The top 30 T of the cover has an opening 30 R for receiving used syringes US, the opening being defined by parallel, spaced apart curved edges 30 T′ and 30 T″ as is clearly shown in FIG. 3, edge 30 T′ being shown in FIG. 2.
[0024] The cover 30 provides a moveable support, e.g., a rotatable support for a used syringe feed means to be described below. At the left end of cover 30 as shown in FIG. 2, such support comprises (i) semicircularly-shaped member 31 having a lip or shoulder 31 ′ and attached to the inside of the cover by vertically extending ribs 32 and 32 ′, and (ii) a curved surface 30 FS′. The support at the right end of cover 30 as shown in FIG. 2 is an almost complete circular shaped surface 30 FS in cover 30 , i.e., a circularly-shaped opening for journaling a cylindrically-shaped end 40 A of used syringe feed means 40 . The other end 40 B of used syringe feed means 40 is supported for rotation by the shoulder or lips 31 ′ of member 31 .
[0025] The used syringe feed means 40 in general is an elongated barrel-shaped or generally-cylindrically-shaped member having two curved outer portions 40 AA and 40 BB as is clearly shown in FIG. 3; the member further having a pair of opposed used syringe receiving pockets 41 and 42 which respectively connect the outer curved sections 40 AA and 40 BB. Referring to FIG. 3, it is seen that pocket 41 is sized so as to receive a used syringe US via the opening 30 R.
[0026] Referring to FIG. 3, the used syringe US shown in phantom within the pocket recess 41 of the feed means 40 may be put within the container for safe storage easily by manual rotation of the barrel 40 in the direction of the arrow R after approximately 180 degrees of rotation of the barrel about its rotational axis, the used syringe then will be free to fail under the influence of gravity into the cup-like top of tray 20 where it will be safely stored and prevented by the invention from ever being available for exit through the exit opening EO. It will be understood that, initially, the tray 20 will be generally positioned near the top of the container 10 , on the assumption that container 10 will be substantially full of either unused individual syringes or packets of syringes. In any event, as unused syringes and packets are removed through the opening EO for use by the user, the tray, as indicated, will begin traveling downwardly under the influence of the weight of the tray per se and used syringes therein toward the bottom 10 B of the container. FIG. 3 shows, in phantom, a plurality of used syringes US within the tray (also shown in phantom) with the tray being at its lowermost or bottommost position, resting on the shoulders 10 S and 10 S′ of the container. It will be noted that when the tray 20 is in this position, it serves as a block between the used syringes and the exit opening EO. Thus, used syringes may not inadvertently or otherwise be removed from the container once they have been inserted into the container via the cover 30 and used syringe feed means 40 .
[0027] As indicated, the clearance between the sides of tray 20 and container 10 prevents any passage therebetween of a syringe. Thus, the invention provides a safe storage of and dispensing of unused syringes; the safe storage is not compromised by used syringes being collected, as aforesaid, in cup-like tray 20 .
[0028] It should be further understood that the feed means 40 does not permit, in normal usage thereof, any used syringe being somehow retransferred from within the container 10 out through the opening 30 R. To completely rule out such an occurrence, the apparatus shown in FIGS. 5, 6, and 7 has been provided, which will now be described in detail.
[0029] A modified barrel 140 has a relatively small diameter central core 140 EE to which are integrally connected two sets of semicircularly-shaped segments, the first set 146 , 147 , and 148 positioned on one side of the rotational axis, and a matching set 146 ′, 147 ′, and 148 ′ positioned on the opposite side of the rotational axis, with the aforesaid sets defining therebetween used syringe receiving recesses 149 and 150 , best shown in FIG. 6. The segments 146 - 148 and 146 ′- 148 ′ are spaced apart by slots YY and XX as is shown in FIGS. 5 and 7. Used syringe feed means 140 further includes at the right end as shown in FIG. 7 a cylindrically-shaped top 140 A′ having, within, a turning means 143 . At the left end, as shown in FIG. 7, is a hub-member 140 B which is adapted to be rotationally supported the lower bearing means 130 XX shown in FIGS. 5 and 6, and at the top by a bearing means 130 X as is shown in FIG. 5. The portion 140 A′ of the used syringe feed means 140 is supported for rotation by an appropriate bore 130 Y provided in the cover 130 .
[0030] A key feature of this modification or embodiment of the invention are a plurality of fingers 160 , 161 , and 160 ′ and 161 ′ which are integral with the cover 130 and which curve downwardly as is shown in FIG. 6, i.e., within the slots or spaces XX and YY of the barrel 140 , the lower extremities of said fingers being in close proximity and/or in touching relationship with the central core 140 EE. The fingers 160 , 161 , 160 ′ and 161 ′ are all springlike, or resilient, so that they may be momentarily deflected sufficiently when the barrel 40 is rotated to permit the transfer of a used syringe from the receiving recess 149 (when the barrel is rotated) to be transferred to and/or deposited in the tray 20 within the container 10 positioned below the cover 130 . Thus, the spring fingers will permit such a transfer from the outside of the cover through the opening 130 R into the tray, as aforesaid, but the fingers will prevent any reverse transfer from within the container to the outside of the cover via opening 130 R.
[0031] Additional features of the apparatus shown in FIGS. 5 - 7 include a pair of barrel side supports 154 and 155 shown in FIG. 6, which help stabilize the barrel. A plurality of ribs 130 M are provided, as is shown in FIG. 5, for providing a certain level of reinforcement or strength to the cover 30 .
[0032] While the preferred embodiment of the invention has been illustrated, it will be understood that variations may be made by those skilled in the art without departing from the inventive concept. Accordingly, the invention is to be limited only by the scope of the following claims.
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A multifunctional box for facilitating the safe transport of the box and a plurality of unused syringes therein. The box further facilitates the safe sequential dispensing of unused syringes from the box, with concurrent facilitation of the safe sequential feeding of used syringes into the box for safe storage therein. The box includes a container having an open top and an exit opening near the bottom sized to permit sequential withdrawal therethrough of either unused syringes and/or packets of syringes. A dividing tray is provided within the container which is used to collect used syringes while simultaneously to provide a blockage between the used syringes and the exit opening. A cover is attached to open top of the container and supports a used syringe feed means which has a first preselected position for receiving a used syringe, which then is moveable to a second preselected position for feeding used syringes into the tray for safe storage.
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BACKGROUND OF THE INVENTION
The present invention is related to the manufacture of mirrors, and more specifically to an apparatus for forming curved mirrors.
Curved mirrors are used in ring laser gyroscopes (RLG's) to create a stable low-loss resonant path. These curved mirrors have been formed by depositing reflective materials on curved substrates. The curved substrates have been formed by traditional grinding, lapping and polishing of a flat substrate.
Furthermore, it is desirable for the mirrors of the ring laser gyros to reflect light at a certain angle after hitting the mirror. However, irregularities and flaws in the substrate surface and/or the mirror coating cause light to reflect in many undesirable angles. The undesirable reflections are referred to as scatter. The scatter decreases the accuracy of ring laser gyros.
Prior to deposition of the mirror on a substrate, the surface to be coated must be super polished. This super polish also serves to minimize scattering of laser light by the mirror. Curved substrates are more difficult to super polish than flat substrates.
SUMMARY OF THE INVENTION
The present invention is an apparatus for holding mirror substrates to produce high quality curved substrates and mirrors by vapor deposition. The apparatus includes a body, substrate holding means, the substrate holding means having an aperture which allows communication between sides of the body and a mask with a support means. The body supports at least one substrate in the substrate holding means. A mask, which may be a sphere, a disk or a cylinder, is supported over the aperture. Thin wires or bands may be used as the supports. Grooves may be cut into the mask to accept the wires or bands and thereby support it at a predetermined gap length from a substrate.
The bands or wires are fastened to the body. They may be spot welded to or supported above the body by feeding them through small holes cross-bored through a series of posts, at least one of which may be rotated axially in order to tighten the wires.
A laser mirror is subsequently deposited on the curved substrate using a substrate holding means in which the aperture is not masked.
The invention will be better understood with reference to the following description and drawings attached hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top-view of a mirror deposition system.
FIG. 2 is a side-view of the system shown in FIG. 1.
FIG. 3 is a bottom-view of a first inventive substrate holder as shown in FIG. 2.
FIG. 4 is a side-view taken along line 2--2 of the substrate holder shown in FIG. 3.
FIG. 5 is a bottom view of a preferred embodiment of the present invention.
FIG. 6 is a slice view taken along line 6--6 of the substrate holder shown in FIG. 5.
FIG. 5a is a bottom-view of a third inventive substrate holder.
FIG. 6a is a slice-view taken along line 6A--6A of the substrate holder shown in FIG. 5a.
FIG. 7 is a side-view of a tightening post 80 shown in FIGS. 5 and 6.
FIG. 8a is a side-view of the substrate holder with the mask between the target material and the substrate.
FIG. 8b is a bottom-view of the substrate holder with the mask between the target material and the substrate.
FIG. 8c is a side-view of the substrate holder with the mask removed.
FIG. 8d is a bottom-view of the substrate holder with the mask removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts a typical mirror deposition system 10. Mirror deposition system 10 includes vacuum chamber 20, ion gun 30, sputtering targets 34, wheel 40 and shaft 44. In operation, vacuum chamber 20, which may be filled with gases of a predetermined mixture, is pumped to a high or ultra-high vacuum. Ion gun 30 generates a beam (in a well-known way) that strikes a selected portion of the sputtering targets 34. The portion of the sputtering targets 34 that is struck may be selected by translating the sputtering targets in a plane generally perpendicular to the beam direction. Atoms and molecules (hereafter called "atoms") are released into the vacuum chamber 20 when a target is struck by the ion beam. The sputtering targets 34 generally include one material having a low index of refraction such as silicon dioxide (SiO 2 ), and one material having a high index of refraction such as titanium dioxide (TiO 2 ).
Referring now to FIG. 2, there shown is a side-view of the system 10 shown in FIG. 1. As now can be seen, substrate holders 46a-46c are located on wheel 40. Wheel 40 can be made to rotate through connection of a motive means (not shown) to shaft 44.
Referring now to FIGS. 3 and 4, there shown are a bottom-view and a side-view of a first inventive substrate holder 46. A substrate 60 is placed in a substrate holding means 62 formed in body 50. Aperture 58 is in communication with one surface of substrate 60 such that when the substrate holder 46 is placed in the mirror deposition system 10, material which has been released from the target has a clear line of sight to the substrate 60. The aperture 58 exposes the substrate 60 to vapor from a distant source. Cylindrical mask 56 is placed in the path between the target and the substrate 60 such that a portion of the target material is intercepted before reaching the substrate surface 60. When the substrate 60 is exposed to a vapor flux from a large vapor source, or a flux from a localized source that (averaged over time) acts like a larger source, the coating beneath the mask 56 develops a curvature. This curvature is a function of the mask diameter, the gap length between the end of the mask 56 and the substrate 60, the angular distribution of the vapor flux impinging the substrate 60, and the coating thickness. The mask 56 is held in place using support posts 52a-52c and support members 54a-54c.
A preferred embodiment of the present invention is shown and described with reference to FIGS. 5 and 6. In FIG. 5, a bottom view of the inventive substrate holder 70 is shown. FIG. 6 is a side slice view of the inventive substrate holder 70. The substrate holder 70 includes body 72, mask 74, wires 76, 77, aperture 78, ring 86 and substrate positioning posts 94. Aperture 78 exposes one side of a substrate (not shown) to material from a vapor source.
Mask 74 is supported at the center of the aperture 78 on crossed wires 76 and 77 which are attached to ring 86. The wires 76 and 77 may be attached by brazing, soldering, clamping or preferably by spot welding. In a preferred embodiment, the masks 74 are stainless steel spheres. Crossed precision slots 88 are formed in the mask 74 by machining, for example wire electrode-discharge-machining. The crossed slots 88 in the mask 74 slide over the crossed wires 76 and 77; gravity holds the mask 74 in position. The substrate 60 is held above the mask 74. The gap length between the substrate 60 and the mask 74 is determined by the mask dimensions, the depth of the slots 88 in the mask 74 and the distance between the wire attachment plane and the substrate.
Spheres with the precision cross slots 88 are suspended a predetermined distance below the substrate surface 60 using fine wire. In a preferred embodiment, 0.004 or 0.006 molybdenum wire is used.
An alternative embodiment of the present invention is shown in FIGS. 5a and 6a. In FIG. 5a, a bottom view of the inventive substrate holder 70' is shown. FIG. 6a is a side slice view of the inventive substrate holder 70'. Substrate holder 70' includes body 72', mask 74a and 74b, wires 76a, b and 77a, b, apertures 78a and 78b, tightening screws 80a-80d and mounting posts 82a-82h. Body 72' includes pockets 84a and 84b for supporting substrate 90a and 90b therein. The substantive difference between this embodiment and the embodiment shown in FIGS. 5 and 6 is that the mask 74a is supported on wires 76a, b and 77a, b which are supported by mounting posts 82a-82h and tightening screws 80a-80d.
Referring now to FIG. 7, there shown is a mounting post 82 as used in FIGS. 5 and 6. Note that it consists of a screw head that has been machined off and a hole 83 has been drilled through the shaft of the screw 82 for supporting the wire.
The high scatter problem is minimized by using spherical masks 56 as seen in FIG. 6, particularly when "an energetic particle deposition" process is used to deposit the curved surface. Spherical masks 56 maximize exposure of the critical surface at the mirror center to energetic particle (e.g., ion) bombardment. This bombardment increases the mobility of "adatoms" (atoms condensed from a vapor stream or from a background gas) which is essential for growing smooth, dense, low scatter films at relatively low temperature.
Scatter is also partly a function of the material used to deposit the curved surface. Multilayer dielectric mirrors deposited on curved bases consisting of pure deposited SiO 2 , or of multilayers of SiO 2 and TiO 2 /5 wt. % SiO 2 , or of SiO 2 and ZrO 2 /10 wt. % SiO 2 , exhibit very high scatter at the mirror center. On the other hand, mirrors deposited on curves deposited using straight TiO 2 /5 wt. % SiO 2 , or straight ZrO 2 /10 wt. % SiO 2 , exhibit quite low scatter. Zirconium/silica composite is preferred over titania/silica because it can be baked to approximately 500° C. without recrystallizing. Another zirconia to silica ratio, or another glassy material may further reduce scatter.
A further benefit to the present apparatus is that deposited curved mirrors can be fabricated in a single pump down. This was done by rotating or translating the masking elements 56 with respect to the substrates 60 after forming a surface of a desired curvature. FIGS. 8a and 8b show the substrate holder 46 for depositing the curve on the substrate 60 through the mask 56. The wires 76 and 77 that support the mask 56 are mounted on a separate plate 92 that seats in a pocket of the moveable plate 90. After the curve is deposited onto the substrate 60, the mask 56 is removed by translating or rotating it out of the way as seen in FIGS. 8c and 8d. With the mask 56 out of the way, the mirror (not shown) is deposited onto the curved substrate 60.
For 1.2-meter (nominal) curves, the best results were obtained using a 13.55-cm (3/16-inch) spherical mask 56 with a gap of approximately 0.127-cm between the mask 56 and the substrate 60. Scatter increases for shorter gaps and decreases for longer gaps. However, using a longer gap requires more deposition time to produce a given curvature. For a 13.55-cm (3/16 inch) spherical mask 56 spaced 0.127-cm from the substrate 60, the radius of curvature, in meters, is given by R=N/t, where N is a proportionality constant and t is the film thickness, in microns, that would have been deposited in the absence of the mask 56.
The foregoing has been a description of a novel and non-obvious method and apparatus for making curved laser mirrors. The Applicant has provided the foregoing description by way of example not limitation. The Applicant defines this invention through the claims appended hereto.
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A substrate holder and mask system for depositing curved films and mirrors on flat mirror substrates. A spherical mask is held in close proximity to a substrate by a support structure to intercept a fraction of vapor from a distant source. The film deposited on the substrate behind the mask has a spherically symmetric curvature when the source has a large area. The cross section of the mask support structure is made as small as possible to minimize irregularities in the spherical figure. A mirror is subsequently deposited on said curved substrate after removing said mask.
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FIELD OF THE INVENTION
The present invention relates to the field of technical development of cosmetics, and more particularly to a plant composition having moisturizing, anti-wrinkle, and anti-allergic efficacies, and a preparation method thereof.
BACKGROUND OF THE INVENTION
Modern people suffer from skin itching, wrinkling, allergy, and other dry skin related problems. The skin has an adequate moisture content, which lays the basis for skin barrier, absorption, metabolism, and other physiological functions. Adequate hydration is favorable to enzymatic reaction, and can facilitate the maturization of the stratum corneum and allow the stratum corneum to remain elastic. Adequate hydration is also favorable to the expansion, and reduction in structural compactness, of the cells in the stratum corneum, such that the permeability is increased. Regular reflection from a stratum corneum layer with a high moisture content gives rise to a bright glow. In contrast, the light is non specularly reflected from a dry and squamous stratum corneum layer, such that the skin looks dim. Therefore for a majority of women, the skin protection is currently focused on moisturizing of the skin, and thus the moisturizing efficacy has become a critical aspect of the skin care products.
The moisture retention ability of the skin mainly depends on the stratum corneum, since the stratum corneum functions as a barrier against water loss. The stratum corneum comprises water soluble moisturizing substances such as amino acids or salts thereof, carbohydrates, and so on (referred to as natural moisturizing factors, NMFs), and oil ingredients such as cellular lipids and sebum (those present in epidermis are referred to as epidermal sebum), in which the natural moisturizing factors account for 30% and the oil ingredients account for 11%. The oil ingredients are in association with, or encircle the natural moisturizing factors, to prevent them from outflow, thus playing a role in controlling the moisture volatilization. In addition, several aquaporins exist in the skin, which affect the transport of water in the skin. Aquaporin 3 (AQP3) is the mostly expressed aquaporin in the skin, which is rather abundant in human epidermal keratinocytes and stratum corneum as detected by RT-PCR. AQP3 is of great importance for water retention in keratinocytes. It is found through observations on the phenotype of AQP3 gene knockout nude mice that the mice are substantially normally developed, except that the moisture content in the epidermal keratinocytes in the AQP3 gene knockout nude mice is considerably reduced, and the water loss is obviously higher than that in normal mice, when exposed to dry conditions.
“Healthy and natural” is the development philosophy of the cosmetic industry. China is long in history of manufacturing and using natural plant cosmetics and rich in practical experiences, and has a technical superiority. Moreover, China has vast territory and rich natural resources, where various distinctive plants are grown due to its unique geographical environment and climatic conditions. Because of their different characteristics, these plants have long been used in cosmetology, and have the effect of nourishing the skin and protecting the skin against the adverse effects from external harmful agents.
In view of this, a cosmetic additive is developed from natural plants in this patent, which is mainly characterized by moisturizing efficacy and also by anti-aging and anti-allergic efficacies. The extracts from many plants are combined, which synergize by means of film forming, water retention, maintenance of normal physiological functions of aquaporins, and others to exert comprehensive moisturizing, anti-wrinkle, and anti-allergic effects.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide a plant composition having moisturizing, anti-wrinkle, and anti-allergic efficacies, and a preparation method thereof.
The traditional Chinese medicine composition provided in the present invention has, as active ingredient, an aqueous extract from the raw material mixture of:
Dendrobium nobile, Viola tricolor, Ophiopogon japonicus, Tremella fuciformis , and an oat material;
where the oat material is oat grains, oat flour, or oat bran.
In the composition, the oat grains may have or have no bran.
The oat flour is a whole oat flour or a refined oat flour, where the whole oat flour is obtained by pulverizing the whole oat grains and sieving through a screen of 100 meshes.
The Dendrobium nobile, Viola tricolor, Ophiopogon japonicus, Tremella fuciformis , and oat material have a weight ratio of 5-15:2-10:2-10:1-5:1-5, and specifically 12:6:3:2:2, 5:8:2:1:1, 12:3:6:5:4, 5-12:3-8:1-5:1-4, or 12:3-6:2-5:2-4.
For the aqueous extract, the weight ratio of water to Dendrobium nobile used in the water extraction step is 160-220:5-15, and specifically 160:12, 220:5, 200:12, 160-200:12, 200-220:5-12, or 160-220:5-12.
The aqueous extract is prepared through a process comprising:
uniformly mixing the Dendrobium nobile, Viola tricolor, Ophiopogn japonicus, Tremella fuciformis , oat material and water in proportion and extracting.
In the extraction step, the temperature is 60-100° C., and specifically 65, 80, 100, 65-100, 80-100, or 65-80° C.; and the time is 1-4 hrs, and specifically 2 hrs.
The method for preparing the composition provided in the present invention comprises:
uniformly mixing the Dendrobium nobile, Viola tricolor, Ophiopogon japonicus, Tremella fuciformis , oat material, and water at a ratio as defined in claim 2 or 3 , and extracting, to obtain an aqueous extract.
In the extraction step of the method, the temperature is 60-100° C., and specifically 80° C.; and the time is 1-4 hrs, and specifically 1, 2, 4, 1-2, or 2-4 hrs.
The method further comprises:
after the extraction step, standing and then filtering the resultant aqueous extract, and collecting the filtrate.
In the standing step, the temperature is room temperature and the time is 1-4 hrs, and specifically 1, 2, or 4 hrs.
In the filtering step, the filter has a hole number of 100-200 meshes.
Additionally, use of the composition according to the present invention in the preparation of products having any one of the functions below is also contemplated in the protection scope of the present invention:
1) moisturizing;
2) anti-aging;
3) anti-allergy; and
4) anti-chapping.
In the present invention, the Dendrobium nobile, Viola tricolor, Ophiopogon japonicus , oat material, and Tremella fuciformis are combined and extracted for external use, with which moisturizing and also delaying skin aging, anti-allergic and anti-chapping efficacies are achieved by means of water retention, maintenance of normal physiological functions of aquaporins, and others.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot showing changes in percent water content on skin's surface vs time.
FIG. 2 is a plot showing changes in water loss on skin's surface vs time.
FIG. 3 shows clearance of DPPH by the composition.
FIG. 4 shows inhibition of the composition on hyaluronidase.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention is further elucidated with reference to specific examples. However, the present invention is not limited thereto. The methods are all conventional methods, unless it is otherwise stated. The raw materials are all publicly commercially available unless it is otherwise stated.
Example 1
A traditional Chinese medicine composition was prepared following the steps below.
1) Dendrobium nobile, Ophiopogon japonicus , and Tremella fuciformis were chopped, and Viola tricolor and oat bran were pulverized. Then, the Dendrobium nobile, Ophiopogon japonicus, Tremella fuciformis, Viola tricolor , oat bran, and water were uniformly mixed at a weight ratio of Dendrobium nobile:Viola tricolor:Ophiopogon japonicus:Tremella fuciformis :oat bran:water=12:6:3:2:2:160, transferred to an electric-heated thermostatic water bath, and extracted at 80° C. for 2 hrs. The solution obtained after extraction was removed from the thermostatic water bath, allowed to stand at room temperature and cool for 2 hrs to normal temperature, and then roughly filtered with gauze of 200 meshes. A filtrate was obtained after the dregs were filtered off. Two layers of filter paper were laid in a Buchner filter, and a layer of diatomaceous earth that was about 0.5 cm thick was sandwiched between the filter paper. The filtrate obtained after rough filtration was suction filtered under vacuum, and the filtrate was collected, to obtain a traditional Chinese medicine composition A of the present invention.
Example 2
A traditional Chinese medicine composition was prepared following the steps below.
1) Dendrobium nobile, Ophiopogon japonicus , and Tremella fuciformis were chopped, and Viola tricolor and oat bran were pulverized. Then, the Dendrobium nobile, Ophiopogon japonicus, Tremella fuciformis, Viola tricolor , oat bran, and water were uniformly mixed at a weight ratio of Dendrobium nobile:Viola tricolor:Ophiopogon japonicus:Tremella fuciformis :oat bran:water=5:8:2:1:1:220, transferred to an electric-heated thermostatic water bath, and extracted at 100° C. for 4 hrs. The solution obtained after extraction was removed from the thermostatic water bath, allowed to stand at room temperature and cool for 4 hrs to normal temperature, and then roughly filtered with gauze of 100 meshes. A filtrate was obtained after the dregs were filtered off. Two layers of filter paper were laid in a Buchner filter, and a layer of diatomaceous earth that was about 0.5 cm thick was sandwiched between the filter paper. The filtrate obtained after rough filtration was suction filtered under vacuum, and the filtrate was collected, to obtain a traditional Chinese medicine composition B of the present invention.
Example 3
A traditional Chinese medicine composition was prepared following the steps below.
1) Dendrobium nobile, Ophiopogon japonicus , and Tremella fuciformis were chopped, and Viola tricolor and oat bran were pulverized. Then, the Dendrobium nobile, Ophiopogon japonicus, Tremella fuciformis, Viola tricolor , oat bran, and water were uniformly mixed at a weight ratio of Dendrobium nobile:Viola tricolor:Ophiopogon japonicus:Tremella fuciformis :oat bran:water=12:3:6:5:4:200, transferred to an electric-heated thermostatic water bath, and extracted at 65° C. for 1 hr. The solution obtained after extraction was removed from the thermostatic water bath, allowed to stand at room temperature and cool for 1 hr to normal temperature, and then roughly filtered with gauze of 200 meshes. A filtrate was obtained after the dregs were filtered off. Two layers of filter paper were laid in a Buchner filter, and a layer of diatomaceous earth that was about 0.5 cm thick was sandwiched between the filter paper. The filtrate obtained after rough filtration was suction filtered under vacuum, and the filtrate was collected, to obtain a traditional Chinese medicine composition C of the present invention.
Example 4. Evaluation of the Moisturizing Effect of the Traditional Chinese Medicine Compositions A, B, and C Obtained in Examples 1, 2, and 3
1. Moisturizing Effect—Test of Hydration Rate in Stratum Corneum/Water Loss in Stratum Corneum of Human Skin
The test sample was a cream, which was formulated following a process below.
Any one of the traditional Chinese medicine compositions obtained in Examples 1-3 was added to a phase B of a blank cream base, to obtain a cream, in which the content of the traditional Chinese medicine composition in the cream was 5% by weight.
The traditional Chinese medicine composition A obtained in Example 1 corresponded to the Cream 1, the traditional Chinese medicine composition B obtained in Example 2 corresponded to the Cream 2, and the traditional Chinese medicine composition C obtained in Example 3 corresponded to the Cream 3.
Additionally, the blank cream base was used as a blank control.
The blank cream base was prepared as follows.
According to the formulation in Table 1, the raw materials in the phase A were uniformly mixed and heated to 82° C.; the raw materials in the phase B were uniformly mixed and heated to 82° C.; and the phase A was slowly added to the phase B while the phase B was homogenized at 2000 r/min, and then homogenized for 5 min. After homogenization, the system was stirred and cooled, and the phase C was added when the temperature reached to 40° C., and stirred until uniform, to obtain the blank cream base.
TABLE 1
Formulation of the blank cream base
Phase
Raw material
INCI name
Amount (wt %)
Supplier
A
EC.FIX.SE
Sucrose
2.00
Nuoxin Fine Chemical
stearate/cetearyl
Research Institute
glucoside/cetyl alcohol
Alcohol mixture
Cetostearyl alcohol
1.50
Cognis Chemicals Co.,
Ltd
Monoglyceride
Glyceryl stearate
1.00
Danisk (China) Co.,
Ltd
White oil
Paraffinum liquidum
1.00
Connell Bros.
(Shanghai) Co., Ltd.
IPM
Isopropyl myristate
3.00
Croda International
Public Limited
Company, UK
DM100
Dimethicone
3.00
Wacker Chemical Bros.
(Shanghai) Co., Ltd.
B
Water
To l00
Glycerol
Glycerol
4.00
P & G Chemicals
Butanediol
Butanediol
3.00
Oxea Corporation, US
Xanthan gum
Xanthan gum
0.10
CP Kelco Us, Inc.
EDTA-2Na
Disodium EDTA
0.03
AkzoNobel
C
MTI
Methyl
0.15
Thor Corporation, UK
isothiazolinone/Iodopropynyl
butylcarbamate
Before test, 30 healthy subjects (male:female 15:15) of 20-30 years old were enrolled who have received professional training, and had no history of skin or systemic diseases. There was no abnormality in the test sites, and no agents or cosmetics irrelevant to the experiment were applied during test.
The test location was set at room temperature (25±1)° C., and set to have a relative humidity of (40±5)%. The subjects were maintained in homeostasis before test. The test began after the subjects had their two arms cleaned with water at about 35° C., and then sit quietly for 30 min in the test environment.
A test area (4 cm×4 cm) was marked at an inner flank of the arm of the test subjects that was 5 cm to the basal portion of the hand, and multiple areas (at an interval of 1 cm) may be marked at the same arm. The test samples were distributed at random. A blank value was measured from each test area initially. Then, the test sample was singly applied at a dosage of (2.0±0.1) mg/cm 2 . The water hydration rate and the water loss in the skin of the test and blank control areas were measured by using a multi-functional skin water content tester and a transepidermal water loss tester at 0.5 hr, 1 hr, 2 hrs and 4 hrs after application respectively.
During test, 5 measurements obtained from an area of the subject that was applied with the same sample were averaged, and analyzed by t-test using SPSS.
Experimental Results
(1) Change in Skin Water Content
The change in water content reflects the change rule of water content in the experimental area over time during the test period. The higher the value is, the higher the water content is. Or otherwise, the lower the value is, the lower the water content is.
Hydration rate=(Water content of the sample group−Initial water content)/Initial water content
The result is as shown in FIG. 1 .
The result shows that the traditional Chinese medicine compositions obtained in the examples all have good anti-drying moisturizing effect, with the anti-drying moisturizing effect of the traditional Chinese medicine composition A obtained Example 1 being the highest.
(2) Change in Transepidermal Water Loss
Transepidermal water loss (TEWL) reflects the change rule of water loss in the experimental area over time during the test period, by which the water holding capacity of the test sample may be characterized. The lower the value is, the smaller the water loss is, and the higher the water holding capacity is. Or otherwise, the higher the value is, the lower the water holding capacity is.
Water loss (%)=(Water loss of the sample group−Initial water loss)/Initial water loss×100
The water loss result is as shown in FIG. 2 .
The result shows that within 4 hrs, the traditional Chinese medicine compositions obtained in the examples all have water holding capacity, and the traditional Chinese medicine composition A has the lowest water loss and thus the most prominent water holding capacity.
In summary, the traditional Chinese medicine composition provided in the present invention allows the skin water content to increase and the water loss to decrease, thus having a good water holding capacity and an obvious moisturizing effect on the skin.
Example 5. Effect of the Traditional Chinese Medicine Compositions a, B, and C Obtained in Examples 1, 2, and 3 on the mRNA Expression Level of AQP3
Aquaporins (AQPs) are a class of membrane transporter proteins correlating with the transmembrane transport of water, glycerol and some small molecular substances. AQP3 is expressed in various tissues and organs including skin. The normal epidermal KC expresses AQP3 only in the basal cell layer. The AQP3 provides a channel for the membrane of the epithelial cells, to maintain the intracellular osmotic pressure and cell volume, and plays a role in the transport of water. The glycerol transport function of AQP3 plays a critical role in hydration, elasticity maintenance and repair post damage of the skin. The composition in this invention can repair the skin barrier and improve the water content in the stratum corneum by means of moisturizing and also potential regulation of the AQP3 level. After the traditional Chinese medicine compositions A, B, and C as solutions were applied to C3H mice, the mRNA expression level of AQP3 in the skin of the mice was detected by real-time quantitative PCR, in which saline was used as a control.
Experimental Method:
(1) Grouping: 20 test mice were assigned to a Sample Group A with the composition of Example 1, a Sample Group B with the composition of Example 2, a Sample Group C with the composition of Example 3, and a negative control group, each group having 5 animals.
Sample group: The traditional Chinese medicine composition obtained in any one of Examples 1-3 was uniformly mixed with deionized water at a weight ratio of 5:95, to obtain a solution of the traditional Chinese medicine composition in water, which was applied onto the experimental mice once a day.
Control group: The animals in this group were applied with saline once a day, that is, the skin was kept in normal physiological state.
(2) The mice were removed of the hair from the upper abdomen by using a depilatory cream, applied with the compositions respectively in accordance with their groups once a day, and housed in a box after absorption. The mice were sacrificed after 30 days, and the skin was removed.
(3) The epidermis was isolated from the skin by using a dispase, and dissociated into individual keratinocytes by using a pancreatin. The RNA in the keratinocytes was extracted with Trizol, reversely transcribed into cDNA, and then detected by real-time quantitative PCR (SYBR GREEN) (QIAGEN 204143). The PCR primer sequence and conditions were as follows: aqp3 sense: 5′-TTGGTGGCTGGCCAAGTGTC-3′ (SEQ ID NO. 1); aqp3 antisense: 5′-GTCTGTGCCAGTGCATAGAT-3′ (SEQ ID NO. 2); B-actin sense: 5′-TGTATGCCTCTGGTCGTACC-3′ (SEQ ID NO. 3); B-actin antisense: 5′-CAGGTCCAGACGCAGGATG-3′ (SEQ ID NO. 4).
35 cycles of 94° C. for 2 min; 94° C. for 40 s; 62° C. for 30 s; and 72° C. for 20 s.
(4) Statistical analysis method: The results were analyzed by One-way ANOVA and t test.
The mRNA expression levels of AQP3 following processing with different methods are shown in Table 2.
TABLE 2
Effect of different amounts of compositions as solution
on AQP3 expression level in mouse skin
Group
AQP3/B-actin
Sample Group A with the composition of Example 1
(5.004 ±
0.015)E−03*
Sample Group B with the composition of Example 2
(4.08 ± 0.05)E−03
Sample Group C with the composition of Example 3
(4.31 ± 0.17)E−03
Negative control group
(3.89 ± 0.26)E−03
*denotes P < 0.05, compared with the blank control
The experimental results show that the traditional Chinese medicine composition up-regulates the mRNA expression level of AQP3 in normal mouse skin, and enhances the skin hydration by promoting the transport of water or glycerol in the stratum corneum. The production of water-binding molecules (e.g. hyaluronic acid) in the skin is increased, and thus the skin dryness and peeling phenomena are alleviated.
Example 6. Evaluation of the Anti-Aging Effect of the Traditional Chinese Medicine Compositions A, B, and C Obtained in Examples 1, 2, and 3
Modern researches suggest that skin photoaging may be caused by sunlight irradiation. UV (in the sunlight) irradiation can cause oxidative stress and production of excessive free radicals in the skin, thus leading to cell damage. Meanwhile, IR irradiation can cause the high expression of matrix metalloproteinase-1 (MMP-1) in dermal cells of the skin, whereby the degradation of elastin and collagen in the dermis is accelerated, thus leading to lost elasticity and deepened wrinkle of the skin. The traditional Chinese medicine composition provided in this patent has the free radical-scavenging and MMP-1 inhibiting efficacies, and can slow down the skin photoaging caused by UV and IR irradiation.
1) Free Radical-Scavenging Efficacy
DPPH, chemical name 1,1-diphenyl-2-picryl-hydrazyl, is a stable organic free radical. The free radical-scavenging efficacy of the traditional Chinese medicine compositions A, B, and C obtained in Examples 1, 2, and 3 was quantitatively analyzed by spectrophotometry.
The traditional Chinese medicine composition obtained in any one of Examples 1-3 was uniformly mixed with deionized water at a weight ratio of 5:95, to obtain a solution of the traditional Chinese medicine composition in water.
The solution of the traditional Chinese medicine composition in water was used in test.
The traditional Chinese medicine composition A obtained in Example 1 corresponded to a Sample 1;
The traditional Chinese medicine composition B obtained in Example 2 corresponded to a Sample 2; and
The traditional Chinese medicine composition C obtained in Example 3 corresponded to a Sample 3.
An aqueous solution of a vitamin C derivative was used as a positive control in the test in place of the traditional Chinese medicine composition.
The determination results are shown in FIG. 3 .
The experimental results show that when present in an aqueous solution in a content of 5.0% by weight, the traditional Chinese medicine compositions obtained in the examples all have DPPH scavenging ability and can reduce the effective concentration of hydroxyl radicals, alkyl radicals or oxygen radicals and disrupt the lipid peroxidation, thus having a good effect on delaying the skin photoaging.
2) Inhibition on Matrix Metalloproteinase-1
The effect of the traditional Chinese medicine compositions on MMP-1 activity was detected by fluorogenic substrate assay. The experimental method was as described in Establishment and application of two in Vitro screening methods for cosmetic additives with anti - aging effect (Lai Jixiang, 2007).
The traditional Chinese medicine composition obtained in any one of Examples 1-3 was uniformly mixed with deionized water at a weight ratio of 5:95, to obtain a solution of the traditional Chinese medicine composition in water.
The above aqueous solutions were assayed. The results are shown in Table 3.
TABLE 3
Inhibition of the composition on MMP-1
No.
Name
Inhibition (%)
1
Composition A obtained in Example 1
81.63
2
Composition B obtained in Example 2
47.64
3
Composition C obtained in Example 3
60.98
The results show that the compositions obtained in the examples all have inhibition on MMP-1 produced due to induction with IR irradiation, and can reduce the over-degradation of elastin and collagen caused by sunlight irradiation, thereby keeping the skin elastic and alleviating the skin photoaging.
Example 7. Evaluation of the Anti-Allergic Effect of the Traditional Chinese Medicine Compositions A, B, and C Obtained in Examples 1, 2, and 3
Hyaluronic acid is an ingredient present in tissue matrices that limits the dispersion of water and other extracellular materials. After hydrolysis catalyzed by hyaluronidase, the cells become non-viscous therebetween, cell degranulation occurs and the newly synthesized media are leaked, such that a biological effect is exerted, and fast onset of allergic reaction is caused. Therefore, the remission and amelioration of type I hypersensitivity by a sample is generally indicated by the inhibition of the sample on hyaluronidase.
The inhibition of the traditional Chinese medicine compositions A, B, and C obtained in Examples 1, 2, and 3 on hyaluronidase was determined following a process below.
The traditional Chinese medicine composition A obtained in Example 1 was uniformly mixed with deionized water at a weight ratio of 5:95, to obtain a sample solution C1.
The traditional Chinese medicine composition B obtained in Example 2 was uniformly mixed with deionized water at a weight ratio of 5:95, to obtain a sample solution C2.
The traditional Chinese medicine composition C obtained in Example 3 was uniformly mixed with deionized water at a weight ratio of 5:95, to obtain a sample solution C3.
The test was triplicated.
Each replication was set as follows.
7 test tubes were designated as A, B, C1-C3, D, and E.
The reagents were added in sequence as shown in respective columns in Table 4, and amenable to operations in corresponding steps.
The tube A was added with a control solution and corresponded to the column A in Table 4.
The tube B was added with a blank control solution and corresponded to the column B in Table 4.
The tube D was added with a sample blank solution and corresponded to the column D in Table 4.
The tube E was added with a positive control solution and corresponded to the column E in Table 4.
The tubes C1-C3 were all added with reagents in sequence as shown in column C in Table 4.
The sample solution added to the tube C1 was the sample solution C1.
The sample solution added to the tube C2 was the sample solution C2.
The sample solution added to the tube C3 was the sample solution C3.
The absorbance, that is, ABS value, of respective tubes at 555 nm was measured, and then the inhibition of the sample solution on hyaluronidase was calculated according to a formula below for calculating the anti-allergic activity:
Inhibition of the sample on hyaluronidase=[(A-B)−(C-D)]/(A-B)×100%
Inhibition of the positive control on hyaluronidase=[(A-B)−(E-D)]/(A-B)×100%
In the two formulas, A is the ABS value of the tube A;
B is the ABS value of the tube B;
C is the ABS value of the tube C;
D is the ABS value of the tube D; and
E is the ABS value of the tube E.
The ABS value of the tube C was determined as follows.
1) 0.1 mL of a 0.25 mmol/L CaCl 2 solution and 0.5 mL of a hyaluronidase solution were incubated for 20 min in a water bath at 37° C.
2) 0.5 mL of the treated sample solution was added, and continuously incubated for 20 min in a water bath at 37° C.
3) 0.5 mL of an aqueous sodium hyaluronate solution was added, incubated for 20 min in a water bath at 37° C., and then stood at normal temperature for 5 min.
4) 0.1 mL of 0.4 mol/L aqueous NaOH solution and 0.5 mL acetylacetone were then added, heated for 15 min in a boiling water bath, and then cooled for 5 min immediately with ice water.
5) 1.0 mL Ehrlich reagent was added, diluted with 3.0 mL absolute ethanol, and developed by standing at normal temperature for 20 min. The absorbance was determined by using a spectrophotometer, to obtain the ABS value of the tube C containing the sample solution.
The experimental steps of Groups A to E are also shown in Table 4.
TABLE 4
Operations in experiment for testing inhibition on hyaluronidase
Experimental steps
Reagent
Group A
Group B
C
Group D
Group E
1) 20 min in a
0.1 ml CaCl 2
+
+
+
+
+
water bath at 37° C.
solution
0.5 ml
+
−
+
−
+
hyaluronidase
solution
2) 20 min in a
0.5 ml sample
−
−
+
+
−
water bath at 37° C.
solution
3) 30 min in a
0.5 ml sodium
+
+
+
+
+
water bath at 37° C.
hyaluronate
stand at normal
solution
temperature for 5 min
4) heated in boiling
0.1 ml NaOH
+
+
+
+
+
water for 15 min,
solution
and then cooled
0.5 ml
+
+
+
+
+
with ice water for 5
acetylacetone
min
5) stand at normal
1.0 ml Ehrlich
+
+
+
+
+
temperature for 20
reagent
min
3.0 ml absolute
+
+
+
+
+
ethanol
measured at absorption maximum wavelength
Note:
“+” denotes that this item is added, and “−” denotes that this item is not added, but replaced by equal volume of acetate buffer solution. “*” denotes that this item is replaced by equal volume of 5% by weight of aqueous dipotassium glycyrrhizinate solution.
The result is as shown in FIG. 4 .
The inhibition of the composition A obtained in Example 1 on hyaluronidase is 75.32%.
The inhibition of the composition B obtained in Example 2 on hyaluronidase is 59.89%.
The inhibition of the composition C obtained in Example 3 on hyaluronidase is 67.26%.
The inhibition of the tube E, that is, the positive control, on hyaluronidase is 92.12%.
The experimental results show that the compositions obtained in the examples all have in-vitro hyaluronidase inhibiting efficacies, and can inhibit the release of allergic mediators, thus having a good anti-allergic effect.
Example 8. Evaluation of the Anti-Chapping Effect of the Traditional Chinese Medicine Compositions A, B, and C Obtained in Examples 1, 2, and 3
3% of the traditional Chinese medicine composition A was added to a phase B of a blank cream base formulation as shown in Table 5, and uniformly mixed, to obtain a cream containing the composition of Example 1.
A cream containing the composition of Example 2 and a cream containing the composition of Example 3 were obtained following a process the same as above, except that the traditional Chinese medicine composition A was replaced by the traditional Chinese medicine composition B obtained in Example 2 or the traditional Chinese medicine composition C obtained in Example 3.
The above three creams were used in human foot skin application test for a period of 1 month (in winter). 120 subjects were enrolled, and assigned to 4 groups at random, that is, a Group A, a Group B, a group C, and a blank control group (blank cream base), each group having 30 subjects.
The group A was applied with the cream containing the composition of Example 1.
The group B was applied with the cream containing the composition of Example 2.
The group C was applied with the cream containing the composition of Example 3.
The blank cream base was prepared as follows.
According to the formulation in Table 5, the raw materials in the phase A were uniformly mixed and heated to 82° C.; the raw materials in the phase B were uniformly mixed and heated to 82° C.; and the phase A was slowly added to the phase B while the phase B was homogenized at 2000 r/min, and then homogenized for 5 min. After homogenization, the system was stirred and cooled, and the phase C was added when the temperature reached to 40° C., and stirred until uniform, to obtain the blank cream base.
TABLE 5
Formulation of blank cream base
Phase
Raw material
INCI name
Amount (wt %)
Supplier
A
EC.FIX.SE
Sucrose stearate/cetearyl
2.00
Nuoxin Fine
glucoside/cetyl alcohol
Chemical
Research Institute
Alcohol mixture
Cetostearyl alcohol
1.50
Cognis
Monoglyceride
Glyceryl stearate
1.00
Danisk
White oil
Paraffinum liquidum
1.00
Connell
IPM
Isopropyl myristate
3.00
Croda
DM100
Dimethicone
3.00
Wacker Chemical
B
Water
To l00
Glycerol
Glycerol
4.00
P & G Chemicals
Butanediol
Butanediol
3.00
OXEA
Xanthan gum
Xanthan gum
0.10
CP Kelco
EDTA-2Na
Disodium EDTA
0.03
Akzo
C
MTI
Methyl
0.15
Thor Corporation,
isothiazolinone/Iodopropynyl
UK
butylcarbamate
After application, the users reflect that the product has both a nourishing effect, and a good healing and repair effect on the chapped would on the skin. The test results are shown in Table 6.
TABLE 6
Evaluation of the anti-chapping effect of the traditional
Chinese medicine composition when applied to human
Roughness
improvement
Wettedness
Softness
Obvious
Ordinary
No
Obvious
Ordinary
No
Obvious
Ordinary
No
Composition A obtained
21
7
2
23
7
0
22
7
1
in Example 1
Composition B obtained
15
12
3
25
5
0
18
10
2
in Example 2
Composition C obtained
17
11
2
25
5
0
20
10
0
in Example 3
Blank control
11
15
4
20
9
1
17
7
6
The investigation results confirm that the traditional Chinese medicine composition has the following characteristics.
1. The active ingredients of the traditional Chinese herbal medicine contained in the product can enhance the self protection ability of the skin, and stimulate the growth of the granulation tissue.
2. A protective film may be locally formed, to shorten the clotting time and reduce bleeding, which is conducive to wound healing.
3. The moisture in the skin may be effectively protected against loss without the greasy feeling of glycerol containing skin care products, such that the people feel soft and comfortable after use.
The active ingredients of the traditional Chinese herbal medicine contained in the product can enhance the self protection ability of the skin, and locally form a protective film to reduce bleeding, which is conducive to wound healing, and the user satisfaction is high.
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Provided is a moisturizing, anti-wrinkle, and anti-allergic traditional Chinese medicine composition and a preparation method thereof. The traditional Chinese medicine composition has an aqueous extract of Dendrobium nobile, Viola tricolor, Ophiopogon japonicus, Tremella fuciformis , and an oat material as active ingredient. The oat material is oat grains, oat flour, or oat bran. In the composition, the Dendrobium nobile, Viola tricolor, Ophiopogon japonicus, Tremella fuciformis and oat material have a weight ratio of 5-15:2-10:2-10:1-5:1-5, and preferably 12:6:3:2:2. The Dendrobium nobile, Viola tricolor, Ophiopogon japonicus , oat material, and Tremella fuciformis are combined and extracted for external use, with which moisturizing and also delaying skin aging, anti-allergic and anti-chapping efficacies are achieved by means of water retention, maintenance of normal physiological functions of aquaporins, and others.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0001] N/A
RELATED APPLICATIONS
[0002] N/A
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates generally to board games and more specifically it relates to a competitive board game which exhibits some problematic areas to which humans are exposed and creates awareness of the social class hierarchy.
[0005] 2. Discussion of the Background
[0006] Various board games have been designed to educate the players by using human experiences and situations such as immigration, financial situations and politics.
[0007] An example is U.S. Pat. No. 6,634,642 to which discloses a board game that deals with the struggle an immigrant has to go through in order to live and seek the American dream. The game shows in a fun way the risks, choices and options an immigrant has to affront when he/she immigrates to the United States. It presents different legal classes such as illegal, tourist, parole, political refugee, resident and professional visa.
[0008] Another board game with educational purposes which deals with human experiences such as financial problems and child education corresponds to U.S. Pat. No. 6,106,300 issued to Kiyosaki. The patent teaches fundamental aspects of personal finance, investing and accounting to children.
[0009] There has always been a SOCIAL CLASS hierarchy in the United States. It is an open secret that few have cared to acknowledge. It is also a known fact that the priorities of the very Rich are not the same as those of the Poor.
[0010] Most people in the U.S. usually place themselves in the “Comfortable MIDDLE CLASS”, working for a living, with money problems, but “living well”.
[0011] All the mentioned board games may be suitable for particular purposes such as immigration, money and financial concepts. However the present invention is not limited by money and financial concepts because it shows how social classes interact by making alliances and fulfilling their own obligations in order to survive. Each social class has to deal with different problems in the path of life wherein the concerns and responsibilities of a particular class are not the same as the others. The present invention also shows how nature is blind with respect to social classes.
SUMMARY OF THE INVENTION
[0012] The present board game goes beyond financial, politics and immigration problems or situations; it combines human experiences and conflicts with their social class. There has always been a social class hierarchy in the United States, wherein a few have cared to acknowledge and wherein the priorities of a higher class are not the same as the lower class. The present board game exhibits the problematic areas to which humans and especially the social classes are exposed. It expresses the competitive nature with each other and delineates the human organism's confrontation with the elements of Nature, with his man-made creation, and with his own inner turmoil.
[0013] The game comprises a board, a set of dice, players' figures representation, chips and several groups of cards. Each player figure represents a social class status and starts with certain amount of chips as money representation depending on the social class. The players move across the board game track or path looking to improve their social class while encountering situations or problems and at the same time being chases by another player of a higher social class wherein the object of the game is to survive and meet or fulfill their social obligations and responsibilities. The BIG FISH tries to eat the LITTLE FISH and the LITTLE FISH tries to escape from the BIG FISH. The HIGHER SOCIAL STATUS Citizen represents brawn in the form of size, strength, status, money and power. The LOWER SOCIAL STATUS player represents brains in the form of “street smarts”, swiftness, knowledge, expertise and flexibility.
[0014] Another object of the present invention is the acknowledgement and awareness of Social Class Systems in the United States.
[0015] Another object of the present invention is to entertain while teaching how strength, size and brawn compete against speed, stealth and smarts. It is the biological and social dominance in the evolutionary process of “Survival of the Fittest”.
[0016] Another object of the present invention is to show the advantages of teaming up and alliances.
[0017] Another object of the present invention is to teach the players to be one step ahead of our competitors, whoever they may be.
[0018] Another object of the present invention is to show how interdependent we are with our environment and the complexities of Modern Living.
[0019] The invention itself, both as to its configuration and its mode of operation will be best understood, and additional objects and advantages thereof will become apparent, by the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawing.
[0020] When the word “invention” is used in this specification, the word “invention” includes “inventions”, that is, the plural of “invention”. By stating “invention”, the Applicant does not in any way admit that the present application does not include more the one patentable and non-obviously distinct invention and Applicant maintains that the present application may include more than one patentably and non-obviously distinct invention. The Applicant hereby asserts, that the disclosure of the present application may include more than one invention, and, in the event that there is more than one invention, that these inventions may be patentable and non-obvious one with respect to the other.
[0021] Further, the purpose of the accompanying abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a top view of the board game design of the present invention.
[0023] FIG. 2 is a view of the outer track and inner accesses
[0024] FIG. 3 represents some of the group card
[0025] FIG. 4 shows CHANCE card group.
[0026] FIG. 5 shows ORACLE card group.
[0027] FIG. 6 represents the INSURANCE card.
[0028] FIG. 7 is a view of the board game outer section.
[0029] FIG. 8 is a top view of the board game design of the present invention.
[0030] FIG. 9 represents the VIP cards.
[0031] FIG. 10 represents the SCIENCE cards.
[0032] FIG. 11 represents the JUSTICE cards.
[0033] FIG. 12 represents the NATURE cards.
[0034] FIG. 13 a - 13 f represents the PANDORAS cards.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] The present board game invention is suitable for 1 or more players and, as shown in FIGS. 1-13 , comprises a board game 1 , player's representation figures, a set of dice, several card groups 6 - 12 , a power factor cube and chips. The players' figures are shaped in representation of diversified objects depending of the level, for example social classes. For example, the social classes are represented by chest figures; wherein the pawn represents the lowest class and the king represent the highest class. Six different social classes are disclosed in the present invention because the United States hierarchy system is usually defined by six classes however the number of social classes may vary. The Social Stratification has been classified as follows:
Social Status
[0036] I—Welfare and Food stamps
II—The Lower Middle Class
III—The Upper Middle Class
IV—Professionals and Entrepreneurs
[0037] V—The Nouveau Riche and other Millionaires
VI—The Billionaires, the “Four Hundred Club,” and The “Rich and Famous”
[0038] The board game 1 , as shown on FIG. 1 , comprises an enclosed track 3 and a board outer section 2 for placing several card groups 6 - 12 . The board outer section 2 for placing the cards 6 - 12 is located at the outer boundaries of the track 3 . The cards' groups 6 - 12 are placed on the board outer section 2 wherein each group is distinct from each other and have their own mean and purpose. Each card group represents a conflict area or obstacle humans must confront and overcome in order to survive on a daily basis. On the instant case the card groups 6 - 12 are separated in four different main groups. The first group is called Pandora's cards 10 . The Pandora's cards are divided into six different subgroups. The subgroups are WAR 10 D, BUSINESS 10 A, MALE-FEMALE 10 B, SOCIAL 10 F, MIND 10 C and SPIRITUAL 10 E. The second group is called Ludus' cards 6 - 9 and is divided in four subgroups: JUSTICE 8 , SCIENCE 7 , NATURE 9 and VIP 6 . The third group is called ORACLE 11 and the fourth group is CHANCE 12 . Groups and subgroups may be added or removed.
[0039] The track 3 , as shown in FIG. 2 , has several contiguous segments 4 defining playing positions, wherein each segment 4 shows at least one of the followings:
[0040] a social class status,
[0041] instructions or
[0042] a card group representation 6 a - 12 a.
[0043] Different card group representations 6 a - 12 a can be used such as images, colors or numbers as long they can be related to one of the card groups 6 - 12 on the outer board section 2 . In the instant case images are used for an easier and more attractive way to relate the card representation with the card groups 6 - 12 . Track 3 is provided with inner track accesses 5 . The inner track accesses 5 extend from a center point 4 a inside the track 3 toward the inner boundaries of track 3 in order to provide an alternative path. The inner track accesses 5 also comprise several segments 4 with at least one of the shows mention above. A hexagonal shape was selected for track 3 in order to provide a shape having at least two segments 4 of the track 3 showing twice the classes II, III, IV and V; wherein an equal number of segments 4 are aligned between them. Any other shape can be used but the hexagonal shape is more efficient for the present invention.
[0044] The board outer section 2 for placing the group cards 6 - 12 , as show in FIG. 11 , is mainly of a square shape with the track 3 placed in the middle. The four main groups of cards are located in specific spaces 6 A- 12 A outside and around the track 3 . In the instant case the Pandora's cards are divided in two sections of three subgroups. The two Pandora's cards sections are parallel to each other with the track 3 between the two Pandora's cards sections. The Ludus' cards are divided in two groups parallel to each other with the track 3 between them and perpendicular to the Pandora's cards. The ORACLE and CHANCE are aligned with each of the Pandora's cards section respectively as shown in FIG. 11 . Each card group comprises several cards per group and subgroup. As shown in FIGS. 13-17 , one side of the card shows the group/subgroup that belongs and on the other side shows a phrase with instruction at the bottom indicating some financial or other penalty or benefits. The cards 6 - 12 have been equally divided 50/50, pro and con, for us and against us. Therefore, before placing the CARDS in their appropriate locations or space 6 A- 12 A they should be shuffled, divided and only part of the cards placed on each particular space 6 A- 12 A.
[0045] The present game is a competitive game and the equipment for playing was disclosed above which is suitable for 1 or more players. Therefore how to play and the rules of the game are provided next for a better understanding of the game.
Rules of the Game
Multiple Players
[0046] One of the players is designated to manage the community money or chips. Each player or citizen starts the game by throwing a single die in order to establish his/her beginning SOCIAL STATUS Level
I-II-III-IV-V-VI
[0048] The number of players may vary but two to six players have been found the most desirable. Citizens will receive the appropriate social class status figure which they will place at a center point 4 a where all the inner tracks accesses 5 are connected. For example, in the preferred embodiment, as shown in FIG. 1 , all the players' figures are placed in the center point 4 a which shows a social class status VI at the middle of the board.
[0049] Citizens receive $10,000 per STATUS level from the community money, for example:
I=$10,000 III=$30,000 VI=$60,000
[0053] The highest SOCIAL STATUS Citizen goes first. In case there is more than one player with the highest social status, the player who threw the highest social status first starts. They must indicate the direction and turn before throwing the pair of dice. The player advances the segments 4 that the dice indicates in the pre-selected direction. Each time a player lands on a new segment 4 he or she must follow the instruction related to that specific segment 4 . For example, if a player lands on a segment 4 showing a social class level which is different from his/her actual social class, the player automatically changes his/her social status by exchanging their status figures for the new social status figure. In case he/she lands on a segment 4 having instructions or if he/she lands on a card representation segment 4 , he/she picks up the top card of the card group deck related to the card representation segment and follows the instructions.
[0054] All other Citizens will follow in a counter clockwise rotation (to the left of the starting player), irrespective of their SOCIAL STATUS ranking. At the beginning of each turn all players must state the direction he/she is moving before throwing the pair of dice.
[0055] If a player forgets to indicate their intention, as to the direction and turn they are to take before throwing the dice, they lose their turn and must give $2,000 to the player that brought it to their attention.
[0056] When a player lands at the same track segment 4 of another player, the lower social class status player has been hit and must pay $20,000 in ransom money to the higher social class status player standing at the same segment. In case the player is located at a segment 4 showing a social class level and another player lands on the same segment, the player of lower social class status must pay the ransom money to the higher social class status player and no change of status is perform.
[0057] The Citizen who has been “HIT” continues playing only if he/she can pay the full ransom. If he/she cannot afford to pay the ransom debt, he/she loses and is removed from the game. Whatever special privilege cards or other property he/she has belongs to the player who “hits” him/her.
[0058] Only Citizens who have been “HIT” and can fulfill their obligations with money, special privilege cards, the Barter System, Insurance Policy, or giving other possessions, can remain in the game.
[0059] Once the game is in progress, it is the objective of each Citizen to:
[0060] 1. Achieve the highest Social Status level
[0061] 2. Avoid being “HIT” by a HIGHER STATUS player.
[0062] 3. Try to “HIT” lower SOCIAL STATUS players.
[0063] 4. Avoid landing on Lower SOCIAL STATUS areas.
[0064] 5. Try to get SPECIAL PRIVILEGE cards.
(The Chiefs, Wizards or God-Fathers of the SECRET SOCIETIES)
[0066] 6. Protect yourself at all times—Buy Insurance
[0067] 7. Fulfill all of your obligations.
[0068] 8. Amass a large financial fortune—chips.
[0069] 9. Try to form ALLIANCES cooperation, with other Citizens in order to compete with a highest social class player in the neighborhood.
[0070] 10. Citizens can try to barter, exchange whatever Special Privileges they may have in order to survive and remain in the game.
[0071] During the game, each player must be able to complete what PANDORA'S problems they have been given. They must be able to overcome conflict situations (obstacles). Each player must be able to resolve his/her own circumstances, while at the same time surviving the competition with their peers.
[0000] Social status VI Level:
[0072] In the present Game there can only be One SOCIAL STATUS VI player at a time. If at the beginning of the game two players throw a single die to the Level VI—the first player to do so is given the SOCIAL STATUS VI Trophy and money ($60,000)—the other player receives “compensation” of $5,000 and must throw again until they get a different social class status.
[0073] If while the game is in progress, one Citizen is a SOCIAL STATUS VI and another player lands on the Central Six (VI) Space 4 a —that player will only receive “compensation” ($5,000)—but continues with his Status level.
[0074] Only when there are no other players with the SOCIAL STATUS VI, can a Citizen achieve a SOCIAL STATUS VI when they land on the Central VI Space 4 a.
Jail:
[0075] When a Citizen lands on the JAIL Space they become an “INMATE”. The INMATE has to immediately pay $5,000 to the Community Bank, and they also lose TWO (2) turns. While in JAIL, serving out their sentence, any HIGHER SOCIAL STATUS Citizen can “HIT” them. The INMATE has to pay the $20,000 RANSOM Debt. If they cannot comply with their Obligations the INMATE loses the game.
[0076] Citizens who throw a DOUBLE, and land on the JAIL space, are only “Visiting” the INMATES in JAIL. After their Visit, they throw the dice and continue on their journey through LIFE. Also if a Citizen is already in jail and any lower social class player lands at the jail segment, the lower social class player is only “visiting” the inmates in jail and stays there waiting for his/her next turn without penalties.
Special Rules
[0077] At the beginning of the game players can omit some of the following special rules so as to simplify the game. As these players become more competent in their understanding of the Underlying Game Dynamics, they can add their combinations for a more complex game.
Casino Royale:
[0078] Before the game begins the players have a GENTLEMEN'S AGREEMENT, that the FIRST Citizen to achieve a SOCIAL STATUS VI level is to receive TWO times (2×) the allocated amount of $60,000 to $120,000, on the first throw of the single die. In case no player achieves a social class VI at the beginning, the FIRST player who achieves the STATUS VI level during the game will receive $60,000. This GENTLEMEN'S AGREEMENT only applies to the FIRST Citizen who achieves the SOCIAL STATUS VI level.
Doubles:
[0079] Each time a Citizen throws a DOUBLE on the dice they receives $2000 and then take another turn. The Citizen receives the money, accomplishes what the segment 4 indicates, and then goes again.
[0080] When a Citizen throws a DOUBLE SIX (6:6) or a DOUBLE ONE (Snake-Eyes), they receive $5,000.
[0081] When a Citizen throws a DOUBLE and lands on the JAIL Space—they are only Visiting—These Citizens receive their money, throws again, and continues on their journey.
Alliances:
[0082] When there is an Overwhelming competitor in the Game—a SOCIAL STATUS VI, who is “Rich and Famous,” part of the “400 CLUB, a Super Citizen, the other players may find it to their advantage to team up and form ALLIANCES following the credo of “THE ENEMY OF MY ENEMY IS MY FRIEND”.
[0083] These disadvantaged competitors could form ALLIANCES. They could focus all of their energies on the “Heavy-Weight” and leave each other alone by:
Not “HITTING” each other Enticing the “Heavy-Weight” to fall into traps
[0086] Naturally, these ALLIANCES may be only a momentary coming together, to surmount the “CLEAR AND PRESENT DANGER”.
The Power Factor Cube:
[0087] Individual Citizens can augment their Risk-Benefits by utilizing the POWER FACTOR CUBE. Before throwing the set of dice the citizen has the choice of throwing the POWER FACTOR CUBE. The resulting POWER FACTOR CUBE number represents the amount of Risk-Benefit they wish to take, from 1-6. After moving, the Citizen either the amount of money he/she is about to WIN OR LOSE is multiplied by the POWER FACTOR CUBE number. This strategy is a possible path UP towards “QUICK RICHES”, or a lonely road DOWN towards “RAGS” and “Giving up the Ghost”.
The Ying-Yang Betting System:
[0088] Citizens can place an UNLIMITED Amount of money, on SIDE BETS, on whether the next role of the dice will be an ODD or EVEN Number, prior to throwing the dice.
[0000] The Citizens WINS or LOSES according to the outcome.
Immortality Card:
[0089] There is one immortality card in this game. The immortality card is part of Chance group cards and has the same benefits of the insurance card plus more. This card helps the player against all catastrophic events such as being hit, annihilation, changing social class or not having enough money to pay a debt. In case of annihilation the card can be used to become The World's Savior. In this case the player receives a payment of $30,000.
[0090] When a social class status VI citizen has the immortality card they become part of the “400 CLUB” and reside on Mount OLYMPUS with the other Deities. They can not lose their social class status if they land on the segment showing a lower class status level. Only if a social class status VI player picks up an APOCALYPSES Card from the Pandora's cards 10 he/she becomes mortal and is destroyed. The citizen is automatically out of the game. All of their Possessions are equally distributed among the other Citizens.
Buying Protection Insurance:
[0091] The insurance card works against some catastrophic events in order to survive life's uncertainties. A Citizen buys an INSURANCE Policy, in advance, against the possibility that some extreme event will harm them. This is providing a Protective Shield, Umbrella, or Buffer for a possible “Rainy Day” in the future.
[0092] The Citizen pays Premiums of $7,000, for an INSURANCE Policy, for any possible extreme event—being “HIT”, going to JAIL and any payments to others. There are only five insurance cards. At the beginning of the game the insurance cards are offer in a counter clockwise rotation starting from the highest social class player. Each player can only have or use the insurance card once during the game. In case a player has more than one insurance card he/she has to exchange for $7,000 dollars from the community money. Any player can buy the insurance card at any moment of the game but only when it is his/her turn.
[0093] In the event a player is hit by a higher social class player and can not pay the debt the insured citizen or player gives up the insurance card to the higher class player in lieu of the catastrophic payment. Thus the victim is saved from being out of the game.
Secret Societies:
[0094] There are FIVE different groups of SECRET SOCIETIES.
[0095] Each Group has its Organizational Chief or Wizard. All of the cards Chiefs of these Secret GROUPS are located in the VIP ZONE.
The CLAN with its GRAND MASTER The FAMILY with its GOD FATHER The MEMBERS with its PREACHER The COMPANY with its BOSS-MAN The ESPIONAGE with its MASTER SPY
[0101] A Citizen becomes Chief or Grand Wizard by selecting the VIP card which has that designation. The Citizen holds the card until another player picks up a card from the card groups 6 - 12 which shows his/her secret society. At this moment the secret society is “activated”. When a secret player is “activated” the player holding the chief card receives the monetary premiums designated by the card augmented by THREE (3×). For example, if the card indicates that the player wins 1,000 dollars the player holding the chief card will receive 3,000 from the community money instead of the player who picked up the card or if the card indicates that the player loses $1,000 the player who picked up the card must pay 3 , 000 to the player holding the chief card. Each deck of cards per group/subgroups has at least one card from each of the Five Secret Groups in the card groups 6 - 12 .
Annihilation Card:
[0102] There are Two ANNIHILATION Cards in this Game. One is in the CHANCE Zone (Volcanic Eruptions) and the other is in the NATURE Zone (Meteoric Impact). These are Total ANNIHILATION Cards. When these cards are uncovered, the Game Stops. Then the following procedure goes into effect:
The Citizen who drew the Annihilation Card goes first. They try to save Humanity. The Citizen plays the dice game, and rolls the dice according to that Game. If on the First roll they hit a SEVEN, they WIN and Humanity is saved. If they roll Snake-eyes (1:1), they LOSE and the next Citizen attempts to become The World's Savior. If a Citizen Rolls a Number and “makes the Number”—they WIN. If the Citizen doesn't make their Number before rolling a SEVEN, they LOSE. Then the next Citizen attempts to Save Humanity. If all Citizens Lose in their attempts to SAVE Humanity, the Game is OVER. There is Total ANNIHILATION, with No survivors unless a player has the IMMORTALITY card. However, if a Citizen WINS in their attempt to Save Humanity, that Citizen will receive $50,000 and an increase of two social statuses. At anytime, prior to the beginning the Game, the ANNIHILATION Cards may be removed from the Game.
Winning the Game:
[0113] The winner is the last player standing, the Citizen who has been able to fulfill all of their SOCIAL OBLIGATIONS, but has also been able to out maneuver all of his/her competitors.
Single Player
Ludus Solitaire—Medusa's Web
[0114] On the single player mode, also called Medusa's web, basically the single player is fighting alone against a permanent higher class enemy. The permanent higher class enemy is PANDORA which starts the game as a Level VI. She receives her social class VI representation but doesn't need MONEY, for she has “all the money in the world”. PANDORA is represented by MEDUSA. MEDUSA, as PANDORA'S emissary, starts first at the Central Level VI space.
[0115] Since MEDUSA is part of PANDORA'S System, all of the Cards Status Symbols do not affect her. Also because you are in mortal combat with her, your interest is to find the Olympian shield (HOLD Card) in the System. Only eight Olympian shield cards are used in the game wherein each one is located in the Pandora's cards, Chance and Oracle groups respectively. Money, status, and relationships are of no interest to you. However the player has to follow the instructions on the track segments. Your need is to SURVIVE your confrontation with MEDUSA.
Rules for Single Player
[0116] Once you are in MEDUSA'S WEB the following may happen:
If MEDUSA “HITS” you—you are DEAD. You lose. If MEDUSA lands ONE space from you, you are FROZEN, She has TWO turns to “HIT” you. If you land ONE space from her you are FROZEN, and she has TWO chances to come after you. If you land directly in her space, without a Protective SHIELD you are DEAD. If She “HITS” you even if you have a SHIELD, you are DEAD. You can WIN only if you have a Protective SHIELD and “HIT” her first, then you can kill MEDUSA.
[0123] As you are trying to evade MEDUSA in her SPIDER-WEB, you will find many Treasures and worldly Possessions of previous VISITORS, but they are of no interest for you.
[0124] These are only Distractions to Lull you into Greed and Satisfaction. Your Goal—Directed Striving is to find your Holy Grail, the OLYMPIAN SHIELD, with which to KILL the dreaded MEDUSA.
[0125] We should note that consciously you are the Ambassador of Fate, therefore, make the best decisions for Pandora and her emissary Medusa. However, unconsciously you are representing your amorphous psyche, which is fighting Pandora.
[0126] In Reality, this is a confrontation between the basic elements of the Individual Unconscious (the SELF) against the Collective Unconscious (SOCIETY). When the Game begins, the die has been cast and your individual fight begins. You can rebel and confront destiny.
[0127] One will notice that the more one plays, the greater awareness one acquires about the complexities of Modern Living, and how interdependent we are with our environment. To acquire mastery of the game one should play numerous times, at different levels of complexities. In this manner we may learn the fine art of the “Juggling Act” needed to refine our behavior and movements in the Real World. For Beginners, the game can be played in a Simplified Format. That is, playing without the multiple Permutations and Combinations of LIFE'S complexities. All of those annoying, fuzzy, irritations of the Real World can be avoided by omitting the following modifications:
Casino Royale—The Yin-Yang betting system—Doubles—The Solitaire Dance in MEDUSA'S Web—The Power Factor Cube—The Secret Societies—and the Annihilation Game.
[0129] All the rules are disclosed in a manual. Also a guide with a summary of the rules for an easy understanding is provided to the players. As the Players become more sophisticated in their understanding of the dynamics of the present game invention, they can expand their Horizons and broaden their Scope of Gamesmanship. Later the players can include all of those Themes and Variations of LIFE'S Complexities. The Game then becomes a True test of the Player's Comprehension and dexterity.
[0130] Finally, one last Element is necessary in mastering the game. In order to become proficient, the Citizen must learn to WIN in the Shortest Time Frame possible so as to be considered the Ultimate Master of the Universe.
[0131] The invention is not limited to the precise configuration described above. While the invention has been described as having a preferred design, it is understood that many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art without materially departing from the novel teachings and advantages of this invention after considering this specification together with the accompanying drawings. Accordingly, all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by this invention as defined in the following claims and their legal equivalents. In the claims, means-plus-function clauses, if any, are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent functions.
[0132] All of the patents, patent applications, and publications recited herein, and in the Declaration attached hereto, if any, are hereby incorporated by reference as if set forth in their entirety herein. All, or substantially all, the components disclosed in such patents may be used in the embodiments of the present invention, as well as equivalents thereof. The details in the patents, patent applications, and publications incorporated by reference herein may be considered to be incorporable at applicant's option, into the claims during prosecution as further limitations in the claims to patentable distinguish any amended claims from any applied prior art.
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The variety human experiences board game provides the player with real life experiences such as confrontations against other players as well with the inevitable elements of nature. The game creates a greater awareness about the complexities of modern living, and how interdependent we are with our environment.
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BACKGROUND AND OBJECTS OF THE INVENTION
This invention relates to internal combustion engines and more specifically to a novel engine design and fuel system therefore.
It is the primary object of this invention to provide an improved internal combustion engine and fuel system therefore which exhibits very high efficiency and low hydrocarbon emission characteristics due to a near perfect combustion of the admixture of air and fuel forming the charge.
This is achieved by providing a six cycle engine having a heat exchanger which furnishes heated air to the cylinders on the 5th stroke to further heat same and which air is expelled on the 6th stroke. In addition, the flow of coolant in the engine has been changed from the conventional method of absorbing heat from the cylinder walls first and then the engine head to permitting the coolant to absorb heat from the engine head first and transfer this heat to the cylinder wall to impart a warming trend thereto. A new fuel system is also disclosed which ensures that the mixture of fuel and air is as complete as possible before entering the intake manifold of the engine.
The prior art structure of which applicant is aware is exemplified, for example, in U.S. Pat. No. 2,355,806 which discloses a six cycle engine wherein additional air is introduced on the 5th stroke and expelled on the 6th stroke. However, the air is substantially cool and is introduced to reduce the temperature of the cylinder head and walls to prevent preignition and not for the purpose of controlling the inner skin surface to inhance combustion as does applicant. Another U.S. Pat. No. 3,964,263 discloses a six cycle engine which teaches the use of fins to increase the temperature inside the combustion chamber, however, the purpose is to readily vaporize a liquid such as water which is introduced during the fourth stroke of the engine and not to increase the temperature of the inner skin surfaces to enhance combustion of the air and fuel mixture as does applicant.
It is therefore a further object of the present invention to provide a six cycle internal combustion engine which utilizes heated air introduced on the 5th cycle thereof to increase the inner skin surface temperature of the head and cylinder walls to facilitate more complete combustion of the charge.
It is another object of the present invention to provide an internal combustion engine with a reversed coolant flow therethrough to inhance the internal temperature of the cylinder walls to further improve combustion.
It is a yet another object of the present invention to provide an improved fuel system for an internal combustion engine and one which insures the thorough mixing of the air and fuel forming the charge.
It is a still further object to provide an internal combustion engine of 6 cycle type which is of simple construction, economically feasible, and relatively trouble free in operation.
The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objectives and advantages thereof will be better understood from the following description considered in connection with the accompanying drawing in which a presently preferred embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the drawing is for the purpose of illustration and description only, and is not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of an internal combustion engine showing the direction of coolant flow according to the principles of the present invention.
FIG. 2 is a side elevational view of the engine of FIG. 1.
FIG. 3 is a schematic illustration of the fuel system for an internal combustion engine according to the invention.
FIG. 4 is a diagrammatic illustration of an internal combustion engine having a six stroke cycle wherein preheated air is introduced during the 5th cycle.
DESCRIPTION OF THE INVENTION
Referring now to the drawings where like characters of reference refer to like elements in each of the several views, FIGS. 1 and 2 show a conventional four cylinder internal combustion engine 10 of the six stroke cycle type it being understood of course that the number of cylinders can be increased or decreased without departing from the spirit of the invention, and four are shown in FIG. 1 for the purpose of illustration. The engine 10 has a block 12 with cylinder walls 14 surrounded by passageways 16 through which a coolant is passed. The engine 10 also has a head 18 containing the spark plugs 20 and valving 22 positioned above the block 12. The head 18 has passageways 24 therethrough which communicate with passageways 16 in the block. The passageways 24 in the head 18 are connected to an engine driven coolant pump 26 which in turn is connected by a hose to a radiator 28 at one end thereof. The other end of the radiator 28 is connected by hosing 29 to upper outlet 30 and lower outlet 32 in the block 12 which outlets communicate with passageways 16 therethrough.
Typically, because the highest degree of heat in an internal combustion engine is generated in the head 18 and the portion of the cylinders adjacent thereto, the flow of coolant has been first through the block passageways 16, then through the head passageways 24 and back to the radiator 28. However, because applicant has discovered that additional heat along the length of the cylinder walls 14 materially aids in ensuring the complete combustion of the fuel and air mixture fed thereto with the resultant increase in efficiency and decrease in hydrocarbon emissions, the direction of coolant flow has been reversed as can be seen by the arrows in FIGS. 1 and 2. More specifically, the coolant is caused by pump 26 to enter the head passageways 24 first whereupon heat is absorbed by the coolant. As the heated coolant travels to the passageways 16 in the block 12, the head absorbed therein provides a warming trend to the cylinder walls 14 prior to its exit through outlets 30, 32 and return to the radiator 28 via hose 29.
The engine 10 has a fuel and air intake manifold 34 connected at one end to each intake valve 36 and at the other end to a fuel-air supply system comprising a carburetor 38 and a source of low pressure vaporized fuel 40. The engine 10 also has a conventional exhaust manifold 42 connected at one end to each exhaust valve 44 and at the other end to a conventional muffler system (not shown). In addition, the engine 10 has a heated air manifold 46 connected at one end to each heated air inlet valve 48 and at the other end to a heated air generator 50.
The heated air generator 50 serves the function of supplying a quantity of warm air to the cylinders walls 14 of the engine to insure that the walls 14 as well as the inner surface 52 of the head 18 is at a constant, preselected temperature at all times to enhance the combustion efficiency of the air-fuel mixture burned therein. The generator 50 as disclosed in FIG. 3 comprises a housing 54 which surrounds a portion of the exhaust manifold 42. The housing 54 has an inlet 56 for introducing air to the interior thereof and an outlet 58 connected to the heated air manifold 46. An electric resistance-type heating element 60 is located within the housing 54 and it is connected to a source of current (not shown) via a thermostatically controlled switch 62 which senses the temperature in outlet 58 to thereby control energization of the heating element 60. In operation, prior to the exhaust manifold 42 reaching its normal operating temperature as the engine 10 is started up, the switch 62 will energize the heating element 60 to warm the air being drawn through inlet 56 prior to its introduction to the cylinders via inlet valves 48. As the exhaust manifold 42 reaches operating temperature, the heating element 60 is deenergized and the air from inlet 56 is heated directly by the exhaust manifold 42 itself. The air in outlet 58 is maintained typically in excess of 100° F.
In addition to the aforedescribed ways of insuring that the cylinder walls 14 and inner surface 52 of head 18 are at a higher temperature than normally experienced in conventional internal combustion engines, namely by the reversal of the coolant flow from the head passageways 24 to the cylinder passageways 16 and the heated air injected through valve 48 from generator 50, the fuel-air mixture forming the charge introduced into the intake manifold 34 is also novel thereby insuring greater combustion efficiency than previously experienced. The charge is formed, generally speaking, by combining vaporized fuel preferably of the no-lead type from generator 40 with air in the carburetor 38 and then thoroughly mixing the combined air and vaporized fuel molecules in a mixing device 64 prior to their entrance into intake manifold 34. It being understood of course that fuels other than gasoline can be used just as effectively in forming the charge.
More specifically, the source of vaporized fuel 40 consists of a housing 70 having a high pressure chamber 72 and a low pressure chamber 74. The high pressure chamber has a quantity of low lead or preferably no lead fuel such as gasoline 76 in the bottom thereof. The fuel 76 is introduced to the high pressure chamber 72 by means of a pump 78 via a valve 80 which is opened and closed by means of a float 82 in a well known manner. A sealed electrical resistance-type heating element 84 is positioned in the fuel 76 to heat same to the point where the fuel turns into a vapor. A pressure activated valve 86 is provided between the high pressure chamber 72 and low pressure chamber 74 to permit fuel vapor to enter the low pressure chamber 74 when the pressure of the fuel vapor in the high pressure chamber 72 reaches a predetermined or preselected amount which can be controlled by knob 88.
The electrical resistance-type heating element 84 is connected to a control 90 which determines when the heating element 84 will be energized. The control 90 operates in response to the temperature of the fuel 76 as measured by adjustable temperature sensor 92 and the pressure senses by high pressure sensor 94 and low pressure sensor 96. Sensors 92, 94 and 96 are electrically connected in series to control energization of heating element 84. The setting of sensor 92 is determined by the characteristics of the particular fuel being used whereas pressure sensors 94 and 96 are chosen for optimum safety and pollution considerations.
The low pressure chamber 74 is connected by piping 98 to the carburetor 38, and more specifically, to a jet 100 in the throat 102 of the carburetor. Air drawn into the throat 102 through filter 104 is controlled by means of the butterfly throttle valve 106 in the conventional manner. A linkage 108 connects the throttle valve 106 with a vapor flow control valve 110 in piping 98 which linkage 108 is in turn connected to an actuator (not shown) such as an accelerator pedal. A solenoid activated switch 112 is also provided in piping 98 which is connected to and activated to its open and closed position when the ignition switch of the vehicle is respectively in its on or off position. Thus, the molecules of fuel vapor entering the throat 102 via jet 100 from low pressure chamber 74 is combined with air molecules in the throat 102 of carburetor 38. This combination of air and fuel molecules is then drawn to the mixing device 64 by the suction existing in intake manifold 34.
The mixing device 64 comprises a screen 114 having a plurality of mixing holes 116 which are, for example, 1/64 inch in diameter. A shaft 118 is secured to the screen 114 and has a first propellor 120 and a second propellor 122 rotatably mounted on one section thereof above the screen 114 and a third propellor 124 rotatably mounted on the section of the shaft 118 beneath the screen 114. The direction of the pitch of the propellors 120, 122 is chosen such that they are caused to rotate counter to each other as the fuel and air combination is drawn around and past them into mixing holes 116. Propellor 124 is also caused to rotate as the thoroughly mixed combination of fuel and air molecules is drawn past it into intake manifold 34. The counter rotation of propellors 120,122, mixing holes 116 and rotating propellor 124 thoroughly mixes the combined vaporized fuel molecules and air molecules to form a charge which when introduced into the cylinders already heated according to the aforedescribed principles and means of the present invention, result in complete combustion during the power stroke with the resultant substantial increase in power and overall operating efficiency. This is in contrast to most conventional internal combustion engines which burn as much fuel on the exhaust stroke as on the power stroke or the fuel is not burned at all but carried out in the exhaust. Relief values are provided in the wall of the intake manifold 34 to permit the release of pressure from the manifold in the event of a premature ignition of the fuel in the manifold itself causing a backfire.
OPERATION
Referring to FIG. 4, the operation of the six stroke cycle engine 10 will be described assuming the direction of coolant flow as previously discussed which results in a higher and more even distribution of heat the length of the cylinder walls. The engine has three values, and intake valve 36, an exhaust valve 44 and a heated air inlet valve 48 all activated by conventional caming and the like, which in the interest of clarity has been eliminated in the drawings. The cylinder 14 has a reciprocating piston 128 connected to a crankshaft 130 in a well known manner. The fuel intake valve 36 and manifold 34 are connected to the aforedescribed fuel-air system comprising vaporized fuel generator 40, carburetor 38 and mixing device 64, the exhaust valve 44 is connected to exhaust manifold 44 and heated air inlet valve 48 is connected to heated air manifold 46.
The following is the sequence of operation of applicants' six stroke cycle engine:
Stroke 1 - Intake valve 36 is opened and the throughly mixed charge of fuel and air is drawn into the cylinder during the downward movement of piston 128.
Stroke 2 - All valves are closed and the charge heated by the cylinder walls is compressed.
Stroke 3 - All valves remain closed and the charge is ignited driving piston 128 down.
Stroke 4 - Exhaust valve 44 is opened and burnt gasses are expelled during upward stroke of piston 128.
Stroke 5 - Inlet valve 48 is opened and warm air from generator 50 is drawn into cylinder by the downward movement of piston 128, thereby further increasing the temperature of the cylinder walls 14 and engine head 18.
Stroke 6 - Exhaust valve 44 is again opened and the heated air is expelled.
Applicant has thus described his novel six stroke cycle engine and its operation, an engine which achieves very high operating efficiency due to the unique combustion of reversed coolant flow, ingested heated air on the 5th stroke of a six stroke cycle, and the completely mixed charge of air and vaporized fuel molecules resulting from applicants vaporized fuel generator, carburetor and mixing device.
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 therein without departing from the spirit and scope of the invention.
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A six cycle combustion engine is disclosed which utilizes the 5th and 6th cycle for drawing in and expelling preheated air to further warm the combustion chamber. The flow of the coolant water has been reversed so that heat absorbed in the engine head will flow to the cylinder walls and give a warming trend thereto. In addition, a fuel system is disclosed which insures the complete mixing of air and fuel vapor molecules prior to their deliverance to the intake of the engine.
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FIELD OF THE INVENTION
[0001] The present invention relates to land anchors and similar devices that are designed to be driven into the earth to anchor an item and also for removal when no longer needed.
BACKGROUND OF THE INVENTION
[0002] The prior art teaches several land anchor devices including those disclosed in U.S. Pat. Nos. 5,806,453; 6,481,364; and 6,606,829, among others. The present invention is an improvement over these devices in many ways including, but not limited to, being significantly less expensive to manufacture, relatively lightweight, capable of being more rapidly driven into the ground, and configured to more steadfastly hold its position once driven into the ground.
[0003] U.S. Pat. No. 5,806,453, issued to Cook for a Land Anchor Device, teaches a relatively complicated slide hammer arrangement that provides up and down hammering and includes a large number of components. The handle has a limited range of motion and is configured for removable attachment. The large number of components makes the device disadvantageously expensive to manufacture and more prone to mechanical failure.
[0004] U.S. Pat. No. 6,481,364, issued to Woyjeck for an Anchoring Device and Methods of Use, teaches a device having a cylindrical hammer assembly that encompass the top half or more of the drive stake and stabilizing fins that extend from the bottom portion of the stake. The long cylindrical hammer and to perhaps a lesser extent the fins add disadvantageously to the bulk, weight and cost of manufacture of the device.
[0005] U.S. Pat. No. 6,606,829, issued to Benincasa et al., teaches a device that is collapsible. The “runner” or handle shaft member may be slid into the “anchor body” permitting the device to be compressed in size for stowing, etc. While this feature may be desirable to some users, it represents a trend in land anchor devices to include a multiplicity of components, to be expensive to manufacture and to have relatively limited drivability due to inherent design limitations (for example, the inherent structural compromises of the '829 design) and a limited range of motion of the hammer.
[0006] A need thus exists for a land anchor device that is configured in a manner that has relatively few parts, is inexpensive to manufacture, is relatively lightweight, can be driven quickly and efficiently to a secure position, is configured to more steadfastly hold a position once driven into the ground, and can be readily removed when desired.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is an object of the present invention to provide a land anchor device that overcomes one or more of the shortcomings of the prior art including being lesser in weight, bulk and/or cost-of-manufacture.
[0008] It is another object of the present invention to provide a land anchor device that is configured for driving by an external force and being extracted by a self-contained mechanism.
[0009] It is also an object of the present invention to provide a land anchor device that has a non-circular lateral cross-sectional configuration.
[0010] These and related objects of the present invention are achieved by use of a land anchor having up-slide hammer as described herein.
[0011] In one of many embodiments, the present invention may include a drive stake having a striking surface and an insertion tip. The drive stake may include a continuous member from the striking surface to the tip to efficiently transfer a driving force to the tip. The extraction anvil is preferably positioned below the striking surface and a hammer member is provided that may be moved upward along the drive stake into contact with the extraction anvil to deliver an upward or de-anchoring force to the device.
[0012] Various embodiments, features and materials are included in the present invention.
[0013] The attainment of the foregoing and related advantages and features of the invention should be more readily apparent to those skilled in the art, after review of the following more detailed description of the invention taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1 and 2 are respectively an elevation view and a top view of one embodiment of a land anchor device with up-slide hammer device in accordance with the present invention.
[0015] FIGS. 3-5 are side views and FIG. 6 is an end view illustrating one embodiment of assembly of the extraction hammer and handle arrangement of the present invention.
[0016] FIG. 7 is a side view of a stop member of the land anchor device of FIG. 1 .
[0017] FIGS. 8-10 are a side view and two top views of auger members in accordance with the present invention.
[0018] FIGS. 11 a - 11 c are lateral cross-sectional views of representative alternative embodiments of a drive stake in accordance with the present invention.
DETAILED DESCRIPTION
[0019] Referring to FIGS. 1 and 2 , an elevation view and a top view of one embodiment of a land anchor with up-slide hammer device 10 in accordance with the present invention is shown.
[0020] Device 10 includes a drive stake 20 that is configured for being driven into the ground or other anchoring medium. An extraction anvil 22 is preferably coupled to the stake near a top portion thereof. An extraction hammer 30 is preferably provided below the extraction anvil and configured for upward movement along stake 20 in the direction of arrows A. Upward movement of hammer 30 into contact with extraction anvil 22 delivers an extraction force to the anvil (and hence stake 20 ), causing the stake to be extracted from its anchoring medium. A stop member 24 is preferably provided on stake 20 below extraction anvil 22 to maintain hammer 30 at a convenient location for being grasped by a user.
[0021] Hammer 30 preferably includes a hammer head 31 and a pair of handles 34 . Hand guards 35 are preferably provided by or on handles 34 in such a manner as to prevent a user's hand or fingers from moving into a position where they might get pinched between hammer head 31 and anvil 22 .
[0022] In use, device 10 is configured for being driven by an external force, for example, a hammer and preferably a sledge hammer. A conventional 5 or 6 lbs. sledge hammer is a suitable driving tool for the approximately 40″ version or the like described below, though other sized hammers may be used (and other sized land anchor devices in accordance with the present invention may be formed). The top or “strike receiving surface” 21 of stake 20 is configured to receive the driving blow of the sledge. As a continuous linear member or the like, stake 20 transfers a blow delivered to striking surface 21 through to the distally located drive tip 26 , thereby driving stake 20 into the ground or other medium. Note that tip 26 is preferably pointed or otherwise configured to facilitate being driven into the ground.
[0023] Extraction anvil 22 may be provided slightly below striking surface 21 . In this arrangement, drive blows are delivered directly to the striking surface. With repeated use, striking surface 21 may mushroom over onto parts of the extraction anvil.
[0024] The present invention strategically supports the combination of external driving to secure the land anchor to land and non-external driving for removal. Typically, the most significant challenge in using a land anchor is driving it into the ground. Use of an external hammer or the like facilitates greater efficacy in driving because a hammer or the like can deliver more momentum than prior art down slide hammers. The increased momentum is attributable to the greater range of motion of the hammer, the positioning of the hammer relative to a user that permits a user to put more force in a blow, and the weight of the hammer head which is often heavier than a prior art land anchor hammer head.
[0025] In addition, by eliminating the down hammer components found in prior art devices, the land anchor of the present invention is lighter and less bulky than those devices.
[0026] Stake 20 may be formed of a sturdy, rigid material such as various metallic materials (with corrosion protection, if necessary). Suitable material, depending on use conditions, include steel (stainless and non-stainless), aluminum and other metals and alloys thereof. It should also be recognized that non-metal materials that are sufficiently sturdy may also be used. In one embodiment, stake 20 is formed of 1″ square steel stock and cut to a length of approximately 40″. The steel stock in this exemplary embodiment preferably has a yield strength of approximately 36K pounds and a tensile strength of approximately 58K to 80K pounds. A stake of this size is designed for use in anchoring a house boat or small plane or the like. For anchoring smaller devices such as smaller water craft and the like, a smaller sized version of device 10 may be used and/or lighter weight materials such as aluminum, etc., may be utilized. In addition, material such as stainless steel may be used for stake 20 and/or other device components for a higher end product or to obtain a given aesthetic appearance.
[0027] Referring to FIGS. 3-6 , assembly of extraction hammer 30 is illustrated. While FIGS. 3-6 illustrate one manner of manufacture the hammer and handle assembly, it should be recognized that other manners of manufacture may be employed without departing from the present invention.
[0028] Handles 34 may be formed of cylindrical pieces of steel or other suitable shapes and materials. In one embodiment, the individual handles 34 are made of 1″ diameter steel rods cut to lengths of approximately 6″. A corner of each of the rods is preferably notched as shown to receive hammer head 31 . Hammer head 31 may be formed as a circular (or otherwise shaped) member with a preferably centered square hole (matching the geometry of stake 20 ). In one embodiment, hammer head 31 has a height of ½″ and a diameter of 3″ and is stamped out of flat plate steel.
[0029] Extraction anvil 22 may have substantially the same dimensions as hammer head 31 and be formed in substantially the same manner. Accordingly, a top view of hammer head 31 may look substantially like anvil 22 as shown in FIG. 2 .
[0030] Handles 34 are preferably welded to hammer head 31 on opposite sides to achieve the arrangement shown in FIG. 4 . Hand guards 35 are preferably coupled to each of handles 34 . While the guards may be made of any suitable materials, in one embodiment, they are formed of steel washers that are welded to handles 34 at the appropriate locations. FIG. 6 illustrates a side view of one embodiment of a guard 36 mounted to a handle 34 . The relative position of hammer head 31 is also shown.
[0031] Handles 34 may then be covered with a rubber or like material that provides better grip and/or shock absorption. These grips 36 may be provided through various manners known in the art, including dipping into a suitable grip material, gluing the grip material in place, spraying on the grip material, etc. Note that the metallic components of the device are preferably powder coated (assuming this is necessary based on the type of metal used), and the powder coating is preferably applied before application of the grip material.
[0032] FIG. 7 illustrates stop member 24 . Stop member 24 may be formed in various ways. In one embodiment, stop member 24 is formed of a hollow cylinder having an inner diameter that can fit around the preferably square stake. The stop member is preferably made of a metallic material and welded to stake 20 .
[0033] Referring to FIGS. 8-9 , an elevation view and a plan view of an auger member 50 in accordance with the present invention are respectively shown. Auger member 50 is preferably configured to fit over a bottom region 28 of stake 20 (see FIG. 1 ). The auger member may include a shaft 51 and an auger blade 52 welded to or otherwise formed with the shaft. Auger blades are know in the art. Shaft 51 preferably has a lateral cross-sectional geometry that is complementary to stake 20 so as to readily fit over the stake yet securely engage it. Complementary holes 29 and 59 may respectively be formed in the stake and auger member for removable insertion of a locking pin 61 or other removable device. Note that other releasable attachment schemes could be used without deviating from the present invention. Many releasable schemes are known in the art. The shaft section 53 at which mounting hole 59 is located is preferably double walled for reinforcement.
[0034] Shaft 51 may b 3 formed of any suitable material, including steel, other metals or other rigid durable materials. Suitable materials for auger blade and shafts are known in the art.
[0035] FIG. 9 illustrates the top edge 55 of auger blade 52 , shaft 51 and mounting hole 59 .
[0036] Referring to FIG. 10 , a top plan view of another embodiment of an auger member 60 in accordance with the present invention. Auger member 60 includes a shaft 61 that in lateral cross-section has a substantially square interior 64 and a substantially circular exterior 66 . The auger blade 62 , attachment hole 69 and other features are substantially as described above for auger member 50 of FIGS. 8 and 9 . The circular exterior may reduce the drag associated with turning the auger member.
[0037] In use, auger member 50 (and 60 ) permits insertion and secure retention of land anchor 10 in a sandy or like substrate such as on a beach. The auger member is attached to the bottom of stake 20 and horizontally disposed handles 34 provide leverage to screw the land anchor into the ground. The position of handles 34 provide good leverage for operating the land anchor in this manner. To remove the anchor, the handles are turned in the opposite direction. The provision of auger member 50 (and 60 and the like) increases the versatility of the land anchor of the present invention.
[0038] Referring to FIGS. 11A-11C , representative, but not limiting, alternative embodiments for the lateral cross-sectional configuration of a drive stake in accordance with the present invention are shown. Each of these embodiments are non-circular, making the drive stake more difficult to turn in an anchoring medium. FIG. 11A illustrates a substantially triangular configuration 81 , while FIG. 11B illustrate a substantially polygonal configuration (hexoganal) 82 and FIG. 11C illustrates a more amorphous curved shape (hour-glass like) 83 with recessed side portions. The embodiments of both FIGS. 11B and 11C are longer (i.e., deeper) than wide.
[0039] With respect to other features of a land anchor in accordance with the present invention, stake 20 may have any lateral cross-sectional configuration. The device of FIGS. 1-2 and 8 illustrates a square configuration, though it should be recognized that a triangular, hexagon, circular, rectangular or other shape may be used. The use of a square shape (or triangular or the like) provides a stake that is less likely to turn in the anchoring medium once it is driven in. Circular shaped stakes tend to turn more readily than square or triangular shapes and this may lead to the stake loosening its position more quickly.
[0040] It should also be recognized that stake 20 may be formed of any length. Some different length embodiments are discussed above.
[0041] It should also be recognized that while handles 34 are configured in an arrangement that facilitates attachment of an anchoring rope or the like, supplemental cleats or loops or the like may be coupled to a land anchor device 10 in any of its various embodiments.
[0042] While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification, and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as fall within the scope of the invention and the limits of the appended claims.
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A land anchor device that is configured for external driving with a hammer or the like and self-contained extraction with an up-slide hammer member. Among other benefits, weight, bulk and cost-of-manufacture are reduced by a land anchor device in accordance with the present invention. The device may include a drive stake having a continuous drive member from striking surface to tip, any of and various cross-sectional configurations. The handle arrangements facilitate easy-of-use. The device includes an auger accessory. Various embodiments and fabrication materials and methods are disclosed.
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This is a divisional of application Ser. No. 433,916, filed Nov. 9, 1989, now U.S. Pat. No. 4,941,687.
BACKGROUND OF THE INVNETION
The advent of high resolution color photocopy equipment simplifies the task of currency replication to the point where it is becoming a crime of opportunity. Whereas such counterfeiting in the past was usually undertaken by skilled artisans perpetrating a deliberate criminal act, it is now becoming a simple process tempting the public to become casual counterfeiters.
U.S. Pat. Nos. 4,652,015 and 4,761,205 both describe techniques whereby a plastic strip containing metal characters is integrally-formed within the currency paper during the papermaking process to provide a "security thread".
The security thread remains virtually undetected under reflected light while being readably discerned with transmitted light which effectively defeats replication by any photocopy process.
When currency paper is printed by the intaglio process, the calendaring effect reduces opacity and thereby the hiding power of the paper fibers. Under careful post print inspection in reflected light, the metal characters appear brighter and lighter than the surrounding paper thus becoming legible.
It is believed that the presence of the light colored characters may be relied upon by the general public to indicate the presence of a security thread without further verification with transmitted light. A counterfeiter could then presumably duplicate the light characters with white toner to give the erroneous impression that a security thread is present.
An early attempt to eliminate the light characters by pigmentation of the plastic substrate strip was not totally successful since the outline of the pigmented plastic strip could be detected upon close scrutiny as a faint continuous line.
U.S. Pat. No. 4,398,994 describes a demetallization process for providing metal characters on a plastic substrate whereby a pigmented coating is selectively applied to the exposed surface of the metal characters. The surface of the metal characters facing the plastic substrate remains reflective. U.S. Pat. No. 4,242,378 teaches a method for coating the plastic substrate under the metal characters with a pigmented coating while leaving the exposed surface of the metal characters uncoated. For security devices fabricated in accordance with the teachings of these Patents the metal characters are discernible from either one surface of the paper or the other depending upon which side of the paper has the bare metal surface outward.
One purpose of the instant invention accordingly, is to provide a security paper containing a metallized security thread that is virtually invisible when viewed under reflected light from both sides of the paper yet is clearly visible from either side of the paper when viewed with transmitted light.
SUMMARY OF THE INVENTION
A security paper employs a plastic strip containing metallized characters incorporated therein as a security thread. A pigmented resin on both sides of the metallized characters prevents detection of the security thread when viewed from both sides of the paper under reflected light. The security thread is readily visible, however, when viewed with transmitted light from either side of the paper.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of the security paper containing the security thread in accordance with the invention;
FIG. 2 is an enlarged end view of the part of the security thread of FIG. 1 containing the security thread composite;
FIG. 3 is a series of end views of the plastic strip within the security thread of FIG. 2 depicting the progression of steps involved in fabricating the security thread;
FIG. 4 is a series of end views of the plastic strip within the security thread of FIG. 2 depicting an alternative method of fabricating the security thread; and
FIG. 5 is a series of end views of the plastic strip within the security thread of FIG. 2 depicting a further method of fabricating the security thread.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A U.S. currency bill 10 of the type described in U.S. Pat. Nos. 4,652,015 and 4,761,205, which patents are incorporated herein for purposes of reference, is depicted in FIG. 1. The currency bill consists of a security thread 12 incorporated within the currency paper 9 which includes printed indicia as generally indicated at 11 to depict a United States president as well as the bill denomination. The end of the bill 10A containing the security thread 12 is depicted in FIG. 2 to show the cross-sectional placement of the security thread 12 relative to the width in the currency paper. The security thread comprises a polyester film 13 of polyethylene terephthalate which is coated with a pigmented resin 14 that is readily soluble in ethyl alcohol and hereafter referred to as "soluble pigmented resin". The pigment is selected to match the color of the currency paper. The soluble pigmented resin is next coated with a thin continuous film of aluminum metal 15 applied by a vacuum deposition process. For ideal opacity, the aluminum layer should be in excess of 300 angstroms in thickness. Next a layer of pigmented resin 16 that is insoluble in ethyl alcohol, hereafter "insoluble pigmented resin", is printed over the aluminum. The insoluble pigmented resin has the same color and consistency of the soluble pigmented resin and contains the necessary security indicia in the form of printed characters. The plastic strip composite is then subjected to an ethyl alcohol etch, whereby all the material is removed from the plastic strip except where protected by the insoluble pigmented resin. A clear polyester film 17 is next applied over the remaining material by a lamination process to provide durability and environmental protection.
The processing steps for forming the complete security thread 12 is best seen by referring now to FIG. 3 wherein the polyester film 13 is depicted proceeding through the successive coating and etching procedures. The polyester film is processed from a continuous roll of film, although only the cross-section of the film is depicted in FIG. 3 for purposes of clarity. The soluble pigmented resin 14 is applied to the polyester film by a surface contact coating technique in which one surface of the polyester film is brought in contact with the soluble pigmented resin. When the soluble pigmented resin has completely dried, the aluminum 15 is vacuum deposited on the top surface. The insoluble pigmented resin 16 is next micro-printed onto the surface of the aluminum and the coated film is then subjected to ethyl alcohol to selectively dissolve the soluble pigmented resin 14. The insoluble pigmented resin 16 prevents the ethyl alcohol from contacting the soluble pigmented resin 14 that lies subjacent to the aluminum and insoluble pigmented resin as indicated. Finally, a clear polyester film 17 is applied to the insoluble pigmented resin and exposed plastic strip 13 to protect the finished security thread composite 12 when later subjected to the papermaking processes described in the aforementioned U.S. Patents wherein which the security thread is embedded within the security paper.
An alternative method of fabricating the security thread 12 is depicted in FIG. 4 wherein a polyester film 13 is coated with a water-soluble pigmented resin 14'. The aluminum 15 is vacuum deposited over the water soluble pigmented resin and a water-insoluble pigmented resin 16' is micro-printed onto the aluminum. Subjecting the plastic strip and the coated materials to water solution effectively removes all material except where protected by the water-insoluble pigmented resin 16'. A similar water-insoluble polyester film 17 is laminated over the surface of the coated polyester film 13 to form the completed security thread composite 12 which is inserted in the security paper in the same manner described earlier with reference to FIG. 3.
It is appreciated that the security thread 12 of the invention can be prepared in a variety of steps as seen by referring now to FIG. 5. A polyester film 13 is first metallized by vacuum deposition of aluminum 15. The insoluble pigmented resin 16 is then printed over the aluminum to provide indicia. The coated plastic film is then subjected to a sodium hydroxide-water solution which effectively dissolves away the aluminum that is not covered by the insoluble pigmented resin. Pigmented resin 16' is then printed on the opposite surface of the polyester film in exact registration with the pigmented resin 16 on the metallized surface 15. Protective polyester film 17 is then applied to the metallized surface of finished security thread 12. This particular process involves less steps than those depicted earlier in FIGS. 3 and 4, however, the positioning of the plastic strip with respect to the micro-printing used to apply the insoluble pigmented resins 16, 16', must be very accurate and precise in order to not distort the final image when viewed under reflected light.
Various methods have herein been described for producing a security thread that when later incorporated within a currency paper is virtually invisible to the unaided eye when viewed from both sides of the paper under reflected light. The security thread becomes readily visible when viewed with transmitted light from either side of the paper to verify the existence thereof.
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A metallized plastic strip containing security indicia is incorporated within within currency paper to deter counterfeiting. The plastic strip is made difficult to detect under reflected light by selective pigmentation to match the currency inks. The presence of the security indicia is verified by detection under transmitted light.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to offshore technology, and more particularly to the effective extraction of foundations supporting offshore platforms.
BACKGROUND OF THE INVENTION
[0002] Offshore platforms are used extensively for construction of piers and bridges, drilling for natural resources and laying underwater cables. One particular offshore platform is a mobile drilling rig that is mainly used for oil drilling and gas well operations in water depths up to 120 meters. A typical mobile drilling rig has three supporting legs, each leg being able to extend independently through a jacking-up system. The base of each leg comprises a foundation or footing known as a “spudcan”. Nowadays, the foundations of most drilling rigs are equipped with an integrated water jetting system to assist in the extraction of the foundations.
[0003] When the drilling rig is moved to a desired drilling location, the legs of the drilling rig are extended until the foundations rest upon the seabed. Throughout the entire drilling operation, the foundations may penetrate deeply into the seabed, thus experiencing soil resistance therefrom. When the drilling rig needs to be relocated, the legs have to be extracted from the seabed. During this stage, the buoyancy of the drilling rig's hull is utilized to overcome the soil resistance exerted on the foundations. The hull is lowered by the jacking-up system controlling each leg to produce the buoyant force. Furthermore, the integrated water jetting system provides highly pressurized water through the outlets located on the foundation during the extraction process. The water jetting system aims to fluidize the soil surrounding the foundation to facilitate the extraction process. Field observations have shown that conventional water jetting system is unable to provide an effective extraction of the foundation. As such, the extraction rate depends largely on the capacity of the jacking-up system, which is usually limited. In cases where the foundations experience large soil resistance, the jacking-up system is required to operate for a longer period in order to provide sufficient buoyant force to overcome the large soil resistance. This delay is a huge factor for the increasing cost in the industry. Furthermore, continuous extraction attempts to overcome large soil resistance may harm the structural integrity of the drilling rig. Therefore, the extraction process can be considered as one of the critical phases in drilling rig operations.
[0004] U.S. Pat. No. 4,761,096 discloses a universal footing with jetting system for marine platforms and structures. More specifically, the disclosed universal footing comprises a spud-can that functions as a footing base to distribute loadings over a large soil area, and an internal jetting system to fluidize the soil around the footing. Fluidization of the surrounding soil aims to facilitate the penetration of the footing into the seabed and also the extraction of the footing from the seabed. The disclosed universal footing addresses the difficulties encountered during the penetration and retrieval of the footing, but has its drawbacks. For example, the method of distributing pressurized water to fluidize the surrounding soil during extraction could cause channeling effects. Specifically, the jetting system provides pressurized water into the soil through jet nozzle openings located on the spud-can. Some of these nozzle openings could create channeling in the soil once the water pressure is released into the surrounding soil, thereby resulting in a pressure drop at the remaining nozzle openings. Thus, the disclosed universal footing may not fluidize the surrounding soil effectively. Furthermore, studies on soil liquefaction had shown that clayey soil does not fluidize. As such, the disclosed universal footing may not be as effective when deployed in areas with clayey seabed soils.
[0005] In addition, the inventor of U.S. Pat. No. 4,761,096 describes the experimental details of the footing penetration and extraction processes in two publications, namely “A Universal Footing With Jetting” presented in the Offshore Technology Conference in 1987 and “Effect of Jetting on Footing Penetration and Pullout” presented in the International Offshore and Polar Engineering Conference in 1995. The experiments disclosed in the above publications suggest good performance of the universal footing only in limited conditions. For example, the experiments were performed in a test pit containing fine to medium sand with a surface water of depth 0.46 m. The model footing used has a diameter of 0.6 m, a submerged weight of 90 kg and a penetration depth of 1.52 m. This small scale model experimented under 1-g conditions does not provide an accurate simulation of real conditions, wherein the footings deployed have larger diameters and the footing experiences higher levels of stress. In field situations, the footing has diameters ranging from 10 to 25 m and is deployed in water depths up to 120 m. The penetration of the footing can reach up to 20 m in depth. The seabed may also comprise clayey sediments that are less permeable compared to fine and medium sand. As mentioned above, clayey soil does not fluidize. As such, the disclosed experiments do not provide a realistic simulation of the actual field conditions.
[0006] Therefore, there is an imperative need to have an effective and efficient method for extracting the foundation of an offshore platform. This invention satisfies this need by disclosing an improved foundation that is able to minimize the soil resistance so as to facilitate the extraction process. Furthermore, the present invention is designed to be easily implemented into existing offshore platforms. Other advantages of this invention will be apparent with reference to the detailed description.
SUMMARY OF THE INVENTION
[0007] The present invention provides a foundation for use in offshore platforms and a system for extraction the foundation penetrated in a seabed.
[0008] Accordingly, in one aspect, the present invention provides a foundation comprising a body having a base, wherein the body is adapted to receive pressurized fluid; and a plurality of outlets disposed on the base, wherein the plurality of outlets are terminated with an interface layer for allowing pressurized fluid to be released to the base external and preventing the ingress of seabed sediments into the body, whereby the body is configured to provide a uniform distribution of the pressurized fluid to the base external through the plurality of porous outlets, wherein the pressurized fluid released through the plurality of porous outlets increases the pore pressure at the base external, and thereby minimizing the suction on the base.
[0009] In another aspect, the present invention provides a system for extracting an offshore platform foundation penetrated in a seabed, comprising a channel for transferring pressurized fluid to the foundation; a chamber disposed within the foundation, wherein the chamber is adapted to receive pressurized fluid from the channel; and a plurality of outlets disposed on the base of the foundation, wherein the plurality of outlets are terminated with an interface layer for allowing pressurized fluid to be released to the base external and preventing the ingress of seabed sediments into the chamber, whereby the chamber regulates the pressurized fluid received, thereby providing a uniform distribution of the pressurized fluid to the base external via the plurality of porous outlets, wherein the pressurized fluid released through the plurality of porous outlets increases the pore pressure at the base external, thereby minimizing the suction on the base.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Preferred embodiments according to the present invention will now be described with reference to the drawings, in which like reference numerals denote like elements.
[0011] FIG. 1 illustrates a cross-sectional side view of a foundation.
[0012] FIG. 2 illustrates a bottom view of a foundation comprising a plurality of outlets according to one embodiment of the present invention.
[0013] FIG. 3 illustrates a cross-sectional side view of an outlet with an interface material according to one embodiment of the present invention.
[0014] FIG. 4 illustrated an alternative bottom view of a foundation comprising a plurality of outlets according to another embodiment of the present invention.
[0015] FIG. 5 illustrates the contribution of the suction force and the overlying soil resistance to the net soil resistance of a penetrated foundation, with respect to the operation period.
[0016] FIG. 6 illustrates the behavior of the pore pressure at the base of the foundation without the application of an external pressure.
[0017] FIG. 7 illustrated the behavior of the pore pressure at the base of the foundation under the application of an external pressure.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention may be understood more readily by reference to the following detailed description of certain embodiments of the invention.
[0019] Throughout this application, where publications are referenced, the disclosures of these publications are hereby incorporated by reference, in their entireties, into this application in order to more fully describe the state of art to which this invention pertains.
[0020] The present invention provides a foundation for an offshore platform that enables the extraction process to be performed effectively and efficiently. In one embodiment, the foundation 1 comprises an upper body 10 and a lower body 20 , wherein the upper body 10 and lower body 20 have a frustum shape (see FIG. 1 ). It should be understood by one skilled in the art that the foundation 1 can take on other shapes. For instance, a caisson is contemplated. The base 22 of the lower body 20 , which also refers to as the base 22 of the foundation 1 , comprises a plurality of outlets 24 and a spigot 26 . A chamber 30 is located within the lower body 20 , wherein the chamber is configured to receive pressurized fluid 60 , for example water. The pressurized fluid 60 is supplied from a source (not shown) located at the hull of the offshore platform to the foundation 1 via a pipeline 40 , wherein the pipeline is connected to the upper body 10 . In specific, the pressurized fluid 60 from the pipeline 40 is channeled to the chamber 30 via a plurality of conduits 12 , wherein the conduits are disposed in the upper body 10 of the foundation 1 .
[0021] When the pressurized fluid 60 is channeled to the chamber 30 , the pressurized fluid is regulated in the chamber and distributed uniformly over the plurality of outlets 24 . The height and base area of the chamber 30 is configured to ensure the proper regulation and uniform distribution of pressurized fluid 60 over the plurality of outlets 24 . Furthermore, the chamber is preferably made from materials that are able to withstand high pressure, for example steel. In existing foundations 1 , the internal framework of the lower body 20 is typically composed of several compartments or cubicles. These compartments can be interconnected to form the chamber 30 . Furthermore, the interconnected compartments allow equalization of the pressurized fluid 60 received by each compartment. This ensures the uniform distribution of pressurized fluid 60 through the plurality of outlets 24 .
[0022] In a preferred embodiment, the plurality of outlets 24 are disposed at the base 22 of the foundation 1 in an arrangement illustrated in FIG. 2 . Each of the outlets 24 is adapted to terminate with an interface material 50 , for example porous metal (see FIG. 3 ). The interface material 50 acts as a membrane that allows the transfer of pressurized water through the outlet 24 to the external of the base 22 , and prevents the ingress of seabed sediments into the chamber 30 . Furthermore, the interface material 50 must be able to withstand the pressure exerted by the soil surrounding the base of the foundation during the entire operation period. The interface material 50 is preferably made from porous materials with a pore size smaller than clay particles, for example steel. In an alternative embodiment, four triangular outlets 24 ′ are arranged at the base 22 (see FIG. 4 ). The outlets 24 ′ are also adapted to terminate with the interface material 50 . The arrangement and number of outlets can be manipulated to provide effective transfer of pressurized fluid 60 to the external of the base 22 .
[0023] As afore-discussed, the foundations 1 supporting the structural weight of the offshore platform may penetrate deeply into the seabed when they are first lowered. The conical spigot 26 at the base 22 of the foundation 1 provides additional structural stability for the offshore platform. As the foundation 1 penetrates deeply into the seabed, soil deposits on top of the foundation 1 and surrounds the base 22 as well.
[0024] Centrifuge tests were performed to simulate the actual field conditions of the foundation 1 penetrating into clayey seabed. The tests utilize a centrifuge model to overcome the limitations of the 1-g model test adopted in the afore-discussed prior art. In FIG. 5 , a series of tests consistently show that the net soil resistance 110 during the extraction of the foundation 1 consists of two main components: the suction 112 of the soil at the base of the foundation 1 and the overlying soil resistance 114 at the top of the foundation. In particular, suction 112 increases at a much higher rate over a predetermined period of time compared to that of the overlying soil resistance 114 . Over a longer operation period, suction 112 contributes significantly, up to 60%, to the net soil resistance 110 . The present invention minimizes the suction 112 effectively so as to facilitate the extraction process of the foundation 1 .
[0025] In general, the water in the pores of soil is known as pore water. The pressure within the pore water is referred to as the pore pressure. Suction 112 can be defined as negative excess pore pressure with respect to the hydrostatic pressure at the base 22 of foundation 1 . This negative excess pore pressure is induced by the extraction of foundation 1 . Hydrostatic pressure can be referred to as the pore pressure for any given depth where there is no water flow. FIG. 6 illustrates the behavior of the pore pressure at the base 22 , wherein pore pressure at the base increases with depth. Experimental studies on the present invention have shown that a portion of the extraction-induced excess pore pressure in the soil surrounding the base 22 of the foundation 1 transforms into suction 112 . The magnitude of suction 112 depends on the pore pressure prior to the extraction of the foundation 1 . Referring again to FIG. 6 , the pore pressure at the base 22 increases during the penetration of the foundation 1 into the seabed, wherein the foundation stabilizes at a stage 210 . Thereafter, the pore pressure starts to dissipate during an extended operation period until it reaches a level proximal to the hydrostatic pressure, as shown in stage 220 . When the foundation 1 is extracted during stage 220 , the extraction-induced excess pore pressure transforms into suction 112 . Continual uplift of the foundation 1 is required to overcome the maximum suction 112 at stage 230 , followed by the remaining overlying soil resistance 114 until the foundation 1 can be fully extracted at stage 240 .
[0026] The present invention improves the extraction of the foundation 1 by increasing the pore pressure at the base 22 prior to the extraction, and supplying pressure throughout the extraction process to compensate for the suction 112 that would have developed at the base 22 . As such, an external pressure needs to be supplied at the base 22 to build up the pore pressure at the base external. Preferably, the pore pressure is accumulated to the maximum level as shown in stage 250 of FIG. 7 when the extraction starts. This provides for an initial pressure that is sufficient to compensate for the negative pressure (suction 112 ) that is generated during the extraction process.
[0027] The pressurized fluid 60 acts as a means for the transferring the external pressure to the base 22 . Pressurized fluid 60 is first supplied to the chamber 30 from the pipeline 40 via the plurality of conduits 12 . The chamber 30 regulates the pressurized fluid 60 received and provides a uniform distribution of the pressurized fluid through the plurality of outlets 24 . The pressurized water transferred to the base 22 external builds up the pore pressure of the soil surrounding the base 22 . Furthermore, the uniform distribution of pressurized water through the plurality of outlets 24 minimizes any channeling effects that may result from the water jetting system discussed above. The size and arrangement of the plurality of outlets are designed to ensure that the coverage area of the pressurized fluid 60 released from one outlet overlaps the neighboring outlets. This ensures that the pore pressure build-up over at the entire base 22 . Pressure sensors (not shown) can be mounted at the base 22 to monitor the pressure thereof.
[0028] While the present invention has been described with reference to particular embodiments, it will be understood that the embodiments are illustrative and that the invention scope is not so limited. Alternative embodiments of the present invention will become apparent to those having ordinary skill in the art to which the present invention pertains. Such alternate embodiments are considered to be encompassed within the spirit and scope of the present invention. Accordingly, the scope of the present invention is described by the appended claims and is supported by the foregoing description.
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The present invention provides a foundation that facilitates the extraction process by minimizing the soil resistance. When the foundation is lowered onto a seabed, it penetrates the seabed and experiences soil resistance therefrom. In particular, the suction generated at the base of the foundation contributes significantly to the soil resistance. The foundation is configured to uniformly distribute pressurized fluid to the base external via a plurality of outlets. The outlets are terminated with an interface layer to allow the transfer of pressurized fluid to the base external and prevent the ingress or seabed sediments into the body. The pressurized fluid released to the base external increases the pore pressure at the base external, thus minimizing the suction at the base.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to adhesive skin coverings and methods, and more particularly, to such coverings and methods for protecting a mark on a person's skin, such as a temporary tattoo applied to a person's skin for use in radiation therapy.
BACKGROUND
[0002] Temporary marks are frequently applied to a patient's skin in preparation for extended treatment programs, such as radiation therapy. Such marks are particularly critical for ensuring that treatment, such as applied radiation, is precisely focused on the appropriate area of the patient's body, and may be made with markers, pens, or other marking means.
[0003] In the particular example of radiation therapy, before commencing treatment, a planning session (sometimes called a “simulation”) is held, in order to plan the treatments and to determine the areas where the radiation will be delivered. The simulation session is generally conducted by a radiation oncologist, aided by one or more radiation therapists and often a dosimetrist, who performs the calculations and measurements necessary in the treatment planning. The simulation may last anywhere from fifteen minutes to an hour or more, depending on the complexity of the treatment.
[0004] During a simulation, a patient lies on a table, and a machine or a “simulator” is used to establish the areas, or “treatment fields,” where radiation will be applied. The simulator is a tool that allows the radiation oncologist and therapist to observe the area to be treated, and the simulator's dimensions and movements closely match those of a linear accelerator. The simulation may, for example, be guided by fluoroscopy or CAT scan to observe the patient's internal anatomy, and the table upon which the patient rests can be raised and lowered, and rotated around a central axis.
[0005] During the simulation, marks are made on the patient's skin with magic markers, paint pens, or other suitable means (e.g., carbolfushin). These marks are very important because they enable precise and consistent positioning of the patient so as to ensure that the treatment radiation is properly directed to the appropriate treatment area, and the radiation therapist uses the marks in each subsequent session as a guide during the radiation treatment. The treatment plan and treatment fields prepared during the simulation session are verified, and radiation treatment is begun only after the radiation oncologist and therapists have confirmed the treatment field and calculations, and are satisfied with the setup.
[0006] Radiation therapy requires reproducibility over a number of days, weeks or even months, and the temporary marks must remain in positions established on the patient's skin after they are set during the simulation. However, given their temporary nature, such marks may be smudged, worn or erased after their initial application or between treatment sessions for a number of reasons, including washing or bathing, friction created by contact with a patient's clothing, or others. If the temporary marks are lost, the patient must undergo a new simulation in order to reestablish the treatment field and receive new temporary marks. Subsequent simulations are both inefficient and undesirable because they can waste time, money and resources, and unnecessarily prolong the treatment process.
[0007] Recent attempts to protect or maintain marks on a patient's skin have achieved limited success in overcoming the shortcomings of the prior art. For example, tiny permanent pinprick dots, sometimes called “tattoos,” can be used in place of the temporary marks. Such permanent tattoos may be particularly advantageous in extended treatment periods because they may enable the therapist to set up treatment fields each day with precision, and the patient is allowed to wash and bathe without worrying about altering the treatment fields. However, there remain instances in which temporary marks are preferable to permanent tattoos. Such situations may include when a patient (e.g., a child) refuses to receive the pinprick associated with a permanent tattoo, or when the treatment field is highly visible (e.g., the patient's neck or face) and a permanent marking is not desirable. Additionally, the patient's skin color may make visibility of the tattoos difficult, and when it is likely that the treatment field will require subsequent modification, a permanent tattoo may not be appropriate. Moreover, unlike permanent tattoos, the use of temporary marks is largely unrestricted, as they provide greater ease, flexibility, freedom in use and margin for error in establishing treatment fields, and can be easily established or relocated. Temporary marks also may be shaped or sized as needed to effectively define a treatment field without permanently blemishing a patient's skin. Thus, it is often preferable to utilize temporary marks in establishing treatment areas or fields, and to attempt to cover or protect such marks from wear or erasure throughout the treatment cycle.
[0008] However, maintaining a temporary mark in place on a patient's skin over an extended period of time (e.g., over a multi-day or multi-week, such as a typical six-week, radiation treatment cycle) can be challenging. Some radiation therapists and facilities cover temporary marks using adhesive composites (e.g., Tegaderm®), tape, wound spray, stickers, or the like. For example, some radiation therapists use Tegaderm, which is commercially available in the form of framed sheets of predefined dimensions (e.g., approximately two inch by three inch sheets). In order to be more effectively used, these framed Tegaderm sheets generally must be manually cut and/or otherwise shaped by the radiation therapist, which can be time-consuming and inefficient. Additionally, once the associated frame is compromised, the Tegaderm material is not easily manipulated, because the material is very thin, and often wrinkles or folds over itself so that effective application is significantly inhibited. Similarly, the drawbacks associated with other conventional covering techniques are found in the handling of the covering materials, the application of the covering materials and/or the reliability or the lack of durability associated with the covering materials.
[0009] U.S. Patent Publication No. 2006/0111656 A1 to Broyles, which is assigned to the Assignee of the present invention, and is hereby incorporated by reference in its entirety as part of the present disclosure, discloses a temporary tattoo cover and related method. The cover comprises an opaque layer superimposed over an adhesive-backed transparent layer. The cover is applied to a mark, such as temporary tattoo on a person's skin, with the transparent layer adhered to the skin and overlying the mark to be covered. Once the cover is in place, the opaque layer is removed, and the transparent layer remains adhered to the skin and overlying the mark. However, one of the drawbacks associated with this type of cover is that the opaque layer covers the underlying transparent layer, and thus prevents the practitioner from easily viewing the underlying mark when applying the cover thereto. Another drawback associated with this type of cover is that the opaque layer is formed by two parts separated along a seam. In order to remove the opaque layer, the practitioner is required to pick at the seam in order to separate one half of the opaque layer from the other, and to then peel away the two halves of the opaque layer. At times, this process of removing the opaque layer can be more complicated and/or time consuming than otherwise desired.
[0010] It is an object of the present invention to overcome one or more of the above-described drawbacks and/or disadvantages of the prior art.
SUMMARY OF THE INVENTION
[0011] In accordance with a first aspect, the present invention is directed to a cover that is releasably attachable to a person's skin having thereon a temporary tattoo or other marking for covering the marking and allowing the underlying marking to be visible therethrough. The cover comprises a first flexible layer that is adhesively attachable to the person's skin over the temporary tattoo or other marking substantially without wrinkling. The first layer defines a first lower surface including an adhesive thereon that is releasably engageable by the adhesive with the person's skin in a position overlying the marking, an opposing first upper surface, and a substantially transparent portion that allows viewing of the underlying marking therethrough. A second layer is superimposed on the first layer. The second layer defines a second lower surface releasably adhered to the upper surface of the first layer, an opposing second upper surface, and a viewing window allowing viewing of the underlying marking through the second layer and the substantially transparent portion of the first layer. The second layer is sufficiently firm in comparison to the first layer to at least substantially maintain its shape under its own weight and the weight of the first layer.
[0012] In some embodiments of the present invention, the second layer extends about a peripheral region of the underlying first layer, and the viewing window extends throughout an inner portion of the second layer. In some such embodiments, the viewing window is defined by an aperture extending through the second layer. In some such embodiments, the second layer further defines a gap extending between the viewing window and a peripheral edge thereof. In some embodiments, the viewing window is defined by a first aperture, and the gap is defined by a second aperture formed through the second layer and extending between the peripheral edge and the first aperture. In some embodiments, the viewing window further defines a gap extending from an inner portion of the second layer to a peripheral edge thereof. In some embodiments of the present invention, the second layer is substantially opaque, and the first layer is substantially transparent throughout.
[0013] In some embodiments of the present invention, the cover defines an oblong peripheral shape and the viewing window defines a substantially linear, axially elongated shape. In some such embodiments, the cover defines two elongated, approximately straight edges located on opposites sides of the cover relative to each other, and two curvilinear edges located on opposite ends of the cover relative to each other and extending between the opposing elongated edges. In some such embodiments, the viewing window is defined by an axially elongated aperture extending approximately parallel to the opposing approximately straight edges from proximate one curvilinear edge to at least proximate the other curvilinear edge. In some such embodiments, the viewing window forms a gap extending through one of the curvilinear edges. In other embodiments of the present invention, the cover defines a substantially curvilinear peripheral shape and the viewing window defines a substantially curvilinear shape in an approximately central portion thereof. The covers may define any of a variety of shapes, including without limitation a substantially circular shape, a substantially oval shape, a substantially rectangular shape, a substantially oblong shape, a substantially curvilinear shape, a substantially elliptical shape, and a substantially rectilinear shape.
[0014] In accordance with another aspect, the present invention is directed to a device including a plurality of covers, and a continuous carrier substrate defining an uninterrupted releasable surface thereon. The plurality of covers are axially spaced relative to each other on the releasable surface of the carrier substrate, and each adhesive lower surface is releasably superimposed on the releasable surface of the carrier substrate. Preferably, the first and second layers of each cover define a predetermined peripheral shape and a maximum diameter or width that is sufficiently small to manually grip and remove the respective cover from the releasable surface of the carrier strip and, in turn, manually adhere the first layer to the person's skin in a position overlying the marking without substantially wrinkling the first layer.
[0015] In accordance with another aspect, the present invention is directed to a cover that is releasably attachable to a person's skin having thereon a temporary tattoo or other marking for covering the marking and allowing the underlying marking to be visible therethrough. The cover comprises first means for releasably and conformably attaching to the person's skin over the temporary tattoo or other marking substantially without wrinkling in a position overlying the marking and for allowing the underlying marking to be visible therethrough. The cover further includes second means superimposed on and releasably attached to the first means for substantially maintaining its shape under its own weight and the weight of the first means, and for releasably attaching the first means to the person's skin over the marking substantially without wrinkling the first means. Third means are provided for allowing viewing of the underlying marking through the second means.
[0016] Some embodiments of the present invention further include fourth means for facilitating manually engaging the second means and removing the second means from the first means after releasably attaching the first means to the skin. In some embodiments of the present invention, the first means is a first substantially transparent, flexible, adhesive backed layer; the second means is a second substantially opaque, relatively firm layer in comparison the first layer; the third means is a viewing window formed on the second layer; and the fourth means is a gap formed in the second layer and extending between the viewing window and a peripheral edge thereof.
[0017] In accordance with another aspect, the present invention is directed to a method for releasably attaching a cover to a person's skin having thereon a temporary tattoo or other marking for covering the marking and allowing the underlying marking to be visible therethrough. The method comprises the following steps:
[0018] (i) providing a cover including a first, flexible, adhesive-backed layer having at least a portion thereof that is substantially transparent, and a second layer superimposed on the first layer and including a viewing window;
[0019] (ii) viewing the underlying marking through the viewing window of the second layer and the substantially transparent portion of the first layer;
[0020] (iii) manually placing the adhesive-backed surface of the first layer of the cover onto the person's skin;
[0021] (iv) manually pressing the first layer of the cover toward the skin and, in turn, adhesively attaching the first layer of the cover to the skin without substantially wrinkling the first layer; and
[0022] (v) removing the second layer from the first layer.
[0023] The method preferably further comprises substantially aligning the underlying marking with the viewing window; and manually placing the adhesive-backed surface of the first layer of the cover onto the person's skin in the substantially aligned position overlying the marking. Some embodiments of the present invention further comprise providing a second layer of the cover defining a gap extending between the viewing window and a peripheral edge of the cover, and manually engaging the peripheral edge of the second layer adjacent to the gap and removing the second layer from the first layer adhesively attached to the skin.
[0024] Some embodiments of the present invention further comprising the following steps:
[0025] positioning the person with respect to a simulation machine suitable to establish one or more radiation treatment fields;
[0026] setting at least one treatment field via the simulation machine;
[0027] utilizing at least one marking made on the patient's skin to position the patient for treatment; and
[0028] adhesively attaching the first layer of at least one cover in a position overlying the respective marking.
[0029] Some embodiments of the present invention further comprise (i) providing a cover defining an axially elongated viewing window, and substantially aligning the axially elongated viewing window with a linear marking; and/or (ii) providing a cover defining a curvilinear viewing window, and substantially aligning an approximately central portion of the viewing window with an approximately central portion of the marking.
[0030] One advantage of the present invention is that the viewing window allows the underlying tattoo or other marking to be viewed through the cover, and thus facilitates properly aligning the cover with the underlying tattoo or other marking. Another advantage of the currently preferred embodiments of the present invention, is that second layer is formed in one piece, and the gap in the second layer facilitates the ability of a practitioner to manually grip the second layer and remove the second layer after the first layer is adhesively attached to the skin. Yet another advantage of the present invention is that the second layer facilitates the ability to adhesively attach the first layer to the skin substantially without wrinkling thereof.
[0031] These and other advantages of the present invention, and/or of the currently preferred embodiments thereof, will become more readily apparent in view of the following detailed description of the currently preferred embodiments and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a top plan view of a first embodiment of a temporary tattoo cover of the present invention defining a substantially circular shape;
[0033] FIG. 2 is an exploded perspective view of the temporary tattoo cover of FIG. 1 showing the underlying transparent layer, and the overlying ring-shaped opaque layer defining an approximately central viewing window and a gap extending between the viewing window and a peripheral edge to facilitate manually engaging the overlying layer;
[0034] FIG. 3 is a top plan view of an exemplary variation of the temporary tattoo cover of FIG. 1 including crosshairs marked on the underlying transparent layer that may be aligned with an underlying tattoo or other marking on the person's skin;
[0035] FIG. 4 is a perspective view of a plurality of the temporary tattoo covers of FIG. 1 axially spaced relative to each other on an axially-elongated, releasable substrate provided in strip form, such as on a roll, and showing an exploded view of one cover;
[0036] FIG. 5 is a top plan view of the plurality of temporary tattoo covers of FIG. 4 on the releasable substrate;
[0037] FIG. 6 is a top plan view of another embodiment of a temporary tattoo cover of the present invention defining an oblong shape, and including an axially-elongated viewing window that is particularly suitable for viewing and alignment with elongated, such as linear shaped, temporary tattoos or other markings;
[0038] FIG. 7 is a perspective view of a plurality of the temporary tattoo covers of FIG. 6 axially spaced relative to each other on an axially-elongated, releasable substrate provided in strip form, such as on a roll, and showing an exploded view of one cover;
[0039] FIG. 8 is a perspective view of the temporary tattoo cover of FIG. 1 adhesively attached to a person's skin with an underlying cross-shaped marking “M” on the skin aligned with the viewing window, and showing a user's fingers manually engaging the overlying cover at the gap to remove the cover;
[0040] FIG. 9 is a perspective view of the temporary tattoo cover of FIGS. 6 and 7 adhesively attached to a person's skin with an underlying linear-shaped marking “M” on the skin aligned with the viewing window, and prior to manual engagement and removal of the overlying layer;
[0041] FIG. 10 is a top plan view of another embodiment of a temporary tattoo cover of the present invention including a printed circular indicia thereon to facilitate locating and aligning the cover with a temporary tattoo or other marking on the skin, and illustrating a plurality of such covers mounted on a strip including a releasable backing; and
[0042] FIG. 11 is a top plan view of another embodiment of a temporary tattoo cover of the present invention including printed crosshairs thereon, wherein the inner ends of the crosshairs are spaced relative to each other to facilitate viewing an underlying temporary tattoo or other marking therethrough and aligning the crosshairs with the marking.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0043] In FIGS. 1 through 5 , a temporary tattoo cover embodying the present invention is indicated generally by the reference numeral 110 . The cover 110 is particularly appropriate for covering and protecting marks made on the skin, for example, in preparation for radiation therapy. However, the cover 110 herein described may be used in any application wherein a marking is made to a person's skin, and wherein it is desired to protect the marking from wear, removal or erasure caused by interaction with water, friction, other external elements or any other source.
[0044] As is shown in FIGS. 1 through 5 , the cover 110 comprises a first or underlying layer 112 and a second or overlying layer 120 . The first layer 112 comprises a first upper surface 114 , a first lower surface 116 , and a first peripheral edge 118 . The first layer 112 is sufficiently transparent or translucent to allow viewing of an underlying tattoo or other marking therethrough. Like the first layer 112 , the second layer 120 comprises a second upper surface 122 , a second lower surface 124 , and a second peripheral edge 126 . The second layer 120 further defines a viewing window 128 , which in the illustrated embodiment is defined by an aperture formed through the second layer. The second layer 120 further defines a gap 132 that extends laterally from the window 128 to the second peripheral edge 126 , and the gap 132 forms two opposing edges radially spaced relative to each other to facilitate manually engaging and removing the second layer 120 from the first layer 112 , as is described further below.
[0045] During operation, the cover 110 may be applied over a skin mark of any kind. A user may orient the cover 110 over the mark by sighting the mark through the transparent first layer 112 and the window 128 of the second layer 120 , and affixing the cover 110 to the person's skin. The first layer 112 adhesively attaches to the person's skin over and around the mark, substantially without wrinkling the first layer, the underlying skin or the mark itself. Once the cover 110 is appropriately positioned over the mark, the second layer 120 is removed, and the first layer 112 remains in place over the marking.
[0046] As is shown in FIGS. 1 through 5 , the first layer 112 is defined by a first peripheral edge 118 and two substantially planar surfaces: a first lower surface 116 , which contacts the skin with an adhesive coating thereon, and an opposing first upper surface 114 , which releasably adheres to the second lower surface 122 of the second layer 120 . In the illustrated embodiment, the planar surfaces 114 , 116 and the first peripheral edge 118 of the first layer 112 form a substantially circular or disc-like shape. However, as may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, the covers of the present invention may define any of numerous different shapes or configurations that are currently known, or that later become known.
[0047] The first layer 112 preferably conforms to anatomical surfaces by flexibly conforming in a complementary fashion with the underlying skin. Although the first layer 112 may be formed from a variety of different materials and/or composites, particularly well-suited materials for use in forming the first layer 112 include elastomeric polyurethane films or the like, which provide the preferred properties of resiliency, high moisture vapor permeability and at least substantial transparency or translucency, and do not irritate the underlying skin. Examples of suitable commercially available materials for use in forming the first layer 112 include 3M 9841 and 3M 9832 polyurethanes available from Minnesota Mining and Manufacturing Co., which are thin, hypoallergenic, fluid resistant, transparent and conformable to various anatomical surfaces. The first layer 112 also may be a composite of two or more sub-layers, such that the first upper surface 114 is defined by one sub-layer providing specific material characteristics while the first lower surface 116 of the second layer 120 is defined by another sub-layer providing the same or different material characteristics. For example, 3M 9841 polyurethane and 3M 9832 polyurethane may be laminated together to form a composite first layer 112 .
[0048] The adhesive suitable for use with the first lower surface 116 can be any conventional adhesive typically used in skin-contacting applications. Exemplary adhesives are disclosed in U.S. Pat. Nos. Re. 24,906, 3,389,827, 4,112,213, 4,310,509, 4,323,557, and 4,737,410. One suitable adhesive transmits moisture vapor at a rate greater than or equal to that of human skin. Additionally, the adhesive on the first lower surface 116 also permits the cover 110 to be mounted on a releasable backing and protected during non-use. The backing materials may include without limitation any of numerous different paper-based products, polypropylene, polyethylene, polyester or any combination of these materials. The releasable backings facilitate transportation and storage when the cover 110 is not in use. If desired, one or more covers 110 may be stored in sheets or rolls, and adapted for ready dispensation when needed.
[0049] The first upper surface 114 of the underlying layer 112 is preferably free of adhesives. However, if desired, the first upper surface 114 may be provided with a low-adhesion coating, such as a solution of polyvinyl n-octadecyl carbamate, as disclosed, for example, in U.S. Pat. No. 2,532,011. However, it will be readily understood by those skilled in the pertinent art that any of a variety of other coatings that are suitable for providing appropriate low-adhesion properties or a low-adhesion bond equally may be used.
[0050] As is shown in FIGS. 1 through 5 , the second layer 120 is defined by a second peripheral edge 126 and two substantially planar surfaces: a second lower surface 124 , which releasably adheres to the first upper surface 114 , and an opposing second upper surface 122 . The second layer 120 also defines the substantially centrally located viewing window 128 , and the gap 132 extending from the window 128 to the second peripheral edge 126 . The gap 132 provides greater visibility for aligning marks while placing the cover 110 into position, and facilitates the removal of the second layer 120 from the first layer 112 once the cover is applied to a person's skin, preferably enabling a user to peel back the second layer 120 from the first layer 112 . Although the viewing window 128 is substantially circular, and the gap 132 is substantially straight and extends radially between the viewing window 128 and peripheral edge 126 , these features may take any of numerous different shapes and/or configurations that are currently known or that later become known. For example, the gap 132 may be curvilinear, or the second layer 120 may define plural gaps or may not define any gaps at all. The inclusion of the gap and/or the characteristics thereof may be selected based on any of a variety of factors, such as the size and location of the mark on the person's skin, the intended therapy or procedure to be performed, or any other criteria.
[0051] Also in the illustrated embodiment, the surfaces 122 , 124 and the second peripheral edge 126 of the second layer 120 define a second substantially circular or disc-like shape, and the window 128 is also substantially circular. As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, the window may take any of numerous different shapes and/or configurations that are currently known or that later become known. For example, the shape of the window 128 may be varied to accommodate skin marks of various sizes and shapes. In addition, the window 128 may encompass any proportion of the second layer 120 , based on the desired use of the cover 110 or other factors.
[0052] The second layer 120 is preferably substantially stiffer than, or relatively rigid in comparison to, the first layer 112 , and preferably cooperates with the first layer 112 so as to maintain the integrity of the cover 110 during both handling and application. Suitable materials for use in forming the second layer 120 include, but are not limited to, silicone-coated papers, polyethylene/vinyl acetate copolymer-coated papers and polyester or polyurethane films. Those skilled in the pertinent art will readily recognize from the present disclosure that any of a variety of other materials and/or combinations thereof equally may be utilized in forming the second layer 120 .
[0053] The first upper surface 1 14 and the second upper surface 122 may be suitable for printing, so as to allow information to be communicated thereon. For example, product information may be provided on the first upper surface 114 so as to allow for ready recognition of the product source (e.g., a trademark). Additionally, drawings, sketches or alphanumeric characters may be provided on either the first upper surface 114 or the second upper surface 122 for any purpose, such as to comfort a wearer, especially a child, during the medical procedure.
[0054] In addition to letters, numbers, prints and the like, the first layer 1 12 and/or the second layer 120 may be marked with any of various indicia, including rings, lines or portions thereof, to aid the user in locating the mark prior to applying the cover 110 to the person's skin, aligning the window and/or cover with the underlying marking, and/or to aid a subsequent user in locating a marking beneath a cover that already has been applied to the person's skin. Such indicia may include crosshairs, rings, concentric rings, or portions thereof, or any other markings for a variety of purposes that are currently known, or that later become known. For example, the exemplary variation of the cover of FIG. 3 comprises crosshairs 134 that are printed on the first layer 1 12 and intersect at the approximate center of the first layer within the window 128 . Indicia such as crosshairs 134 may be used to accurately position the cover 110 over a marking on a person's skin to align the window and cover with the underlying marking, and also aid in locating the covered marking during treatment. If desired, the crosshairs 134 or other indicia may be applied to one or both of the underlying and overlying layers. In addition, the color or type of indicia may be selected based on a number of factors, including the color or tone of the person's skin; the color, type, or style of marking to be covered; or the application for which the cover 110 is to be used. For example, dark-colored indicia may be printed on a first layer 112 which is intended to be applied to a temporary mark on a fair-skinned person (i.e., the indicia is darker than the person's skin to visually contrast therewith), whereas relatively light-colored indicia, such as white, yellow, green, turquoise, bright versions of the foregoing colors, and/or fluorescent-colored indicia, may be printed on a cover 110 which is intended for use on a person with darker skin (i.e., the indicia is lighter and/or brighter than the person's skin to visually contrast therewith). In one such embodiment, indicia in the form of a “plus sign” (i.e., “+”) is printed on the underlying layer within the viewing window, and the color of the indicia is white, lime green, or other light, bright, or fluorescent color, for enhancing the visual contrast between the indicia and relatively dark skin, such as brown or black. Accordingly, one advantage of such embodiments of the present invention is that the coloration of the indicia on the first or underlying layer that is adhesively attached to the skin is selected to contrast with the color of the skin to facilitate viewing the marking, or the indicia of the cover overlying the marking, and to visually distinguish the marking, or the indicia aligned with and covering the marking, from the surrounding skin, during, for example, a radiation therapy treatment.
[0055] In the illustrated embodiment, the second peripheral edge 128 is substantially coincident or coterminal with the first peripheral edge 118 of the first layer 112 , corresponding to the substantially equal sizes of the first layer 112 and the second layer 120 . However, the second peripheral edge 128 , or a portion thereof, such as a portion forming a tab, may extend beyond the first peripheral edge 118 , so as to facilitate the manual removal of the second layer 120 from the first layer 112 . For example, a portion of the second layer 120 may form a tab or other extension which enables a user to easily remove the cover 110 from a releasable backing prior to application, and also to remove the second layer 120 from the first layer 112 after the cover 110 has been applied.
[0056] The second lower surface 124 of the second layer 120 may be provided with a low-adhesion coating such as, for example, a solution of polyvinyl n-octadecyl carbamate as disclosed, for example, in U.S. Pat. No. 2,532,011, for effectuating an appropriate bond between the first upper surface 114 of the first layer 112 and the second lower surface 124 of the second layer 120 . It will be readily apparent to those skilled in the pertinent art from the present disclosure that any of a variety of other coatings suitable for providing appropriate low-adhesion properties equally may be used. In addition, as indicated above, the first upper surface 120 of the first layer 112 also may be provided with any of a variety of different adhesives for purposes of accomplishing any of a variety of objectives.
[0057] The bond between the second lower surface 124 and the first upper surface 114 is preferably stronger than the bond between the first lower surface 116 and a releasable backing that may be provided to store or transport the cover 110 when not in use. This difference in bond strength preferably ensures that the second layer 120 remains adhered to the first layer 112 when the cover 110 is removed from such backing. Conversely, the bond between the first lower surface 118 and a person's skin is preferably stronger than the bond between the second lower surface 124 and the first upper surface 120 , ensuring that the first layer 112 will remain in place on the person's skin when the second layer 120 is removed.
[0058] In the illustrated embodiment, the first layer 112 and second layer 120 are of substantially equal thickness. Preferably, the first layer 112 has a thickness of about 0.02 millimeters to about 0.04 millimeters, while the second layer 120 has a thickness of about 0.02 millimeters to about 0.08 millimeters, although the thicknesses of the first layer 112 and second layer 120 may be modified for different applications or purposes as desired. Because the second layer 120 is preferably more rigid than the first layer 112 , a user may manipulate the entire cover 110 by grasping about the second peripheral edge 126 without compromising the integrity of the first layer 112 , prior to and during application of the cover 110 to a person's skin with or without the use of additional structures (e.g., tabs). This arrangement maintains the integrity of the first layer 112 via the relative rigidity of the second layer 120 during both handling and application, because the first layer 112 is prevented from becoming folded, wrinkled or otherwise compromised by the second layer 120 when the cover 110 is removed from its backing for positioning and ultimate application to a person's skin. Consequently, the arrangement also provides for an improved adhesion between the first layer 112 and the person's skin, as wrinkles, creases, punctures and/or other adhesion imperfections are substantially reduced or eliminated. In substantially circular or like curvilinear embodiments of the cover 110 , the first layer 112 and the second layer 120 preferably define a width or diameter within the range of about 10 millimeters to about 40 millimeters, and more preferably within the range about 20 millimeters to about 30 millimeters. However, the dimensions of the cover 110 of the present invention may be modified for different applications or purposes as desired.
[0059] As is shown in FIGS. 4 and 5 , the adhesive on the first lower surface 116 of the first layer 112 permits the cover 110 to be affixed to a releasable backing material during storage or transportation, such as an axially-elongated substrate 136 . If desired, a single cover 110 may be applied to a single respective backing, or plural covers 110 may be applied to the same backing, which may be stored in a sheet-like form, rolled or otherwise maintained for ready dispensation and use. Preferably, the backing may be a continuous carrier substrate 136 defining a releasable surface thereon, with a plurality of covers 110 axially spaced relative to each other on the releasable surface of the continuous carrier substrate 136 . More preferably, the first and second layers of each cover 110 define a predetermined peripheral shape and a maximum width that is sufficiently small to manually grip and remove a cover 110 from the substrate 136 , and manually apply the first layer 112 to a person's skin. Further, the sheet-like form may enable mass production of covers 110 through, for example, mechanical processes which apply the first layer 112 and the second layer 120 to a substrate 136 in a series of operations, or all at once.
[0060] Although the covers 110 described in FIGS. 1 through 5 are substantially circular, the scope of the present invention is not limited to such embodiments, and other shapes may be used. The covers of the present invention may take any of numerous different shapes that are currently known, or that later become known, including without limitation, substantially rectangular, substantially oblong, substantially oval, substantially triangular, or any other curvilinear or rectilinear shape. Criteria for selecting the shape of the cover may include the size and location of the mark on the person's skin, the intended therapy or procedure to be performed, and others. In the context of radiation therapy, substantially circular covers (such as those shown in FIGS. 1 through 5 ) may be appropriate for covering three-point set-ups, isocenters, corners of field borders, or match lines.
[0061] Turning to FIGS. 6 and 7 , another embodiment of a cover of the present invention is indicated generally by the reference numeral 210 . The cover 210 is substantially similar to the cover 110 described above, and therefore like reference numerals preceded by the numeral “2” instead of the numeral “1” are used to indicate like elements.
[0062] The primary difference of the cover 210 in comparison to the cover 110 described above, is that the cover 210 is oblong shaped. More specifically, the cover 210 defines two elongated, approximately straight edges 219 located on opposites sides of the cover relative to each other, and two curvilinear edges 221 located on opposite ends of the cover relative to each other and extending between the opposing elongated edges 219 . The viewing window 232 of the second or overlying layer 220 is defined by an axially elongated aperture extending approximately parallel to the opposing approximately straight edges 219 from proximate one curvilinear edge 221 to the opposite curvilinear edge 221 forming a gap extending through the edge.
[0063] The cover 210 may be applied to a person's skin and utilized in the same or substantially similar manner as the substantially circular cover 110 described above. However, the cover 210 may be more appropriate than the cover 110 when the mark to be covered is axially elongated or linear shaped. In the context of radiation therapy, a substantially oblong cover such as the cover 210 may be particularly appropriate for covering election breast borders, match lines, leveling lines or spine fields. Additionally, the cover 210 may define a width within the range of about 10 millimeters to about 40 millimeters, and more preferably within the range of about 30 millimeters to about 60 millimeters. However, as may be recognized by those of ordinary skill in the pertinent art, these dimensions are only exemplary, and any of numerous dimensions equally may be employed.
[0064] In practice, a radiation therapist or other user may preserve a mark by utilizing the cover 110 or the cover 210 of the present invention to cover a mark that was applied to a patient in preparation for treatment, such as during a simulation, thereby ensuring that the relevant treatment areas are consistently and properly maintained among different treatment sessions. Covers 110 , 210 can be replaced as needed at any time during the therapy treatment period (e.g, at week three of a six-week treatment) so as to optimize the protective effect provided by such covers.
[0065] Thus, as shown typically in FIGS. 8 and 9 , the currently preferred embodiments of the present invention are directed to a method for releasably attaching a cover 110 , 210 to a person's skin having thereon a mark M thereon, for covering the mark M and allowing the underlying mark M to be visible therethrough. The method comprises (i) providing a cover 110 , 210 including a first, flexible, adhesive-backed layer 112 , 212 having at least a portion thereof that is substantially transparent or translucent, and a second layer 120 , 220 superimposed on the first layer 112 , 212 and including a viewing window 128 , 228 ; (ii) viewing the underlying marking M through the viewing window 128 , 228 of the second layer 120 , 220 and the substantially transparent portion of the first layer 112 , 212 , and substantially aligning the underlying marking M with the viewing window 128 , 228 ; (iii) manually placing the adhesive-backed surface of the first layer 112 , 212 of the cover 110 , 210 onto the person's skin in the substantially aligned position overlying the marking M; (iv) manually pressing the first layer 112 , 212 of the cover 110 , 210 toward the skin and, in turn, adhesively attaching the first layer 112 , 212 of the cover 110 , 210 to the skin without substantially wrinkling the first layer 112 , 212 ; and (v) removing the second layer 120 , 220 from the first layer 112 , 212 .
[0066] As described above, the second layer 120 , 220 of the cover 110 , 210 defines a gap 132 , 232 extending between the viewing window 128 , 228 and a peripheral edge 126 , 226 of the cover 110 , 210 , and the method includes manually engaging the peripheral edge 126 , 226 of the second layer 120 , 220 adjacent to the gap 132 , 232 , as shown typically in FIG. 8 , and removing the second layer 120 , 220 from the first layer 112 , 212 adhesively attached to the skin. Some embodiments further comprise the steps of positioning the person with respect to a simulation machine suitable to establish one or more radiation treatment fields; setting at least one treatment field via the simulation machine; utilizing at least one marking M made on the patient's skin to position the patient for treatment; and adhesively attaching the first layer 112 , 212 of at least one cover 110 , 210 in a position overlying the respective marking M. Some embodiments of the present invention may also comprise providing a cover 110 , 210 defining an axially elongated viewing window 128 , 228 , and substantially aligning the axially elongated viewing window 228 with a linear marking M on a person's skin, or providing a cover 110 , 210 defining a curvilinear viewing window 128 , 228 , and substantially aligning an approximately central portion of the viewing window 128 , 228 with an approximately central portion of the marking M.
[0067] Thus, it will be readily understood by those of ordinary skill in the pertinent art from the present disclosure that the exemplary temporary covers disclosed herein, and corresponding methods of using such covers, are well suited for use in radiation therapy and other treatments. Indeed, the covers and methods of the present invention are well-suited for use in protecting temporary marks, such as temporary tattoos, on patients for an extended period of time during radiation therapy or other treatments. In addition, the covers equally may be used to cover, and facilitate identification of permanent marks, such as permanent tattoos, particularly in applications involving darker skin, such as brown or black skin. In such applications, the covers employing skin-color contrasting indicia, such as white or other relatively light or bright colored indicia as described above, are particularly advantageous with respect to facilitating identification of the permanent tattoo or other indicia.
[0068] Turning to FIG. 10 , another cover embodying the present invention is indicated generally by the reference numeral 310 . The cover 310 is substantially similar to the cover 110 described above in connection with FIGS. 1 through 5 , and therefore like reference numerals preceded by the numeral “3” instead of the numeral “1” are used to indicate like elements. The primary difference of the cover 310 in comparison to the cover 110 is that the cover 310 includes a circular indicia 338 printed on the central region of the first layer 314 to facilitate viewing therethrough an underlying marking, such as a temporary tattoo, and aligning the underlying marking with the circular indicia and thus the cover. As can be seen, a plurality of covers 310 are mounted on a strip 336 forming a releasable backing. On the far left of FIG. 10 the cover 310 is shown with the upper layer 320 removed to better illustrate the underlying layer 312 . In the illustrated embodiment, the printed indicia 338 is substantially opaque, and preferably is defined by a relatively light or bright skin-contrasting color, such as white, yellow, green, turquoise, or combinations of these or other light or bright colors. Also in the illustrated embodiment, the remainder of the layer 312 is substantially transparent or translucent to allow viewing therethrough. Preferably, the inner diameter or width of the indicia is within the range of about ⅛ inch to about 3/16 inch, and the line thickness of the indicia is within the range of about 0.02 inch to about 0.1 inch. In the illustrated embodiment, the inner diameter of the circular indicia is about ¼ inch, and the line thickness of the indicia is about 0.04 inch. As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, the indicia may take any of numerous different shapes, sizes and/or line thicknesses that are currently known, or that later become known. One advantage of the circular or other annular shaped indicia is that they allow viewing the underlying marking through the central region of the indicia (i.e., the indicia does not interfere with viewing the underlying marking at the center of the cover) for purposes of aligning the indicia and cover with the marking. Yet another advantage of the currently preferred embodiments is that the coloration of the indicia significantly facilitates the viewing and marking alignment process, particularly with relatively dark skin, such as brown or black skin, applications.
[0069] Turning to FIG. 11 , another cover embodying the present invention is indicated generally by the reference numeral 410 . The cover 410 is substantially similar to the cover 310 described above in connection with FIG. 10 , and therefore like reference numerals preceded by the numeral “4” instead of the numeral “3” are used to indicate like elements. The primary difference of the cover 410 in comparison to the cover 310 is that the cover 410 includes indicia 438 in the form of crosshairs, wherein the inner ends of the crosshairs are radially spaced relative to each other to define an unobstructed central viewing region 440 located at the approximate center of the cover. The cover 410 is shown with the upper layer 420 removed to better illustrate the underlying layer 412 . In the illustrated embodiment, the printed indicia (crosshairs) 438 is substantially opaque, and preferably is defined by a relatively light or bright skin-contrasting color, such as white, yellow, green, turquoise, or combinations of these or other light or bright colors. Also in the illustrated embodiment, the remainder of the layer 412 is substantially transparent or translucent to allow viewing therethrough. Preferably, the diameter or width of the central viewing region 440 is within the range of about ⅛ inch to about 3/16 inch, and the line thickness of the indicia is within the range of about 0.02 inch to about 0.1 inch. As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, the crosshairs or other indicia may take any of numerous different shapes, sizes and/or line thicknesses that are currently known, or that later become known. In addition, the crosshairs of other indicia may be applied to the upper layer instead of the lower layer, or may be applied to both layers.
[0070] As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, numerous changes and modifications may be made to the above-described and other embodiments of the present invention without departing from its scope as defined in the appended claims. For example, the viewing window formed in the second or overlying layer may be formed in any of numerous different ways that are currently known, or that later become known, such as by forming an aperture through the second layer as described above, or by forming the second layer in whole or in part of a transparent or translucent material to define a transparent or translucent window. The term “transparent” is used herein to include any level of transparency that is sufficient to allow viewing of the underlying marking through the window, and includes without limitation, completely transparent, partially transparent, or translucent. The term “temporary tattoo” or “tattoo” is used herein to mean without limitation any type of marking applied to person's skin that is to be covered, including a marking applied by a marking pen, such as a Sharpie® pen, in any of numerous different shapes or configurations, that are currently known, or that later become known. In addition, the covers may include two layers as described above, or may include more than two layers, and the layers may be defined by laminated or multi-layer materials or not. In addition, the layers of the covers may be formed of any of numerous different materials, and may take any of numerous different shapes, that are currently known, or that later become known. Accordingly, this detailed description of the currently preferred embodiments of the present invention is to be taken in an illustrative sense, as opposed to a limiting sense.
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A cover for protecting a temporary mark on a person's skin includes a transparent layer and an associated opaque layer, wherein the opaque layer features an opening through which the temporary mark may be located as the cover is applied. An adhesive is superimposed upon the transparent layer in order to releasably affix the cover to the temporary mark, and also to permit maintaining the cover on a backing material during transportation or storage. During use, the mark is sighted through the transparent layer and the opening in the opaque layer, and applied to the patient's skin. The opaque layer is then removed from the transparent layer, which remains in place over the temporary mark, permitting the person to bathe or otherwise participate unhindered in his or her life's routines without smudging, wearing or removing the mark.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is an U.S. national phase application under 35 U.S.C. §371 based upon co-pending International Application No. PCT/NO2006/000345 filed on Oct. 6, 2006. Additionally, this U.S. national phase application claims the benefit of priority of co-pending International Application No. PCT/NO2006/000345 filed on Oct. 6, 2006. The entire disclosures of the prior applications are incorporated herein by reference. The international application was published on Apr. 10, 2008 under Publication No. WO 2008/041856.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a platform which produce electric power, more specific an oil or/and gas producing platform holding its own power plant on one of its upper decks.
2. Description of the Prior Art
Productions of hydrocarbons (oil and gas) is normally done through concepts consisting of platforms either floating or standing on the seabed or by use of special purpose built ships.
Today power plants are positioned onshore with a fuel supply from a hydrocarbon source. This source could be either through a pipeline from a platform or it could be from a hydrocarbon storage facility nearby. The energy generated by the power plant is then transported across a power energy network to the end user.
One of the negative aspects of power plants using hydrocarbon fuel today is the CO2 outlets through the exhaust. Today it is known that CO2 gas influence the weather and temperature and thus a threat to the environment. The handing of CO2 has become an expensive and difficult task to clean before the exhaust fumes can be let out into the air. Furthermore, it is very expensive to transport hydrocarbons from an oil producing facility offshore to an onshore facility either through permanent pipelines or by vessel and thus contribute considerably to the cost of producing electric power using hydrocarbons.
SUMMARY OF THE INVENTION
Thus, the main objective with present invention is to provide an offshore platform which is constructed with an eye to reduce the cost of transporting hydrocarbons on shore and getting rid of CO2 gas without adding it to the atmosphere and causing further environmental problems. This is achieved with the platform according to present invention as it is defined in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a cross section of a separate module.
FIG. 2 is a horizontal cross section of a completed platform.
FIG. 3 is a vertical cross section A-A of the platform showing the circular columns partly filled with oil or ballast.
FIG. 4 is a block diagram of an additional process on the platform which will be carried out in connection with the power plant.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 , 2 , 3 and 4 . A platform 10 according to the invention will consist of a circle of modules 1 , each module consisting of at least one of circular column 2 , with the same or different size of diameter, surrounded by concrete to create a desired outer surface. The straight sides 3 , 4 of the module will have an angle [alpha] given by the number of modules 1 the platform 10 shall consist of and thus giving the size of the platform. The modules will be held together by some fixing means, like bolts or similar. The internal circular “column” 5 generated by the modules 1 in the middle of the platform 10 can be either sealed at the bottom and be used for storage of oil, gas, etc. or nothing, or completely filled with the water surrounding the platform. The modules may be put together in a sealing way so that the central space of the platform can be utilized as desired. The production of a module 1 is based on the Norwegian patent 162 255 for building bridges submerged in water (fresh or sea water). The Norwegian patent 162 255 describes a method for producing these circular columns 2 in a rational and economical way. However, the method is not essential for the end result, so other methods available can be used. When all the modules 1 have been produced and put in place to create the complete platform 10 , it is then taken offshore, positioned and either lowered down to the seabed on top of one or more production wells for oil and or gas, anchored in position like a floating vessel/platform, or “tied” down like a tension-leg platform.
The production of this type of platform 10 is much cheaper than the method used for known platforms like a Condeep where the use of a sliding frame which is moved in the vertical direction which results in a higher cost and more difficult process of providing concrete at a steady pace. The known techniques for such sliding frames require high level of man power compared to the technique described in the Norwegian patent 162 255.
As the modules 1 are produced they are simply turned 90[deg.] into a vertical position and put in the respective radial position until the platform 10 has reached its final dimension/size.
Some of the advantages with this type of platform relative to the known concepts utilized today are, a) expansion chambers (i.e. one of the circular columns 2 ) can be utilized in stead of a flare system, b) the internal volume of the platform makes it possible to utilize passive separation for separation of production water, and c) through the vertical circular columns 2 it can be carried out dry drilling (i.e. not subsea/subwater drilling) which reduces the danger for uncontrolled blowouts. Any leakage in or collapse of one or more of the circular columns 2 will not necessarily be critical for the platform 10 when it comes to lack of buoyancy etc., because of the number of circular columns 2 the platform 10 consist of.
On at least one of the deck 6 to the platform 10 there will be a processing plant adapted to the type of hydrocarbons being produced, in addition to the power plant. The oil and/or gas which normally would have been transported either by a vessel or by a pipeline to an oil refinery/storage facility onshore will now be fed to an onboard storage tank. This storage tank could be at least one or more of the vertical circular columns 2 . When the oil/gas are placed in one or more of these columns at a high temperature, a natural horizontal separation will take place in that or those columns 2 , hereafter referred to as the separation tank 12 .
The different quality of hydrocarbon will be used for specific engines suitable for that type of fuel. The engines will drive a generator to produce electric power. In the separation tank 12 will sand and/or debris 13 be taken out and deposited. Any water from the production, production water 14 , will be drained out and used for reinjection 24 . The power production can be carried out by use of different type of engines 18 . However to simplify the description we have only described the process by use of diesel engines, but the process would be the same with the use of other types of engines.
With reference to FIG. 4 . Oil and/or gas 11 from the oil well are allowed to separate in the separation tank 12 . Sand/debris 13 and production water 14 is taken out from the separation tank 12 . The separated oil and gas 15 is lead to the process plant 16 on the platform for production of fuels which are stored in the fuel tanks 17 . The fuel for the diesel engines will be taken from the fuel tank and supplied to the diesel engines 18 . The diesel engine cooling water 19 and exhaust gas 20 will be used to heat up the production water 14 . When the exhaust gas have been through a dry filter 21 to remove debris, the exhaust gas 20 and the production water 14 are put under high pressure by a compressor 22 for injection 24 . By adding the exhaust gas 20 and the temperature transfer 23 from the cooling water 19 of the diesel engine 18 to the production water 14 will combined create very high efficiency when injected back into the reservoir. The advantage with this method is that the mixture of water and oil remnants 14 together with the exhaust gas 20 which include CO2, having a high temperature, will better dissolve the oil and gas within the reservoir when injected.
However, the most important reason for returning the exhaust gas 20 is that it would be deposited in its entirety at a low cost and the withdrawal from the reservoir will be increased. This process is feasible because the present invention has a very large storage capacity. No other platform today has this opportunity.
Another advantage with the present invention is that there exists no need for transportation of the hydrocarbons to an onshore facility, either through pipelines or by use of vessels. The distribution network for electric power is much cheaper to install and do not hold such a threat environmental pollution as a pipeline or vessel do.
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Platform for a power plant equipped for producing oil and made of reinforced concrete to reduce maintenance cost, consisting of at least one module. Each module will consist of at least one circular column surrounded by concrete to create a desired outer surface. Any of the columns can be used to store the petroleum (oil, gas, production water, sand, etc.), act as expansion chamber(s) and act as passive ballast or separation tank. The platform will have at least one deck for oil producing equipment, at least one deck for a power plant, and will have equipment necessary for electric power distribution.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of prior application Ser. No. 036,401, filed Apr. 9, 1987, for "Apparatus and Method for Separating Water from Aviation Fuel, and Float Control Therefor," now abandoned.
In accordance with the present apparatus and method for separating water from aviation fuel, there is provided a practical, efficient and economical weight and weight-operating system which make it possible and practical for the operator to make certain that the float of the system, and its associated components, are in perfect operating condition, for example that the float has not become waterlogged and thus inoperative.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, a removable weight is operatively associated with the float, the amount of the weight being so selected that flow of fuel out of the filter separator will be shut off when the water level in the sump becomes excessively high, and also so selected that the drainage of liquid from the sump will be shut off when the water level in the sump becomes low. The method further comprises removing such weight from its association with the float, thus testing the system for buoyancy of the float, operativeness of all valve elements, etc.
In accordance with an aspect of the preferred embodiment of the invention, the weight is not mounted on the float itself, but instead is provided on the arm that tethers the float. The amount of the weight, and the moment arm of the weight relative to the pivot axis for the float, are selected to achieve the above-specified results.
In accordance with other aspects of the invention, there is provided a weight-elevating means that lifts the weight when desired, and that can be stowed away to prevent any possibility that the weight-elevating means will interfere with operation of the float. Such other aspects include, also, isolating the weight-elevating means from the valve-actuating elements operated by the float, to prevent undesired interaction therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a fuel-water separator system incorporating the present invention;
FIG. 2 is a vertical elevational view of the float control apparatus looking from the exterior of the sump;
FIG. 3a corresponds to the solid-line position of FIG. 3, and also shows the water and fuel and the interface therebetween;
FIG. 3 is a vertical sectional view on line 3--3 of FIG. 2, showing the float ball and associated weight mechanism;
FIG. 4 is a horizontal sectional view on line 4--4 of FIG. 2, showing the weight and weight-actuator mechanism and also showing the valve-controlling means;
FIG. 5 is an isometric view showing the weight and its arm;
FIG. 6 is a view showing the distributor element in large scale;
FIG. 7 is a view showing the disc associated with the distributor, and in the same scale as that of FIG. 6; and
FIGS. 8-11, inclusive, are schematic views, not to scale, showing the positions of the valve-controlling means at certain times when the float is moving upwardly or downwardly, the views being from the right in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, there is shown a type of system for separating water from aviation fuel, such system having long been known in the art. For example, U.S. Pat. Nos. 2,609,099 and 2,805,774 shows such a system. The disclosures of such patents are hereby incorporated by reference herein.
Aviation fuel enters via a pipe 10 into a filter separator tank 11, and then leaves the tank through a pipe 12. Water that is separated from the aviation fuel by the filter separator 11 drops into a sump 13. It is the purpose of the system and of the present invention to guarantee that there is never too much water in the sump 13 and filter separator 11, that water never emanates through pipe 12, and that no significant amount of fuel emanates from any pipe other than 12.
There are two valves that provide such assurance, but only when the valves are properly operated by a substantially fail-safe mechanism as described below. The first valve is a fuel valve 14, such valve being incorporated in pipe 12 and being closed when the amount of water in sump 13 becomes alarmingly high. The second valve is a water valve 15, and it drains water through a pipe 16 from sump 13 so long as there is a sufficient amount of water in the sump. When there is little or no water in sump 13, water valve 15 is closed to prevent wastage of the aviation fuel.
Fuel valve 14 and water valve 15 are, preferably, diaphragm valves of a type well known in the art. Preferably, each diaphragm valve is such that the valve remains open at all times except when pressurized fluid is injected into a chamber above the diaphragm, thus forcing the diaphragm (or an element connected thereto) onto the valve seat. The valve then remains closed until the chamber above the diaphragm is drained or vented, at which time the pressure in the system forces the valve-closing element off of its seat so that flow through the valve is resumed.
to achieve substantially fail-safe operation of the fuel and water valves 14 and 15, respectively, an improved float-operated control system 17 is associated with sump 13. As in prior-art float-operated control systems, there is a float-ball (or other shape of float) in sump 13, and such ball controls valve or pilot elements that either supply pressure to, or drain, the diaphragm chambers of valves 14 and 15 in response to the position of the float. In accordance with the present invention, there is provided a practical, efficient and economical weight and weight-operating system which make it possible and practical for the operator to make certain that the float and its associated components are in perfect operating condition, for example that the float has not become water-logged and thus inoperative.
Referring particularly to FIGS. 2 and 3, float control 17 has a housing 18 that is generally disc-shaped except at the central region. The periphery of the disc is secured by screws to a wall 19 of sump 13, covering an opening in such wall, there being a gasket 21 provided as shown in FIG. 3 to prevent leakage of the high-pressure aviation fuel out of the filter separator 11 and sump 13. The fuel may be, for example, at a pressure of 150 psi.
At its central region, the housing 18 has an outwardly-protuberant wall portion 22 that defines a chamber 23. Extending horizontally from both sides of the wall portion 22, in coaxial relationship relative to each other, are generally cylindrical boss portions 24 and 25 adapted to receive operating and control valve or pilot means described subsequently.
A bearing 26 is inserted into the left boss 24, having a flange 27 secured by screws 28 (FIG. 4) to such boss. Extending through bearing 26 is a shaft 29, and this shaft has an axial bore in the right end thereof to receive, in freely-rotatable relationship, part of the stem 31 of a driver assembly for the control valve or pilot means. Such stem extended across chamber 23 and through an internal bearing 32 that is formed integrally with housing 18, the stem protruding toward the right from such internal bearings.
There is nonrotatably secured on the right end of the stem 31, as by being press-fit over knurls on such stem end, a drive element 33. The left end of the drive element engages a disc-shaped thrust bearing 34. A roll pin 36 extends diametrically through the drive element 33 and also through a hole in the stem 31, and only one end of such roll pin extends outwardly from the drive element for performance of a driving function.
Stated more specifically, the outwardly-extending end of the roll pin 36 is disposed in a notch 37 (FIGS. 4 and 7) in the rim portion of a disc 38. Such rim extends to the left as viewed in FIG. 4, and the interior cylindrical surface of the rim extends around on the exterior cylindrical surface of driver 33. A helical compression spring 39 is disposed within the rim of disc 38, and tends to force the bottom of the disc (the right end thereof) toward the right due to compressive forces exerted between such bottom end and the right end of the driver 33.
The force of spring 39, and (more importantly) fluid pressure, force the disc 38 against a distributor 41 (FIGS. 4 and 6) that is secured by screws 42 (FIG. 4) to the right end of boss 25, there being a suitable gasket interposed to prevent leakage. Leakage from other parts of the system shown in FIG. 4, during testing of the mechanism and/or during operation thereof, is prevented by suitable O-rings 44-46.
As shown in FIG. 6, distributor 41 has three axial ports 47-49 that connect, respectively to radial passages 51-53. Port 47 and its passage 51 connect through a conduit 54 (FIG. 1) to the diaphragm chamber of water valve 15. Port 48 and its passage 52 connect through a conduit 55 to the diaphragm chamber of fuel valve 14. Port 49 and its passage 53 connect through a conduit 56 to a suitable drain.
A supply or pressure conduit 58, preferably having a filter 59 therein as shown in FIG. 1, is connected to a portion of filter separator 11 where the fuel is clean and free of water. The other end of such conduit connects to a port in boss 25 of housing 18, and thus to a chamber 60 (FIG. 4) defined by such boss. Accordingly, pressurized fuel surrounds the disc 38 and is present within the rim of the disc. Such fuel can pass through a port or passage 61 (FIG. 7) in the disc to the extreme right end thereof. It can thus conduct fuel to one of the ports 47 and 48 in the distributor 41 when the disc is in certain positions relative to the distributor. The disc 38 also has an arcuate groove 62 in the right (FIG. 7) end thereof, and this accurate groove is adapted at certain positions to connect the water port 47 and/or fuel port 48 to drain port 49. A pin 63 extends axially of the disc and distributor, as shown in FIG. 4, and serves to center the disc relative to the distributor.
To rotate the stem 31 and thus disc 38 to determine the registration of registry of the described ports and groove, a float ball (or other-shape float) 66 is disposed in sump 13. Securely connected to the float ball, along an extended diameter thereof, is an arm 67 that is preferably hexagonal in cross section and that has a bore therethrough (between opposed flat surfaces of the arm) to receive the above-described stem 31. The stem 31, in turn, has a bore therethrough to receive the inner end of a locking screw 68. Stated more definitely, the outer end of arm 67 is axially bored and counter bored, and the locking screw 68 is threaded into the counter bore so that a reduced-diameter inner end of the locking screw projects through the transverse bore in stem 31 and locks the stem against rotation relative to the float arm. Thus, the ball 66 and its arm drive stem 31 rotationally in accordance with the position of the float. To provide access to the locking screw 68, a cap 69 is provided on housing 18 directly outwardly of such screw.
The Weight and Weight-Actuating Mechanism Associated with Arm 67 and thus with Float 66
A weight 71, having a precisely-determined mass and moment arm, is mounted so as to seat on the float-ball arm 67. As shown in FIG. 5, the preferred weight 71 is U-shaped, with the arms of the U extending downwardly and spaced from opposite surfaces of the float-ball arm 67. The center of the base of the U seats on the upper surface of arm 67, being held in such position by a or weight arm crank 72. Such crank or weight arm, as best shown in FIG. 4, normally extends parallel to float-ball arm 67 and laterally spaced therefrom, terminating at a bearing portion 73. Such bearing portion surrounds a low-friction bushing 74 on a necked-down portion of shaft 29 that is adjacent the float-ball arm 67.
The weight 71 is so shaped, and the crank or weight arm 72 has such length, that the weight may pivot upwardly until it is adjacent the housing (FIG. 3). The weight 71 does not engage the wall 19 of the sump, and is preferably in the opening in such sump wall. Reference is made to FIG. 3, which shows in phantom lines the extreme upward-pivoted position of the ball 66 and weight 71.
Means are provided to lift the weight 71 off the float-ball arm 67, or to lift the weight so that the ball follows it upwardly due to buoyant forces. Such means comprise a weight-actuating crank 77 (FIG. 4) that is secured radially in a boss 78. The boss, in turn, is non-rotatably secured to the left end (FIG. 4) of shaft 29, as by a set screw 79. Inwardly adjacent the liner end of bearing 26, shaft 29 has a flange 80 one portion of which protrudes toward the weight 71. Fixedly mounted in such protruding flange portion, and extending longitudinally of shaft 29 to a position beneath crank 72 for the weight 71, is a lift pin 81. Preferably, the relationships are caused to be such that the upper surface of lift pin 81 is in engagement with the underside of crank 72 when the weight-actuating crank 77 is parallel to float-ball arm 67.
When the crank 77 is actuated downwardly by an operator, shaft 29 is rotated so as to cause the lift pin 81 to operate against the underside of weight arm 72 and thus lift weight 71. The ball then floats upwardly, unless it is waterlogged, and the system is tested as described subsequently.
It is pointed out that the lifting of the weight due to operation of crank 77 and consequent rotation of shaft 29 does not itself rotate stem 31 and thus cause operation of the valve-controlling or pilot elements at the right portion of FIG. 4. It is only when the ball 66 floats upwardly, so that the float-ball arm 67 rotates stem 31, that such a valve-controlling elements at the right end of FIG. 4 are operated.
Stated otherwise, there is relative isolation between the weight-lifting mechanism and the valve-control mechanism, this being caused by the low friction relationship between bearing 73 and bushing 74, and by the relatively free-rotation relationship between shaft 29 and stem 31.
Description of the Method, and Further Description of Operation
In accordance with one aspect of the method, a removable weight is operatively associated with the float ball 66, the amount of the weight being so selected that the flow of fuel out of the filter separator 11 will be shut off when the water level in the sump becomes excessively high, and also so selected that the drainage of liquid from the sump will be shut off when the water level in the sump becomes low. The method further comprises removing such weight from its association with the float ball, thus testing the system for buoyancy of the float ball, operativeness of all valve elements, etc.
In accordance with another aspect of the invention, the weight is not mounted on the float itself (it being emphasized that the float does not need to be ball shaped), but instead is provided on the arm that tethers the float. The amount of the weight, and the moment arm of the weight relative to the pivot access for the float, are selected to achieve the above-specified results.
In accordance with other aspects of the method, there is provided a weight-elevating means that lifts the weight when desired, and that can be stowed away to prevent any possibility that the weight-elevating means will interfere with operation of the float ball. Such other aspects include, also, isolating the weight-elevating means from the valve-actuating elements operated by the float-ball, to prevent undesired interaction therebetween.
The preferred system is one in which the float-ball, having weight 71 operatively associated therewith, floats with its central horizontal plane or center line (or, less preferably, other reference line) at the interface between fuel and water. Stated otherwise, the float ball 66 has its lower half in the water and its upper half in the fuel, provided there is sufficient water in the sump. When the ball floats with its center at the interface, there are substantially equal torques exerted on stem 31 in the upward and downward directions. When an amount of water is drained out of the sump (by a separate drain system, not shown) to cause the water to be below the float ball, such ball (with weight 71 thereon) sinks in the fuel.
FIG. 3a shows the interface I between the water W and the fuel F, such interface being at the central horizontal plane of the ball as above stated.
Ball 66 is made sufficiently large to assure that there will be sufficient moment in both upward and downward directions to effect operation of the valve-controlling means even if such means have (on occasion) relatively high friction. The ball may be, for example, 5 inches in diameter. Even with a ball of this size, the net bouyant forces are small, about 2 ounces.
The weight is brought to an exact value by drilling holes therein or removing portions thereof, so that a precise value of weight is achieved. Less preferably, the moment arm of weight 71 on float-ball arm 67 may be varied so as to achieve the desired torque. The relationships are such that when the weight is lifted, there is simulated the change in flotation or buoyancy forces of the ball between fuel and water.
When the amount of water in sump 13 rises until the ball is in the position marked by the legend "WVSTO (RISING)" in FIG. 3, the valve-controlling elements are in generally the position shown in FIG. 8. The arcuate groove 62 then becomes registered with port 47 as well as with port 49, which causes diaphragm-pressurizing fuel from water valve 15 to drain through conduit 54 and out conduit 56, so that the water valve opens.
If the water level continues to rise, for example due to an excessive inflow of water, the float ball 66 rises until generally the position shown in FIG. 3, marked "FVSTC (RISING)", is reached. The valve-controlling or pilot means are then generally in the FIG. 9 position. This means that the fuel valve 14 starts to close, because supply port 61 becomes registered with port 48. It is thus assured that no fuel containing water can get out of the filter separator 11 and be conducted to the airplane.
Let it next be assumed that the water level starts to drop, until the float ball sinks to the position marked (FIG. 3) "FVSTO (SINKING)". This corresponds generally to the valve-operator position shown in FIG. 10, and is such that fuel drains through conduit 55 from valve 14, then through port 48, then through the arcuate groove 49 to conduit 56, so that valve 14 opens and passage of fuel through the system starts.
When the amount of water in the sump reduces to such a level that the float ball 66 is in the position marked (FIG. 3) "WVSTC (SINKING)", the valve operator elements are generally in the position shown in FIG. 11. The supply port 61 is then registered with port 47 to pressurize the conduit 54 and thus close the water valve 15. It is thus assured that no fuel can drain from the sump and be wasted.
It is pointed out, relative to FIG. 3, that the range of movement of the float ball 66 is quite small when the system is functioning normally as it is almost always the case. The float-ball then floats with its center (preferably) at the interface between fuel and water, and is half in fuel and half in water. It is only in the event of malfunction, or draining of the sump, or when no substantial water has ever entered the system, that ball positions above or below those shown in FIG. 3 come into play.
To test the system, the operator grasps the weight-actuating crank 77 (FIG. 4) and pivots it clockwise (as viewed from the left in FIG. 4) until the lift pin 81 engages and lifts the arm 72 for weight 71. This causes the float ball to be buoyed up so that its arm 67 follows the weight 71.
When the ball floats up, it simulates a rising water level in the system, the result being that water valve 15 opens and fuel valve 14 closes. The operator knows that such valves are thus operating, because he can see and/or hear them work.
The operator then releases the crank 77, so that weight 71 engages float-ball arm 67 and forces it downwardly despite the buoyant effect of ball 66. The operator then observes and/or hears that the fuel valve opens and the water valve closes.
After the testing is completed, the operator pivots the crank 77 upwardly and forwardly until it is engaged with the housing 18. Such pivotal movement moves the lift pin 81 far away from crank 72, making sure that there is no interaction between the weight-lifting means and the ball and its arm. However, it is pointed out that in the event an operator forgets to thus "stow" the crank 77 near the housing, the amount of friction in the weight-lifting system is so low, and the amount and torque arm of weight 71 are sufficient, that the system will still function.
It is pointed out that the ball cannot be just a little waterlogged, because the pressure in the filter separator is high, e.g. 150 psi as stated. Since the ball has an interior that is hollow and is at atmospheric pressure, even a very small hole in the ball will cause much fuel to enter the ball and waterlog it substantially. Such waterlogging will be readily detected by the present system.
The foregoing detailed description is to be clearly understood as given by way of illustration and example only, the spirit and scope of this invention being limited solely by the appended claims.
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For use in combination with a system for separating water from pressurized fuel in a filter-separator tank, there is provided a float valve and weight device that prevents fuel from leaving the tank if the interface between fuel and water is at an undesirably high elevation. The float of the float valve is associated with a weight, the relationships being such that the float floats at the interface. To test the float for waterlogging, and to test the entire system, the association between float and weight is discontinued. The float then floats up unless waterlogging has occured.
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FIELD OF THE INVENTION
[0001] The present invention relates to a warming system for patient care and, particularly, but not exclusively, to a warming system for use in veterinary care.
BACKGROUND OF THE INVENTION
[0002] There are many circumstances in human and animal medicine where it is necessary to keep a patient warm to, for example, prevent or treat hypothermia.
[0003] In human medicine, it is known to provide patient warming systems which include a patient warming blanket and a heating unit. The patient warming blanket includes two layers which are bonded or stitched together at a seam and are otherwise separable from each other to form a hollow space within the blanket when warm air is pumped from the heating unit via a delivery tube in between the two layers. One of the layers contains a plurality of air holes which allow the pumped warm air to escape from the blanket. In operation, the patient is wrapped or covered in the warming blanket with the layer with the holes next to the patient. Warm air is pumped in from the heating unit and escapes from the air holes on the inside layer of the blanket and keeps the patient warm.
[0004] These patient warming systems are designed for use in human medicine only, for the prevention and treatment of hypothermia during anaesthesia and critical care.
[0005] There is, however, a similar need for a patient warming system in veterinary care. Presently, similar warming systems are used as those designed for human patients. There are a number of problems associated with the use of the human patient warming system in veterinary care, however.
[0006] Small animals have a relatively large surface area to volume ratio, which makes them particularly susceptible to hypothermia. The applicants have found that using a conventional human warming system to maintain the body temperature of a relatively small animal can actually result in cooling of the animal (which can lead to death). This occurs, we believe, because the air flow is delivered to the patient by individual, discreet holes in the inner layer of the warming blanket. In a patient with relatively large surface area to volume, delivery of air from an air hole, so that the air is moving relatively rapidly, can cause the patient to chill, as the air takes away more heat from the surface of the patient than it delivers. Obviously, this is very dangerous in a critical care situation.
[0007] Another problem is that the heating unit used in the human systems typically only heats to a temperature of 43° C. Animals have a range of body temperatures and in many circumstances a system which provides heated air at a maximum of 43° C. is not sufficient.
[0008] Another problem which relates to animals, which in veterinary situations are often smaller and sometimes much smaller than human beings, is that the human patient warming blankets are relatively large, and a small animal placed under one of these will not be adjacent sufficient air holes to provide sufficient warm air to maintain the animal's temperature.
[0009] Further, in surgery and other circumstances where sterile conditions are required, having air blown at relatively high velocity through a small hole can result in contamination of the site eg. the surgical site, via substances blown onto the surgical site by air from the air holes.
SUMMARY OF THE INVENTION
[0010] In accordance with a first aspect, the present invention provides a surgical warming blanket arranged for use during surgery on a patient and comprising at least two layers capable of forming a hollow air space between them for receiving warmed air from a heating unit, the two layers and air space being arranged in operation to form a substantially tubular arrangement at least partially surrounding a patient receiving space, whereby when warm air is passed into the air space it is delivered to the patient receiving space via the blanket, to maintain warm air within the patient receiving space, the patient receiving space receiving the patients body and allowing access to the patients body for surgery without disturbing the blanket.
[0011] In one embodiment, at least one of the two layers has a proportion of its surface formed of porous material so that warmed air may escape via the porous material into the patient receiving space.
[0012] The pervious material is adjacent to, in use, a patient receiving treatment. Delivering heat spread over the surface of the porous material advantageously has the effect of evenly warming the patient without forming relatively high velocity streams of air (as in the prior art blanket where the air is delivered via discreet holes). Animals, therefore, and in particular small animals, are not at risk of being cooled by relatively high velocity air streams. In one embodiment, a substantial proportion of the surface of the one layer is of porous material. Preferably, a majority of the surface of the one layer is of porous material. In operation, warm area is advantageously delivered at relatively low velocity over the proportion of the surface of the one layer.
[0013] Preferably, the blanket is designed not to cover the animal patient, but instead to provide a patient receiving area in which the patient lies surrounded at least on three sides by a tube formed by the blanket when air is pumped into the air space. In this embodiment, at least the sides of the tube facing inwards towards the patient are of the porous material. This has the effect of passing warm air over the patient within the space, so no matter how large the patient, the air in the space will be kept at substantially the same temperature.
[0014] Preferably, the surface of the blanket is fluid repellent, so that any liquid contamination rolls off the blanket.
[0015] In an alternative embodiment, the entire blanket may be made of porous material so that warmed air is delivered over the entire surface of the blanket that is exposed. The unexposed surface of the blanket e.g. facing down on a bench, may not deliver air. The exposed surface, however, including the surface which may be adjacent to patient in operation, will deliver air. This saves cost in manufacture of the blanket as it is only necessary to manufacture the blanket from one type of material. This can be significant, as in the majority of cases these blankets are intended to be disposable after one use.
[0016] In an alternative embodiment, the entire blanket may be made of porous material so that warmed air is delivered over the entire surface of the blanket that is exposed. The unexposed surface of the blanket e.g. facing down on a bench, may not deliver air. The exposed surface, however, including the surface which may be adjacent to patient in operation, will deliver air. This saves cost in manufacture of the blanket as it is only necessary to manufacture the blanket from one type of material. This can be significant, as in the majority of cases these blankets are intended to be disposable after one use.
[0017] One other problem with the conventional human patient warming systems is that it has been known for carers to direct heat directly from the heating unit via a delivery tube directly onto the patient. This can cause burning, particularly in small animals, and is not something that should occur.
[0018] In accordance with a third aspect, the present invention provides a heating unit for a patient warming system, the heating unit including a delivery port for delivering warmed air to a patient warming blanket, and a feedback means for determining whether a patient warming blanket is attached and being responsive to a determination that the patient warming blanket is not attached, to disable delivery of warmed air via the port.
[0019] Preferably, the feedback means comprises a pressure sensor, for sensing back pressure on the air delivery port. When a blanket is attached, there will be a certain amount of back pressure on the delivery port, so that when this back pressure is detected, air may delivered.
[0020] Preferably, the heating unit is arranged to heat air to a range of temperatures, preferably up to 46° C.
[0021] In accordance with a fourth aspect, there is provided a heating system comprising a patient warming blanket in accordance with the first aspect of the present invention and a heating unit in accordance with the third aspect of the present invention.
[0022] In accordance with a fifth aspect, the present invention provides a method of warming a patient during surgery, comprising the steps of receiving the patient within a patient receiving space within which the patients body is accessible for surgery, and passing warmed air into the patient receiving space to keep the patient warm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a plan view of a patient warming blanket in accordance with one embodiment of the present invention, shown connected to a heating unit in accordance with one embodiment of the present invention;
[0024] FIG. 2 is a cross sectional view on line XX of FIG. 1 ;
[0025] FIG. 3 is a plan view of a patient warming blanket in accordance with a further embodiment of the present invention; and
[0026] FIG. 4 is a view from the front of the embodiment of FIG. 3 .
DESCRIPTION OF PREFERRED EMBODIMENT
[0027] With reference to the figures, a patient warming system in accordance with an embodiment of the present invention is illustrated, particularly being designed for use in veterinary medicine. The patient warming system comprises a heating unit 1 (to be described in more detail later) and a patient warming blanket 2 .
[0028] The patient warming blanket 2 includes first 3 and second 4 layers of material which form a hollow air space 5 between them. In this embodiment, when the warming blanket 2 is not being used, it will lie substantially flat as no air is being pumped into the air space 5 . In use, however, when air is being pumped into the air space 5 , the blanket “inflates” to give the profile shown in the cross-section of FIG. 2 .
[0029] The first layer 3 is substantially non porous to air. The second layer 4 , however, is made of porous material and is substantially porous over its entire surface area. Warm air pumped into the hollow air space 5 , therefore, escapes via the entire surface of the second layer 4 .
[0030] The warming blanket 2 may be made of any appropriate material and in this embodiment is made from polyester. The second surface 4 being of porous polyester.
[0031] The arrangement of the first 3 and second layers 4 in operation in this embodiment forms a tubular arrangement which extends about three sides of a patient receiving space 6 . In this embodiment, a continuation 7 of the first layer 3 provides a blanket base on which the patient may lie.
[0032] In operation, warmed air is provided from the heating unit 1 via a flexible heat delivery tube 8 into a port 9 to the interior space 5 of the blanket. The warmed air inflates the blanket to give the profile illustrated in FIG. 2 . The patient is positioned within the patient receiving space 6 . Warm air escapes via the porous second layer 4 into the patient receiving space maintaining the patient receiving space 6 at a substantially even temperature. The shape of the blanket maximises the convective surface area for heating.
[0033] The material of the warming blanket 2 is treated to be fluid repellent, so that any liquid contamination rolls off the blanket.
[0034] In an alternative embodiment, the blanket may consist of the same main material over all of its surface. Warmed air is therefore delivered over all of the exposed surface of the blanket. This blanket may be cheaper to make.
[0035] The heating unit 1 includes a feedback means which in this embodiment is a pressure sensor. The pressure sensor is arranged to sense a certain amount of back pressure on a delivery port 10 of the heating unit which delivers warmed air to the delivery tube 8 . The existence of this back pressure implies that a warming blanket 2 is attached to the delivery tube 8 . If the back pressure signal is not received by the pressure sensor, then delivery of warmed air 10 via the port is disabled. This prevents any operative attempting to provide warmed air directly to a patient via the delivery tube 8 , without using a warming blanket.
[0036] The heating unit 1 includes control and selection means 12 , 13 , 14 that enables a selection of plurality of temperatures for the warmed air, and in this embodiment warmed air can be delivered at temperatures of 34, 37, 40, 43 or 46 degrees Centigrade.
[0037] The heating unit 1 is based on a conventional heating unit, but adapted to deliver the above temperatures. A further adaptation is the addition of the pressure sensor and feedback to temperature control circuitry (not shown) to switch off the delivery of warmed air if a back pressure is not sensed (implying that the warming blanket 2 is not attached to the delivery tube 8 ).
[0038] FIG. 3 and FIG. 4 show an alternative embodiment of the patient warming blanket. The alternative patient warming blanket 20 comprises an air inlet 21 which is on one “leg” 22 of the blanket. Otherwise, the blanket is of similar construction to the patient warming blanket of FIGS. 1 and 2 . Similar reference numerals have been used for similar components as the embodiment of FIGS. 1 and 2 .
[0039] In the above-described embodiment the patient warming blanket will be appropriately dimensioned for veterinary care. Example dimensions include 560 mm width, 1110 mm length, with width of each of the arms when inflated being 110 mm. Note that these dimensions are examples only and, the present invention is not limited to these dimensions.
[0040] While the above description refers to application of the warming system with animal patients, the system of the present invention is not limited to use with animal patients and can be used with human patients eg. small human patients.
[0041] Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.
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The present invention relates to a patient warming system and in particular a patient warming blanket for warming patients undergoing medical care. The patient warming blanket is particularly for use in veterinary medicine. The warming blanket includes a porous surface from which warmed air can escape over the entire porous surface, evenly warming the patient.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. patent application Ser. No. 891,224 filed May 29, 1992.
BACKGROUND OF THE INVENTION
The present invention relates to cyclodextrin and, more specifically, to the removal of residual cyclodextrin from a system without contaminating the system with enzyme. The present invention is especially applicable to food systems.
In recent years cyclodextrin has been used to remove unwanted substances from a number of different systems, especially food systems. For example, cyclodextrin has been used to remove cholesterol from eggs and butter; caffeine from chocolate, tea and coffee; phenylalanine from protein hydrolysates; and phenolic compounds, pigments and bitter components from fruit juice. Typically, this removal process entails a two-step process of first mixing cyclodextrin or an aqueous slurry of cyclodextrin with the food system to form a complex between the cyclodextrin and the unwanted substance; and subsequently removing the complex from the food system. Conventionally, the complex is then separated into its individual components and the cyclodextrin recycled to be used again in the removal process.
One of the problems associated with this process is that a small amount of cyclodextrin is left in the system after the complex is removed from the system. The source of this residual cyclodextrin is twofold, unrecovered complex and unremoved, uncomplexed cyclodextrin. Since the complexation process is an equilibrium reaction, an excess amount of cyclodextrin is mixed into the system to push the equilibrium toward complexation. This inevitably means that a certain amount of cyclodextrin is in the uncomplexed state when the complex is removed from the system. Some of the uncomplexed cyclodextrin is left behind in the system when the complex is removed from the system, thus accounting for the unremoved, uncomplexed cyclodextrin.
The other source of residual cyclodextrin, unremoved complex, is due to the inefficiency of the removal of the complex from the system. In some food systems, for example coffee, the complex is removed as a precipitate from solution. Oftentimes soluble or readily suspendable complexes are not removed from the system. In other cases, such as butter, the complexes are removed by washing the butter with water. In these instances, not all of the complex is washed away. In either case, washing or precipitation, the unrecovered complex goes through an equilibrium reaction wherein the guest and cyclodextrin move between a complexed and uncomplexed state. Thus, the unremoved complex is another source of residual cyclodextrin. No matter what the source, the residual cyclodextrin must be removed from the system. The term residual cyclodextrin as used in the specification and claims means cyclodextrin which remains in the system after the majority of the complex has been removed from the system.
It has been suggested that the residual cyclodextrin be removed from egg yolk or egg yolk plasma by adding a soluble enzyme to the egg yolk and then incubating the system to allow the enzyme to decompose the cyclodextrin. Specifically, U.S. Pat. No. 4,980,180 teaches using a soluble alpha-amylase derived from the microorganisms of the group Aspergillus niger, Aspergillus oryzae, Bacillus polymyxa, Bacillus coagulans, Flavobacterium, or domestic hog pancreas amylase to remove cyclodextrin from eggs. A problem associated with soluble alpha amylases which have been used to hydrolyze cyclodextrin is that they do not hydrolyze all cyclodextrin. Specifically, it has been found that they do not hydrolyze branched cyclodextrin and they do not hydrolyze all of the alpha cyclodextrin.
It has also been suggested to use a combination of alpha-amylase and cyclodextrin glycosyl transferase (CGTase) to hydrolyze the residual cyclodextrin. Such a combination has been found to hydrolyze virtually all of the residual cyclodextrin.
Whether using one or two enzymes to remove residual cyclodextrin, these enzymes remain in the system and must be inactivated. Typically, the enzymes are inactivated by a conventional means such as high temperature or extremely high or low pH. Such an inactivation step is not acceptable in food systems like milk and eggs because such an inactivation step can change the physical properties of the treated food. Additionally, the inactivated enzyme remains in the system and acts as a contaminant to the system. There is a need for a process wherein residual cyclodextrin is removed from a system without the need to go through a deleterious step to inactivate the enzyme and without contaminating the system with inactivated enzyme.
SUMMARY OF THE INVENTION
It has now been discovered that residual cyclodextrin can be removed without contaminating a system with inactivated enzyme and without subjecting the system to an enzyme inactivation step. The process of the present invention comprises treating the system containing residual cyclodextrin with an immobilized enzyme in the presence of water to hydrolyze the residual cyclodextrin. Because the enzyme is immobilized, it is easily separated from the system and can be used repeatedly, thereby providing a cost saving to the user.
The use of the immobilized enzyme in accordance with the present invention not only removes the residual cyclodextrin from the system but avoids contaminating the system with inactivated enzyme.
More specifically, the immobilized enzyme for use in accordance with the present invention is either a fungal alpha-amylase or a combination of at least two separate enzymes wherein one of the enzymes is an immobilized cyclodextrin glycosyl transferase (CGTase) and the other enzyme is an immobilized amylase.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a preferred embodiment of the present invention, the system containing the residual cyclodextrin is also treated with an immobilized debranching enzyme in order to remove the branches from residual branched cyclodextrin. Branched cyclodextrin is more resistant to hydrolysis by immobilized fungal alpha-amylase and the combined immobilized CGTase/amylase than non-branched cyclodextrin. The debranching enzyme removes the branches from the branched cyclodextrin and makes the cyclodextrin more susceptible to hydrolysis by the other enzymes. The use of the immobilized debranching enzyme preferably precedes the fungal alpha-amylase or CGTase/amylase combination because certain amylases such as glucoamylase and fungal alpha-amylase will work on the branch itself to reduce the branch to a glucosyl stub, and the glucosyl is resistant to debranching enzymes.
The fungal alpha-amylases used in the present invention are derived from microorganisms such as Aspergillus niger and Aspergillus oryzae. A good commercial source of fungal alpha-amylase is sold under the name FUNGAMYL® by Novo Industri A/S.
Suitable sources of cyclodextrin glycosyl transferase include Bacillus macerans, Bacillus megaterium, Bacillus circulans, and Bacillus stearothermophilus. Good results have been obtained with Bacillus stearothermophilus.
When using the combination of CGTase and amylase, suitable amylases include alpha-amylase, beta-amylase, and glucoamylase. The alpha-amylase can be either bacterial, fungal or mammalian. Suitable sources of alpha amylases include Bacillus polymyxa, Bacillus coagulans, Bacillus licheniformis, Bacillus subtilus, Aspergillus niger, Aspergillus oryzae, Flavobacterium, or domestic hog pancreatic amylase. Suitable beta amylases are obtained from Barley malt, soy bean, and wheat. Suitable glucoamylases are obtained from Aspergillus niger, Aspergillus oryzae, Rhizopus oryzae and Rhizopus nivens. The preferred glucoamylase is Aspergillus niger and Aspergillus oryzae.
The combination of a CGTase and an amylase wherein the amylase is a fungal alpha-amylase has the fastest reaction rate compared to the other combinations of CGTase and other amylases or fungal alpha-amylase alone; however, the combined CGTase and fungal alpha-amylase is also the most costly at the present time. Additionally, it has been found, at this time, that the fungal alpha-amylase alone has a faster reaction rate than the combined CGTase and bacterial alpha-amylase. Therefore, fungal alpha-amylase alone is preferred over the combination of CGTase and fungal alpha-amylase or the combination of a CGTase and another amylase.
Suitable debranching enzymes are pullulanase, isoamylase and any other endo-enzymes which hydrolyze only alpha D-(1-6) glucosidic linkages of starch. Preferably, pullulanase is used as the debranching enzyme.
In order to prepare immobilized enzyme in accordance with the present invention, any conventional procedure may be employed. Typically, an inert support is used to which the enzyme is bonded.
In the case of fungal alpha-amylase and the other amylases, good results can be obtained by bonding the enzyme to a support such as diatomaceous earth, cellulose, agrose, and silica gel. The procedure for bonding the fungal alpha-amylase consists of polyethyleneimine reaction product with 1,2-dichloroethane and glutaraldehyde as a cross-linking agent for the immobilized enzyme.
In the case of the CGTase, the enzyme can be bonded to a support of diatomaceous earth, cellulose, agrose, and silica gel by any conventional technique, such as that used for the fungal alpha-amylase.
There are a number of immobilized amylases available in the marketplace which can be used in accordance with the present invention. For example, glucoamylase covalently bonded to glass, glucoamylase bonded to DEAE-cellulose, glucoamylase covalently bonded to silica, and fungal alpha-amylase bonded to diatomaceous earth.
In order to treat the system with immobilized enzyme to remove the residual cyclodextrin in accordance with the present invention, any conventional process can be used which treats a system with an immobilized enzyme. The process can be continuous or batch. For example, columns such as a packed bed, or a fluidized bed reactor can be used. Alternatively, a tank can be used with an impeller or a continuous flow stirred tank reactor. Additionally, the immobilized enzyme can be packed in a basket surrounded by a fine screen and immersed in a reactor while the system is stirred. Which of these reactors is employed depends on the flow characteristics of the system being treated as well as the stability of the enzyme on the support. There are different chemical bonds between the support and the enzyme and the chemical bonding has an effect on the stability of the enzyme.
When the combined immobilized CGTase and amylase are employed in accordance with the present invention, the reactor is packed with both immobilized enzymes on a support.
In order to treat the system with the immobilized enzyme, the pH and temperature of the system are adjusted to optimum conditions for the enzyme and the system being treated. As can be appreciated, both the optimum pH and temperature for the system must be taken into consideration so as not to have a deleterious effect on the system. Preferably, the pH is adjusted to about 5.0 to about 7.0 and the temperature is adjusted to about 30° C. to about 60° C. More preferably, a temperature of about 50° C. and a pH of about 6 is used. These are the preferred pH and temperature for fungal alpha-amylase and the combined CGTase/amylase.
Good results for treating the system with immobilized enzyme have been accomplished in a batch operation by adding immobilized enzyme to the system at the optimum pH and temperature; and maintaining the system at that temperature and pH for a period of about 10 minutes to about 24 hours. The system is agitated during treatment to uniformly mix the system and enzyme. The system was adjusted to the appropriate pH prior to treatment with either acid or base. More preferably, the system is treated for about 10 minutes to about 1 hour and, more preferably, about 10 minutes to about 30 minutes. The time of treatment will be dependent upon the microbial situation. As a general rule, growth of microbes should be avoided.
Consideration of the enzymes employed and the system itself dictates the treatment conditions. Additionally, the temperature will preferably be adjusted to optimize the activity of the enzymes in the system without having a deleterious effect on the system.
Treatment of the system is carried out with conventional equipment and in the presence of water. Treatment is preferably conducted under agitation using conventional equipment. Alternatively, one or more of the enzymes are immobilized and the system is passed through the immobilized enzyme.
The present invention is especially suited for food systems such as egg or dairy which have been subject to a decholesterolization step wherein beta cyclodextrin has been added to complex with the cholesterol. In such a food system, the process of the present invention is employed to remove residual cyclodextrin after separation of the complexed cyclodextrin/cholesterol without contaminating the food system with enzyme. The present invention works not only on cyclodextrin and branched cyclodextrin, but also on modified cyclodextrin with low degrees of substitution.
The process of the present invention has also been found to be useful in removing residual cyclodextrin from maltodextrin which is a by-product from the formation of cyclodextrin.
The amount of immobilized enzyme used to treat a food system to remove residual cyclodextrins depends substantially upon the amount of residual cyclodextrins that are in the system, the system itself, and the activity of the enzyme. Preferably, about 0.005% to about 0.05% by weight immobilized enzyme fungal alpha-amylase or, for the combination of CGTase/amylase, about 0.005% to about 0.05% CGTase with about 0.005% to about 0.05% amylase. The amount of debranching enzyme used is preferably about 0.001% to about 0.05% by weight. These weight percents are based on the weight of enzyme to weight of residual cyclodextrin.
It is known that enzymes from different sources have different reactive rates. Applicants have found that the preferred amount of enzyme used in the present invention is the amount of enzyme that can digest a set amount of residual beta-cyclodextrin in a system within about 30 minutes. In other words, the preferred amount of enzyme used in the present invention is dependent upon the enzyme activity in the given system. The optimum amount of enzyme for each system varies from system to system and enzyme to enzyme. In fact, as will be seen in the examples herein, two different sources of the fungal alpha-amylase have different reaction rates in the same system treated under the same conditions.
Applicants have found that the preferred amount of enzyme for a given system can digest about 8,000 to 9,000 ppms of residual beta-cyclodextrin contained in about 100 gram sample of said system when said sample is treated at about 50° C. and a pH of about 6 for a period of about 30 minutes. The system comprises a slurry of foodstuffs (egg yolk) and water having a solids content of about 25% by weight and having about 8,000 to about 9,000 ppms of residual beta-cyclodextrin. After about 30 minutes no detectable beta-cyclodextrin remained in the sample. The amount of beta-cyclodextrin in the system is determined by conventional techniques, using conventional equipment, namely HPLC. Such a test is conducted in a 250 ml flask while the flask is agitated.
The treatment with the immobilized debranching enzyme is preferably done prior to the treatment with the fungal alpha-amylase or the combination of CGTase/amylase. However, the treatment with immobilized debranching enzyme can be done at the same time as the other immobilized enzyme. It will be appreciated by those of skill in the art that most commercial sources of cyclodextrin contain a small portion of branched cyclodextrin.
These and other aspects of the present invention may be more fully understood by reference to the following examples.
EXAMPLE 1
This example illustrates the use of two sources of immobilized fungal alpha-amylase to decompose residual cyclodextrin from the same food system, namely egg yolk, under the same conditions.
Two samples of 100 grams aqueous solution of egg yolk (25% solids) which contained 8000 to 9000 ppms of residual beta-cyclodextrin were treated with different immobilized fungal alpha-amylase enzyme. Both enzymes were immobilized onto an inert substrate. For example, Enzyme A was immobilized on a diatomaceous earth. Both enzymes were obtained from Aspergillus oryzae. In this example, 20 grams of immobilized Enzyme A was used, while 40 grams of Enzyme B was used. It should be understood that these weights included the enzyme and the inert support to which the enzyme was bonded. The treatment was conducted by placing the 100 gram sample and respective enzyme into a 250 ml flask and the flasks were shaken throughout the treatment step. Both treatments were conducted at a pH of 6 and at a temperature of 50° C. Samples from both flasks were withdrawn at varying time intervals as listed below to determine the amount of residual cyclodextrin remaining in the system.
______________________________________ Concentration of Beta-Cyclodextrin (PPM)Time Enzyme A Enzyme B______________________________________0 8000-9000 8000-900015 minutes 699 54130 minutes None detected None detected1 hour None detected None detected______________________________________
The amount of beta cyclodextrin present in the egg system was determined by conventional chromatography (HPLC). Additionally, a conventional Phadebus Amylase Test Method was used to measure the amount of enzyme in the system after treatment. No enzyme was found in the system after treatment in accordance with the present invention.
EXAMPLE 2
This example illustrates using a combined alpha amylase and CGTase to remove residual beta cyclodextrin from an egg system.
A 100 gram sample of egg yolk which contained 8000-9000 ppms of residual beta-cyclodextrin is treated with a combination of immobilized bacterial alpha-amylase and CGTase in the same manner as taught in Example 1 above. The pH of the solution is 6 and the temperature is 50° C. during treatment. After completing the treatment, neither residual cyclodextrin nor enzyme is present in the system.
It will be understood that the claims are intended to cover all changes and modifications of the preferred embodiments of the invention herein chosen for the purpose of illustration which do not constitute a departure from the spirit and scope of the invention.
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The immobilized enzyme for removal of residual cyclodextrins is either a combination of an alpha-amylase and a CGTase which has been immobilized or a fungal alpha-amylase which has been immobilized. In addition to either the fungal alpha-amylase or the CGTase and alpha-amylase, a debranching enzyme can also be employed. When using a debranched enzyme, the debranched enzyme is also immobilized. By using the immobilized enzyme, the step of inactivating the enzyme is eliminated and the contamination due to the inactivated enzyme is also eliminated.
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PRIOR ART
Various hyodeoxycholic acid preparation processes starting from swine bile are known from literature, e.g. as described in U.S. Pat. Nos. 2,758,120 and 3,006,927. All such methods are adversely affected by their being extremely laborious, hence industrially burdensome; moreover, they are scarcely effective insofar as product purity is concerned.
SUMMARY
We have now found a new process based on simple, economic and high yield steps allowing to obtain high purity hyodeoxycholic acid starting from swine bile.
The process is characterized by the fact that:
a) swine bile is made react with an NaOH aqueous solution;
b) the reaction mixture is added with an organic solvent plus water and treated with a mineral acid to liberate biliary acids and remove the other bile components;
c) the biliary acids solution is treated with an ammonium zincate aqueous solution to precipitate the zinc salts of the same biliary acids;
d) the zinc salts of the biliary acids are treated, in an organic solvent plus water environment, with a mineral acid to liberate biliary acids;
e) the biliary acid solution is treated with a magnesium salt to selectively precipitate the magnesium salt present in the hyodeoxycholic acid and remove the other biliary acids;
f) the hyodeoxycholic acid magnesium salt is treated, in an organic solvent plus water environment, with a mineral acid for the purpose of liberating the hyodeoxycholic acid and removing magnesium as a salt of said mineral acid;
g) hyodeoxycholic acid is recovered at high purity, by crystallization.
DETAILED DESCRIPTION OF THE INVENTION
The features of the process for the preparation of hyodeoxycholic acid by the present invention will be better described in detail hereinafter.
The process raw material is swine bile with a water content ranging from 10 to 80% and containing taurine-conjugated hyodeoxycholic, chenodeoxycholic and hyocholic acids. Said acids are also referred to simply as biliary acids.
Bile is treated to reflux with a 10 to 50% sodium hydroxide solution, for 20-30 hours.
The mixture resulting from this treatment is taken up with water and added with an organic solvent selected from the group consisting of C 1 to C 4 alcohol acetate, propionate, and butyrate. Preferably ethyl acetate is used, mixed with water. The mixture obtained is added with a mineral salt selected among sulphuric, hydrochloric and phosphoric acids, in such a quantity as to secure a 3 to 5 pH.
The organic phase of the mixture contains biliary acids, while the aqueous phase contains all the other bile components. Thus the aqueous phase is separated and removed, while the organic phase is Further treated For the obtainment of hyodeoxycholic acid. Then, the organic phase is treated with an ammonium zincate aqueous solution at a concentration ranging from 30 to 200 g/l, the ammonium zincate/initial bile weight ratio ranging From 0.02 to 0.1.
The treatment is carried out at a temperature From 0° C. to 60° C. and brings about the precipitation of the zinc salts of the three biliary acids, namely of hyodeoxycholic acid, chenodeoxycholic acid, and hyocholic acid. The suspension is allowed to cool to a temperature ranging From 0° C. to 10° C. and is filtered; the solid product is washed with an ethyl acetate-water mixture. This operation is meant to remove the impurities contained in the biliary acids.
The solid product consisting, as said above, of the three biliary acids zinc salts mixture is resuspended in a mixture Formed by water and one of the aforesaid organic solvents, then it is heated to a temperature ranging from 30° C. to 80° C., and acidified with a mineral acid to a pH ranging from 0 to 2.5. The aqueous phase, which contains zinc sulphate, is eliminated, while the organic phase, which contains free biliary acids, is added with water and then with ammonia until reaching a pH ranging from 8 to 9. The thus obtained mixture is added with a magnesium salt solution, such a salt being chosen among chloride, sulphate and acetate, with a magnesium concentration ranging from 20 to 60 g/l, the ammonium zincate/initial bile weight ratio ranging from 0.004 to 0.02. This operation is conducted at a temperature ranging from 0° C. to 60° C. and leads to the iodeoxycholic acid magnesium salt selective precipitation, whilst chenodeoxycholic and hyocholic acid magnesium salts remain in the solution.
The suspension is allowed to cool, if necessary, to a temperature ranging from 0° C. to 20° C. ; then, it is filtered for the removal of the solution and the recovery of the solid consisting of hyodeoxycholic acid magnesium salt. The solid is washed with an ethyl acetate aqueous solution; the suspension thus obtained is heated to a temperature ranging from 40° C. to 60° C. and acidified with a mineral acid to a pH between 1 and 3 to liberate hyodeoxycholic acid.
The aqueous phase containing the magnesium salt of said mineral acid is separated and eliminated. The organic phase, which contains hyodeoxycholic acid, undergoes purification by water washing and activated carbon filtering; then, it is vacuum concentrated to the removal of approx. half the solvent volume. Finally, by cooling to about 0° C. , hyodeoxycholic acid crystallizes and is recovered as pure product as a result of standard operations, such as filtering, washing, and drying.
The hyodeoxycholic acid obtained via the invention process exhibits a high purity level, which makes it suitable for pharmaceutical use.
Moreover, the various process stages are based on simple high efficiency operations.
The following examples are conveyed by way of indication, not of limitation.
EXAMPLE 1
2.5 kg concentrated swine bile with a 36% water content was treated with 1.5 kg 30% sodium hydroxide and refluxed for 20 hours. Then, the mixture was taken up with 11 water and 2 1 ethyl acetate. Further to the addition of 35% sulphuric acid, the pH was brought to approx. 4.
The aqueous phase, separated at 50° C. , was eliminated, while the organic phase was treated with an ammonium zincate aqueous solution at a concentration of 70 g/l, the ammonium zincate/initial swine bile weight ratio being equal to 0.06.
The zinc salts of iodeoxycholic, chenodeoxycholic and hyocholic acids precipitated.
The mixture was allowed to cool to 0° C. ; the product was filtered and washed with an ethyl acetate aqueous solution.
The moist product was suspended in 1000 ml water and 1000 ml ethyl acetate, heated to 50° C. , and acidified with sulphuric acid approx. to pH 2.
The aqueous phase containing zinc sulphate was separated, prior to elimination.
The organic phase was treated with 1000 ml water.
The pH was corrected in the 8 to 9 range by NH 3 addition; then, a magnesium sulphate aqueous solution at a concentration of 170 g/1 was added, the magnesium sulphate/initial bile weight ratio being 0.04.
The precipitation of the hyodeoxycholic acid magnesium salt occurred soon.
After cooling to 0° C. , the product was filtered and washed with an ethyl acetate aqueous solution. The moist product was eventually suspended in 1000 ml deionized water and 1000 ml ethyl acetate, heated to 50° C. , then the mixture was acidified with sulphuric acid.
The aqueous phase containing magnesium sulphate was separated. The organic phase containing hyodeoxycholic acid was water-washed twice, then filtered with decolourizing carbon and vacuum concentrated to half its volume.
The residual solution was allowed to cool to 0° C. , the hyodeoxycholic acid was filtered and then washed thoroughly with ethyl acetate at first and then with water.
Drying at 70° C. yielded 120 g pure product with the following characteristics:
Grade: 100.0% (by titration with NaOH 0.1 N);
[α] 20 D =+8.2°;
m.p.=196°-200° C. ;
HPLC purity >99.0% (presence of traces of chenodeoxycholic and hyocholic acids).
EXAMPLE2
Example 1 was repeated using ethyl isopropyl acetate as solvent and magnesium chloride as magnesium salt. The final product purity was slightly below that resulting in Example 1, mainly owing to the presence of hyocholic acid.
EXAMPLE 3
Example 1 was repeated using ethyl isobutyl acetate as solvent and magnesium acetate as magnesium salt. The final product purity was slightly below that resulting in Example 1, mainly owing to the presence of chenodeoxycholic and hyocholic acids.
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Process for pharmaceutical grade high purity hyodeoxycholic acid preparation starting from swine bile, consisting in the treatment of swine bile with sodium hydroxide, isolation of hyodeoxycholic, chenodeoxycholic and hyocholic acids by precipiation of their zinc salts and subsequent selective precipitation of the hyodeoxycholic acid magnesium salt, from which the acid is freed by acidification and then crystallized.
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CROSS REFERENCE To RELATED APPLICATIONS
This application is a continuation-in-part of pending U.S. patent application Ser. No. 11/528,850, filed Sep. 28, 2006.
FIELD
This invention relates to the field of systems for improving the installability of floor drains, especially drains used for concrete floors finished with a tile or the like on the surface of the concrete.
BACKGROUND
Floor drains are typically installed by plumbers on the ends of drain pipes at a certain level above grade prior to pouring a concrete slab. After a drain has been installed at the desired level, a concrete slab is poured. After the concrete slab has set, tile or other flooring is laid on top of the concrete base.
It is desirable to have the entire floor, including the grate of the drain, at a substantially uniform level. However, after the concrete sets, the grate member is fixed in position and cannot be easily adjusted to correct any differences with the level of the flooring. It is often necessary to chip away the concrete from around the grate to allow the height of the grate to be adjusted. Therefore, it is an object of this invention to allow the floor drain to remain adjustable after the concrete has set so that the level of the upper surface of the grate may be adjusted to be coextensive with the level of the flooring.
Previous attempts to remedy this problem have been made by placing plugs on top of the floor drain base when the concrete is poured. However, the drain is inoperable when these plugs are in place. As is well known, construction can often last for months or even years with long periods of inactivity possible on a job site. In floor construction, it is not uncommon for a concrete slab to be poured and then flooring to be laid several months later. Thus, it is an objective of the present invention to provide an operable height adjustable floor drain throughout construction of a floor in order to drain water and other liquids that collect.
Also, a concrete base is often ground by large grinding machines or otherwise finished prior to laying a floor. It is necessary for such finishing machines to be able to access all portions of the floor. Accordingly, it is an object of the present invention to provide a height adjustable drain which does not have portions protruding above the surface of the concrete base.
SUMMARY
The above and other needs are met by an apparatus and method for installing an adjustable height drain onto a conduit in a layer of hardenable material. The drain includes a grate member in fluid communication with a base member. In some embodiments, the grate member is adjustably connected to the base member and in other embodiments is adjustably connected to an adapter adjacent the base member. A spacer is disposed substantially adjacent at least a portion of the grate member to limit hardenable material from setting around the grate member when a layer of hardenable material is poured.
The spacer may be a loop of compressible material which is compressible generally between the grate of the grate member and the base member. The compressible material creates a void in the area around the grate member and prevents hardenable material from setting around the grate member.
The grate member may include a grate portion substantially nested in a removable concentric disc. As the grate member is elevationally adjusted towards the base member, the removable disc is biased towards the base member, thereby compressing the compressible material against the base member.
The spacer may also be the removable disc itself. The disc may be of a sufficient height that it prevents the hardenable material from setting adjacent the grate member.
After a layer of hardenable material is poured, flooring material may be installed on the upper surface of the hardenable material. The spacer may be removed from adjacent the grate member. The grate member may then be elevationally adjusted so that its upper surface is substantially flush with the upper surface of the flooring material. A second hardenable material can be placed into the void around the grate member formed by the sealing mechanism to create a base for flooring to be laid against the grate to create a coextensive floor.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the invention are apparent by reference to the detailed description when considered in conjunction with the figures, which are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein:
FIG. 1 is an exploded view of a floor drain apparatus according to a preferred embodiment of the invention;
FIG. 2 is a cutaway view of a floor drain apparatus according to a preferred embodiment of the invention;
FIG. 3 is a cutaway view of a preferred embodiment of a floor drain apparatus wherein a concrete floor base has been poured to the level of the upper surface of the grate and extension ring;
FIG. 4 is a cutaway view of a preferred embodiment of a floor drain apparatus installed in a concrete floor base wherein the extension ring and sealing ring have been removed;
FIG. 5 is a cutaway view of a preferred embodiment of a floor drain apparatus installed in a concrete floor base where tile has been laid on areas of the floor, the height of the grate member has been adjusted so that the upper surface of the grate will be the same level as the upper surface of the tile, and a filler material has been placed into the recess in the concrete created by the extension ring and sealing ring;
FIG. 6 is a cutaway view of a preferred embodiment of a floor drain apparatus installed in a concrete floor base wherein flooring has been installed up to the perimeter of the grate;
FIG. 7 is an exploded view of a floor drain apparatus according to an alternate embodiment of the invention;
FIG. 8 is a cutaway view of a floor drain apparatus according to an alternate embodiment of the invention;
FIG. 9 is a cutaway view of an alternate embodiment of a floor drain apparatus wherein a concrete floor base has been poured to the level of the upper surface of the grate and extension ring;
FIG. 10 is a cutaway view of an alternate embodiment of a floor drain apparatus installed in a concrete floor base wherein the extension ring has been removed;
FIG. 11 is a cutaway view of an alternate embodiment of a floor drain apparatus installed in a concrete floor base where tile has been laid on areas of the floor, the height of the grate member has been adjusted so that the upper surface of the grate will be the same level as the upper surface of the tile, and a filler material has been placed into the recess in the concrete created by the extension ring;
FIG. 12 is a cutaway view of an alternate embodiment of a floor drain apparatus installed in a concrete floor base wherein flooring has been installed up to the perimeter of the grate;
FIG. 13 a is a perspective view of an adapter for connecting the grate member of the floor drain apparatus to a drain base according to an embodiment of the invention;
FIG. 13 b is a top view of the adapter for connecting the grate member of the floor drain apparatus to a drain base;
FIG. 14 is an exploded view of the floor drain apparatus including an adapter for connecting the grate member to a drain base according to an embodiment of the invention;
FIG. 15 a is a top view of the floor drain apparatus including an adapter for connecting the grate member to a drain base; and
FIGS. 15 b & 15 c are cutaway views of the floor drain apparatus including an adapter for connecting the grate member to a drain base.
DETAILED DESCRIPTION
A preferred embodiment of the floor drain system 10 of the present invention is shown in FIGS. 1 & 2 . The system includes a drain base 12 with a central, substantially circular through opening 11 oriented on a vertical axis. The base member 12 perferably comprises an integral disc-shaped, horizontally disposed surrounding base flange 14 which forms the top part of the base member 12 and extends outwardly from generally around the central opening 11 in the base 12 . The base flange 14 is removably connected to the upper portion of the base 12 using bolts 16 or other suitable means thereby allowing access to the interior of the base for maintenance of otherwise. A substantially cylindrical base flange opening 18 is internally threaded to receive a depending cylindrical, externally threaded connector 22 integrally formed as part of an upstanding grate member 20 . The cylindrical connector 22 of the grate member 20 has a central circular opening 24 extending vertically through its length in flow communication and in vertical alignment with the opening 11 in the base member 12 when the two are threadably interconnected.
The bottom portion of the base is connectible to any of the standard conduits for draining liquid away from the area, typically disposed beneath the floor within or below concrete. For example, as shown in FIGS. 1 & 2 , a PVC drain pipe 26 may be connected to the base by a pipe coupling 28 , where the pipe coupling 28 has an externally threaded end portion 30 which is threadably connected to the bottom of the base 12 . The drain pipe 26 and pipe coupling 28 have substantially cylindrical openings extending vertically through at least a portion of their lengths in flow communication and vertical alignment with the opening 11 in the base member 12 .
Also, a water inlet 19 may be disposed in the base 12 which admits a steady, slow stream of water into the floor drain system 10 to keep a trap (not shown) primed in order to prevent sewer gas from entering the floor drain.
The grate member 20 further preferably includes an upper, integrally formed outwardly projecting disc-shaped grate flange 32 disposed in substantially parallel, vertically spaced-apart relation to the base flange 14 . The upper surface of the grate flange has a narrow, upstanding circular rim 34 around its perimeter. A recessed circular grate shelf 36 just inside the rim 34 is concentrically arranged vis-à-vis the rim 34 and the grate opening 24 , and is dimensioned to fittingly receive a circular grate thereon 38 . The grate 38 is removably attached to the shelf by spaced-apart screws or other suitable connection devices so the top surface of the grate 38 is flush with the top surface of the surrounding rim 34 .
The rim area of the grate flange 32 fits onto a narrow interior, circular ledge 42 of an extension ring 40 , the outer edge of which is generally vertically aligned with the outer edge of the base flange 14 . The upper and lower surfaces of the extension ring 40 are relatively wide and flat, and the ring is preferably dimensioned so that its upper surface 44 is substantially flush with the upper surfaces of the rim 34 and the grate 38 . In alternate embodiments, the external ring 40 may be integral with the grate flange 32 .
A resiliently compressible substantially donut-shaped seal ring 46 made of a material such as Armiflex is dimensioned to fit between the base flange 14 and the extension ring 40 around the threaded, cylindrical connector 22 of the grate member 20 . The seal ring 46 may be a continuous loop. Alternately, the seal ring 46 may be a discontinuous loop or even comprise two or more separate portions so that the seal rings may be disposed around the connector 22 after the grate member 20 has been connected to the base 12 .
As the grate member 20 is advanced deeper into the base 12 via the threaded interconnection of the two parts, the seal ring 46 becomes resiliently compressed between the upper surface of the base flange and the lower surfaces of the grate flange and extension ring. In alternate embodiments, no extension ring 40 is used and the seal ring 46 may be compressed between the grate flange 32 and the base flange 14 .
The base, grate member, and extension ring are preferably a made from a suitable metallic material, such as cast iron or stainless steel, but may also be made of any other suitable material such as plastic.
In use of the system of the preferred embodiment, as shown in FIGS. 2-6 , the components of the drain system 10 are assembled with the grate flange 32 resting on the ledge 42 of extension ring 40 and the seal ring 46 disposed between the base flange 14 and the extension ring 40 . The grate member 20 is then threaded down into the base member 12 until the top surface of the grate member 20 is at a height in the base 12 above grade 50 substantially corresponding to the expected height to which a concrete layer 52 will be poured. This downward movement of the grate member 20 and its flange portion 32 carries the extension ring 40 downwardly along with it, thereby compressing the seal ring 46 against the base flange 14 as described above. Concrete 52 is then poured so that its top surface is substantially flush with the top surface 44 of the extension ring 40 . The seal ring 46 in compression and the extension ring 40 above it serve to prevent concrete 52 from setting around the grate member 20 , thereby allowing the threaded connector 22 of the grate member 20 and the base member 12 to remain adjustable. Also, the drain 10 is operable before, during, and after the concrete has been laid.
After concrete 52 has been poured and sufficiently set such that it no longer exhibits substantial liquid characteristics, the grate member 20 , extension ring 40 , and seal ring 46 can be removed. Thereafter, a tile 56 or other floor may be laid on top of the surface of the concrete. Once the tile floor has been partially laid, the grate member 20 can be threaded back into the base 12 a distance and adjusted to a height substantially level with the grade of the tile. Caulking, grout, or other material 54 may then be placed in the void left by the seal ring and extension ring up to the level of the concrete 52 . Tile 56 may then be laid up to the edge of the rim 34 of the grate member 20 to finish the tile flooring. In the alternative, the extension ring 40 can be left in place and the tile 56 finished up to its edge. The drain grate 38 will then be flush or level with the surface of the tile floor.
Another preferred embodiment of the apparatus and method of the drain system of the present invention is shown in FIGS. 7-12 , wherein a seal ring 46 is not used. The base 112 and grate member 120 and their components are of corresponding structure to the base 12 and grate member and their components in the embodiment described above. However, rather than using the compressible seal ring, extension rings 140 of various heights may be used.
The rim area of the grate flange 132 fits onto a narrow interior, circular ledge 142 of an extension ring 140 , the outer edge of which is generally vertically aligned with the outer edge of the base 112 or base flange 114 in various embodiments. The upper surface 144 of the extension ring 140 is relatively wide and flat, and the ring is preferably dimensioned so that its upper surface 144 is substantially flush with the upper surfaces of the rim 134 and the grate 138 . The extension ring 140 has sidewalls 158 extending down from an upper disc-like portion 160 . The sidewalls generally rest on the top of the base 112 .
In use of the drain system 110 , as shown in FIGS. 8-12 , an extension ring 140 is chosen with sidewalls of a sufficient height so that when the components of the drain system 110 are assembled with the grate flange 132 resting on the ledge 142 of extension ring 140 and the grate member 20 is threaded down into the base member 112 , the top surface of the grate member 120 and the extension ring 140 are at a height in the base 112 above grade 150 substantially corresponding to a desired height to which a concrete layer 152 will be poured. A drain installer may be provided with a kit having extension rings of various heights to allow for a wide variation in heights to which the grate may be set prior to pouring the concrete layer.
After the grate member 120 is threaded into the base member 112 , concrete 152 is then poured so that its top surface is substantially flush with the top surface 144 of the extension ring 140 . The extension ring 140 serves to prevent concrete 152 from setting around the grate member 120 , thereby allowing the threaded connector 122 of the grate member 120 and the base member 112 to remain adjustable. Also, the drain 110 is operable before, during, and after the concrete has been laid.
After concrete 152 has been poured and sufficiently set such that it no longer exhibits substantial liquid characteristics, the grate member 120 and extension ring 140 can be removed. Thereafter, a tile 156 or other floor may be laid on top of the surface of the concrete. Once the tile floor has been partially laid, the grate member 120 can be threaded back into the base 112 a distance and adjusted to a height substantially level with the grade of the tile. Caulking, grout, or other material 154 may then be placed in the void left by the seal ring and extension ring up to the level of the concrete 52 . Tile 156 may then be laid up to the edge of the rim 134 of the grate member 120 to complete the tile floor. In the alternative, if desired, the extension ring 140 can be left in place and the tile 156 finished up to its edge. The drain grate 138 will be then flush or level with the surface of the tile floor.
In a further embodiment of the invention, an adapter may be used for connecting the threaded connector 22 / 122 to the drain base 12 / 112 , in order to allow the system to be used with drain bases of various sizes having cylindrical base flange openings 18 of various diameters. As shown in FIGS. 13 a and 13 b , the adapter may be a tabbed collar 80 with a threaded cylindrical opening 86 extending therethrough for receiving the threaded connector 22 / 122 therein. A first set of tabs 82 a and 82 b extend outwardly from the circumference of the collar 80 substantially adjacent the bottom edge 87 of the collar. The first set of tabs 82 a and 82 b are preferably spaced apart from each other about the circumference approximately 180 degrees. A second set of tabs 84 a and 84 b extend outwardly from the circumference of the collar 80 substantially adjacent the top edge 88 of the collar. The second set of tabs 84 a and 84 b are preferably spaced apart from each other about the circumference approximately 180 degrees and are preferably spaced apart from the first set of tabs approximately 90 degrees.
The first set of tabs 82 a and 82 b are sized such that the bottom portion of the threaded collar may be slid into cylindrical flange openings 18 of various sizes. IAs shown in FIGS. 15 b and 15 c , after being slid into a cylindrical flange opening, the first set of tabs 82 a and 82 b abut the base flange 14 / 114 when the tabbed collar is substantially centered within the cylindrical flange opening, thereby limiting the ability to remove the tabbed collar from the opening and holding the floor drain apparatus in place in the drain base during use. When placed in the cylindrical flange opening, the second set of tabs 84 a and 84 b preferably rest on the base flange to prevent the collar from falling into the drain base. In this regard, the second set of tabs 84 a and 84 b preferably extend farther from the circumference of the collar 80 than the first set of tabs 82 a and 82 b in order to limit the ability to slide through the cylindrical flange opening.
After placement of the tabbed collar 80 into the cylindrical flange opening 18 , the threaded connector 22 / 122 may be threaded into the threaded cylindrical opening 86 . Thereafter, as exemplified in FIGS. 15 b and 15 c , the system may be used substantially as described in the previous embodiments with the seal ring 46 or extension ring 140 . The tabbed collar 80 may remain in the drain base flow through opening and the grate member may be used as the drain in the finished floor. However, in alternate embodiments, the tabbed collar 80 may be removed from the drain base after concrete has been poured to the desired level and a second grate member sized to be threadably connected directly to the base member may be used.
In alternate embodiments, various other adapters may be used to facilitate the use of the system of the present invention with drain bases of several different sizes.
The foregoing description of preferred embodiments for this invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. For example, although the floor drain system is described with regard to preferred base members and grate members, adjustable drains with base members and grate members of various configurations typical in the plumbing field may be used with the invention. Further, the invention may be used in “non-floor” applications where a drain is at least partially enclosed in a solid material. The disclosed embodiments are chosen and described in an effort to provide the best illustrations of the principles of the invention and its practical application, and to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as is suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
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An apparatus and method for installing an adjustable height drain onto a conduit in a layer of hardenable material. The drain includes a grate member adjustably connected to and in fluid communication with a base member. A connection member connects the grate member and base member and is adjustable to allow the elevation of the grate member to be adjusted in relation to the base member. A spacer is disposed substantially adjacent at least a portion of the connection member to limit hardenable material from setting around the connection member when a layer of hardenable material is poured.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority right from the U.S. provisional patent application No. 61/695,540 that was filed on Aug. 31, 2012, the content of which is herewith incorporated in its entirety by reference.
FIELD OF THE INVENTION
The present invention generally relates to cyanocobalamin containing medications that are placed in the mouth, dissolved and swallowed for the prevention and treatment of headaches and body pains in humans and for enhancing the normal functioning of the human body by boosting the human defense against headaches and body pains.
BACKGROUND OF THE INVENTION
Human brains are one fiftieth of our body's weight, and yet consume up to one fifth of the body's energy. Two thirds of the brain's energy consumption goes into making nerve cells fire, and one third into cell maintenance. Most of the brain's energy is chemical energy manufactured in the mitochondria and stored in the form of ATP. Mitochondria live as organelles within cells, including brain cells. The number of mitochondria per cell can range from one to thousands, depending on the energy needs of the cell. Energy-hungry brain cells contain thousands of mitochondria. Once inside the body cyanocobalamin is converted to adenosylcobalamin and methylcobalamin. Adenosylcobalamin is critical to the health and functioning of the brain's mitochondria while methylcobalamin is critical to the health and functioning of the rest of the brain's and body's cells.
Muscle cells have a large energy demand and require lots of ATP. Muscle cells also have a correspondingly high number of mitochondria, and are often the site of the body's soreness and pain. The current invention focuses on musculoskeletal pain.
The current invention discloses novel approaches to prevent and treat the malfunctioning or underperformance of the body's mitochondria and cells with methylcobalamin, and adenosylcobalamin, and their chemical precursor, cyanocobalamin, especially in the central and peripheral nervous systems. The inventor of the current invention puts forth the theory that by providing cyanocobalamin, methylcobalamin, and/or adenosylcobalamin in therapeutic doses to headache and body pain sufferers that their mitochondria will attain sufficient therapeutic concentrations of these essential micronutrients to survive, increase in number and function properly, thereby not creating the symptoms of certain types of headache and body pain.
The current invention differs substantially from prior uses of cobalamins, such as hydroxycobalamin to take up excess nitric oxide, or cobalamins to prevent IgE-mediated allergic diseases, neurogenic inflammation or cobalamins to repair nerve cell-insulating myelin sheath.
Cyanocobalamin, methylcobalamin, adenosylcobalamin and hydroxocobalamin each contain a biologically rare cobalt metal atom as a central feature. Around that cobalt is the active part of each molecule (i.e. the moiety) which is the location responsible for the unique type of chemical reactions that molecule causes to make happen. Attached to their central cobalt atoms; cyanocobalamin has a cyano group, methylcobalamin has a methyl group, adenosylcobalamin has an adeno group, and hydroxocobalamin has a hydroxyl (OH) group. Because of these distinct electromagnetic properties, each of these compounds plays a distinct biochemical role.
Cyanocobalamin, methylcobalamin, and adenosylcobalamin (the three chemicals pertaining to the current patent) differ in some important ways from hydroxocobalamin (which does not pertain to the current patent).
Once inside the body cyanocobalamin is converted to methylcobalamin and adenosylcobalamin, but not to hydroxocobalamin.
Hydroxocobalamin is known to scavenge nitric oxide (NO) which is associated with migraine. Hydroxocobalamin does this scavenging by trading its OH group connected to its central cobalt with the nitric oxide molecule. Because neither cyanocobalamin, nor methylcobalamin, nor adenosylcobalamin have the ability to scavenge nitric oxide, their ability to lessen the frequency and severity of headaches cannot be ascribed to nitric oxide scavenging.
In 1999 Merkus disclosed in U.S. Pat. No. 5,925,625 a method and composition for the prophylaxis and treatment of headaches using intranasal hydroxocobalamin. The current invention can be distinguished from Merkus' patent because the current invention discloses the use of different chemical entities, namely cyanocobalamin, methylcobalamin, and adenosylcobalamin. The current invention can be distinguished from Merkus' patent because Merkus describes a short-term treatment while the current patent describes a long-term treatment. The current invention can be further distinguished from U.S. Pat. No. 5,925,625 because Merkus states that “Oral, sublingual as well as nasal administration of vitamin B12 appeared to be ineffective treatments . . . ” while the current patent teaches away from Merkus because the current patent discloses that buccal and sublingual administration do indeed yield effective treatments for headache.
In 2001 Ernest T. Armstrong (the inventor of the current invention) disclosed in U.S. Pat. No. 6,255,294 a method to treat allergy using cobalamins. However, in U.S. Pat. No. 6,255,294 there is no mention of headache or migraine. In U.S. Pat. No. 6,255,294 the invention relied on a method for treating Immunoglobulin E (IgE) mediated atopic disease including allergic rhinitis and asthma. Such atopic diseases are a completely different class of disease and human condition with different causations and modes of action than the headaches and body pains disclosed in the current invention. The claims of U.S. Pat. No. 6,255,294 were approved with cyanocobalamin, methylcobalamin, and hydroxocobalamin, but not with adenosylcobalamin.
In 2002 van der Kuy showed in an unblinded, open-label study on 19 migraine patients that intranasal hydroxocobalamin can have an effect on migraine. The authors of the van der Kuy study hypothesize that hydroxocobalamin might be effective in migraine because of its nitric oxide-scavenging activity. Flaws in the van der Kuy study include the lack of a placebo group as a comparator, and the lack of any follow up after the last day the subjects received their last dose of medication which could have demonstrated (or not demonstrated) a persistence of effect. The current invention can be distinguished from van der Kuy's research because van der Kuy used hydroxocobalamin while the current invention discloses the distinct chemical entities of cyanocobalamin, methylcobalamin, and adenosylcobalamin. The current invention can be distinguished from van der Kuy's research because van der Kuy's treatment has a short-term persistence of effect while the current invention has a long-term effect. The current invention can be distinguished from van der Kuy's research because for all subjects van der Kuy showed essentially no reduction in severity (mean of 2.2 at baseline versus 2.1 at the end of the study, on a 0-3 scale). The current invention can be further distinguished from van der Kuy's research because van der Kuy's mechanism of action describes hydroxocobalamin as a nitric oxide (NO) scavenger. Nitric oxide is created and excreted by the body within a matter of hours. The important distinguishing point is that the current invention's mechanism of action most certainly is different than that of van der Kuy's invention because the scavenging of nitric oxide lasts only hours while the current invention has a persistence of effect lasts weeks, and perhaps months or years. (Van der Kuy, H et al. Hydroxocobalamin, a nitric oxide scavenger, in the prophylaxis of migraine: an open, pilot study. Cephalalgia, 2002, 22, 513-519.)
Dalsgaard-Nielsen performed a double-blind, placebo-controlled study on 29 patients (active n=15 and placebo n=14). During two months every two weeks 2 mg of cyanocobalamin were administered intramuscularly. The patients reported a: “Good result” active n=4 versus placebo n=2, and “Considerable improvement” active n=2 versus placebo n=5. The authors concluded that no therapeutic effect attributable to cyanocobalamin was demonstrated. (Dalsgaard-Nielsen A T, Trautmann J. Profylaktisk behandling of migraene med vitamin B12. Almindelige Danske Laegeforening 1970; 132:339-41.)
The authors of the van der Kuy study also hypothesize that since cyanocobalamin has no nitric oxide-scavenging activity, in contrast to hydroxocobalamin, it is not surprising that in the Dalsgaard-Nielsen trials on cyanocobalamin no effect was seen in migraine patients. Van der Kuy was correct about the lack of cyanocobalamin's nitric oxide-scavenging activity, but they missed another flaw in the Dalsgaard-Nielsen trials: Dalsgaard-Nielsen administered cyanocobalamin only once every two weeks. Based on the current inventor's original clinical research, the current invention teaches away from Dalsgaard-Nielsen and discloses a particularly preferred embodiment of daily administration of cyanocobalamin, with repeated delivery ranging from about 15 days to about 60 days.
The non-obviousness of the instant claims can be established by considering that oral (buccal) dissolving strip, sublingual lozenges and other disclosed means of introducing the headache and body pain opposing medications orally provide significant improvements over the prior art in that the dissolving strip are more convenient for the headache patient than a series of injections, or a nasal spray. Compared to an injection, or nasal spray, a dissolving strip or a sublingual lozenge is much more convenient because it takes from between one minute and five minutes to inject oneself or to administer a nasal spray. These few minutes may not seem like much, but to the headache patient, time is of the essence.
Another advantage is that people in pain do not want something stuffed up their nose or an injection in the body.
Among the surprising advantages of the dissolving strip and sublingual lozenge over the injection and nasal spray is that the headache patient would not be further irritated by a painful injection process or by a nasal spray up a sensitive nostril. This is an important aspect of the oral strip which comes in an easy to use soft plastic container because headache patients are often hypersensitive to bright lights (photophobia), shrill sounds (phonophobia), smells (osmophobia), and metallic objects touching the body. Such extraneous irritations are the last thing a headache sufferer would want at the time he or she is experiencing an episode of headache, thus the strips and sublingual lozenge differ in a significant way.
The significance of the difference between the oral dissolving medication and other delivery means becomes apparent when one examines the large numbers of people and money involved. There are between 30 and 50 million headache sufferers in the United States, thus if only ten percent can be provided an improvement, then some 3 to 5 million people will be helped. According the American Academy of Pain Medicine, pain affects more Americans than does diabetes, heart disease, and cancer combined. Back pain problems in the United States are reported to cost more than $100,000,000,000 annually.
Many large pharmaceutical companies have spent millions of dollars over many years investigating new medications for headache sufferers, but none of them have developed any medication with the safety profile, efficacy and ease of use afforded by the current invention.
EXAMPLE 1
This clinical study was designed and directed by the inventor of the current patent. Methods: 162 human subjects with demonstrated seasonal allergic rhinitis (hay fever) in the Pacific Northwest region of the United States were split into two groups with approximately 50 percent in the active group and 50 percent in the placebo group. Subjects were given their study medication, either Cyanocobalamin, USP or placebo in the a.m. and p.m. every day for 21 consecutive days. Data on adverse events including headache was captured throughout the ten-week duration of the study. Week One was a baseline during which time no medication was administered; Weeks Two, Three and
Four were the weeks during which time the subjects received their study medication; and Weeks Five through Ten were a post-treatment period during which time no medication was administered but observations of symptoms and adverse events were documented. Each time a subject felt a “Headache”, he or she reported its occurrence.
Results: The subjects' post-treatment reports of “Headache” decreased from baseline in the following surprising and unexpected results: Week Five −1.4 active vs. −0.9 placebo, Week Six −1.6 active vs. −2.0 placebo, Week Seven −1.4 active vs. −0.1 placebo, Week Eight −2.1 active vs. −1.2 placebo, Week Nine −3.4 active vs. −1.8 placebo, and Week Ten −3.2 active vs. −0.3 placebo.
The results also demonstrated a persistence of effect of at least six weeks after finishing the treatment. The results also demonstrated that there was a greater reduction in the frequency of headache in the active group versus placebo in five out of six post-treatment weeks. Additionally, almost one year later a follow-up questionnaire was completed by 43 active and 49 placebo subjects, the results of which suggest a persistence of effect lasting almost one year.
EXAMPLE 2
This clinical study was designed and directed by the inventor of the current patent. A large, multi-center, Phase 3, randomized, placebo-controlled clinical study on 1,551 patients was designed and directed by the inventor of the current patent. Methods: The study was titled: “A Phase 3, randomized, double-blind, placebo-controlled, parallel group study of the safety and efficacy of pre-seasonal sublingual cyanocobalamin lozenges on moderate to moderately severe seasonal allergic rhinitis in humans”. The study took place before and during the ragweed pollen season at 23 study sites in the Midwest, Northeast and Central Texas regions of the United States. Essentially all of the 23 investigators were Board Certified in Allergy/Immunology. Qualified subjects were randomized into an active or placebo group (approximately 50% and 50%) using an interactive voice recognition system (IVRS). All subjects (or their guardians) signed an Informed Consent form approved by the IRB. Each subject had three visits to the clinic. At Visit 1 and at Visit 3, they were given a physical exam (HEENT, chest, lungs, heart, vital signs, height and weight); and donated blood and urine samples for laboratory analysis. CBC and chemistry panels were run for safety analyses. The blood samples were analyzed by chemiluminescent immunoassay for the presence of ragweed specific immunoglobulin epsilon (IgE), and were assayed for cobalamins (cyanocobalamin, methylcobalamin and adenosylcobalamin) levels.
Subjects self-rated the severity their allergy symptoms in the morning (a.m.) and in the evening (p.m.) by entering a numeric score in a keypad of a telephone (IVRS) or in a computer connected via the Internet to a database.
Subjects were given their study medication, either 3.3 mg Cyanocobalamin, USP or placebo in the a.m. and p.m. Subjects were instructed to let the study drug “dissolve completely in your mouth, especially under your tongue, then swallow.”. Subjects self-administered the study medications for six consecutive weeks. For the next four weeks subjects did not take any study medications.
Any adverse event (AE) or serious adverse event (SAE) was documented by the subject in a paper diary and then transcribed to the appropriate case report form (CRF) page. All SAEs were attended to by the investigator, and reported to the FDA by the sponsor. All sites were monitored multiple times by qualified monitors.
Results: There was a total enrollment of 1,551 subjects (RA5555 n=763 and RA3333 n=788). The total number of doses possible was 84 doses. Over 50 percent (n=766) of the 1474 subjects who reported taking at least one dose, took at least 80 doses of study medication.
The allergy symptom scores were derived by summing and averaging all a.m. plus all p.m. scores for the symptoms of sneezing, runny nose, nasal congestion, nasal itch and eye itch. The primary comparison of interest was the scores across Weeks 4, 5 and 6 (i.e. during the pollen season). All randomized subjects who took at least one dose were included in this intent-to-treat (ITT) analysis. The reduction in symptom severity from baseline was greater for the active group than the placebo group for all five composite symptoms: sneezing, runny nose, nasal congestion, nasal itch and eye itch.
In terms of safety, the active study medication was well tolerated.
As per the laboratory results, a significant average increase of more than 250 percent in post-treatment blood serum cobalamin (cyanocobalamin, methylcobalamin and adenosylcobalamin) levels was reported in the cyanocobalamin-treated subject groups compared with essentially no increase in placebo-treated subjects.
The following types of headaches were self-diagnosed and documented by subjects in the study: tension headache, headache, migraine, increased frequency of headaches, worsening sinus migraine headache, increased headache, headache worsening, worsening of migraine, sinus headache, severe sinus headache, and sinus pressure headache.
The following types of body pains and myasthenia were self-diagnosed and documented by subjects in the study: ear pain, earache, sore throat, sore muscles, leg cramps, myalgia, back pain, sprained ankle, ache, toothache, hip pain, finger pain, knee pain, pulled back muscle, shoulder pain, pulled hamstring, neck pain, femur pain, gum pain, sore muscle, toenail pain, sore foot, and pulled neck muscle.
Of the 294 documented reports of some type of headache and of body pain, the study yielded the following surprising and unexpected frequencies demonstrating positive results: 137 reports in the active group compared to 157 reports in the placebo group. The severities of those headaches and body pains were rated in the following surprising and unexpected intensities: “Mild” 63 reports (or 46.0%) in the active group versus 71 reports (or 45.2%) in the placebo group; “Moderate” 68 reports (or 49.6%) in the active group versus 68 reports (or 43.3%) in the placebo group; and “Severe” 6 reports (or 4.4%) in the active group versus 18 reports (or 11.5%) in the placebo group.
EXAMPLE 3
The current invention was successfully tested in humans with a history of headache and/or body pains in a variety of formulas. These formulas comprised dissolving medications containing combinations of cyanocobalamin, methylcobalamin, adenosylcobalamin, magnesium, coenzyme Q10, L-carnitine, and riboflavin.
Formula 1 was a dissolving medication with 3.3 mg of cyanocobalamin.
Formula 2 was a dissolving medication with 6.6 mg of cyanocobalamin.
Formula 3 was a dissolving medication with 3.3 mg of methylcobalamin.
Formula 4 was a dissolving medication with 3.3 mg of adenosylcobalamin.
Formula 5 was a dissolving medication with 2.2 mg of cyanocobalamin, 2.2 mg of methylcobalamin, and 2.2 mg of adenosylcobalamin.
Formula 6 was a dissolving medication with 3.3 mg of adenosylcobalamin.
Formula 7 was a dissolving medication with 5.6 mg of cyanocobalamin, 0.5 mg of methylcobalamin, and 0.5 mg of adenosylcobalamin.
Formula 8 was a dissolving medication with 1.1 mg of cyanocobalamin, 1.1 mg of methylcobalamin, and 1.1 mg of adenosylcobalamin.
Formula 9 was a dissolving medication with 2.2 mg of cyanocobalamin, 2.2 mg of methylcobalamin, 2.2 mg of adenosylcobalamin, 15 mg of coenzyme Q10, and 2.1 mg of riboflavin.
Formula 10 was a dissolving medication with 1.1 mg of cyanocobalamin, 1.1 mg of methylcobalamin, 1.1 mg of adenosylcobalamin, 18 mg of coenzyme Q10, and 2.1 mg of riboflavin.
Formula 11 was a dissolving medication with 1.1 mg of cyanocobalamin, 1.1 mg of methylcobalamin, 1.1 mg of adenosylcobalamin, 5 mg magnesium, 9 mg of coenzyme Q10, 5 mg L-carnitine, and 2.1 mg of riboflavin.
Formula 12 was a dissolving medication with 5.6 mg of cyanocobalamin, 0.5 mg of methylcobalamin, 0.5 mg of adenosylcobalamin, 15 mg of coenzyme Q10, and 1 mg of riboflavin.
Formula 13 was a dissolving medication with 5.6 mg of cyanocobalamin, 0.5 mg of methylcobalamin, 0.5 mg of adenosylcobalamin, 5 mg magnesium, 10 mg of coenzyme Q10, and 2.1 mg of riboflavin.
Formula 14 was a dissolving medication with 5.6 mg of cyanocobalamin, 0.5 mg of methylcobalamin, 0.5 mg of adenosylcobalamin, 10 mg of coenzyme Q10, and 1 mg of riboflavin.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Headaches, such as tension headache and sinus headache, are painful and can rob individuals of quality of life. Headache symptoms include a pounding headache, nausea, vomiting, and light sensitivity. Body soreness is a pain in the body. Conventional headache and body pain remedies include various types of pain relievers, pain killers, and analgesics, including COX-1, COX-2, opioids, and NSAIDs; none are without side-effects, including drug addiction, liver damage and cardiovascular events; and none get to the truly underlying causes of pain and neurological health, as does the current invention.
The International Classification of Headache Disorders (ICHD) is a classification of headaches published by the International Headache Society. The current patent applies to primary headaches which the ICHD-2 classification defines as migraines, tension-type headaches, cluster headache and other trigeminal autonomic cephalalgias stabbing headaches, headaches due to cough, exertion and sexual activity (coital cephalalgia), continuous headache on one side of the head (hemicrania continua), paroxysmal hemicrania, daily-persistent headaches along with the hypnic headache and thunderclap headaches.
Vitamin B12 or simply B12 are unspecific terms often used casually for a variety of cobalamins, including cyanocobalamin, methylcobalamin, and adenosylcobalamin.
All other headache remedies with adequate research proving their efficacy have safety profiles that contrast sharply with cyanocobalamin, methylcobalamin, and adenosylcobalamin which are considered by the nutritionists and the FDA to have excellent safety profiles, they are so safe and vital to health, that—like exceedingly few other products—they are recommended to women who are pregnant and lactating! The metal cobalt plays a central role in these molecules with its unique electrochemical bounding abilities. These molecules are the only molecules in the human body to utilize these special properties of cobalt, are difficult to absorb from food, and cannot be manufactured by the body.
Cyanocobalamin (also known as CNCbI, or 5,6-dimethylbenzimidazolyl cyanocobamide) has the molecular formula C63H88CoN14O14P. Cyanocobalamin is a manufactured commercial form of a cobalamin, and not native to the human body. Once inside the body cyanocobalamin is converted to methylcobalamin and adenosylcobalamin, but not to hydroxocobalamin.
Methylcobalamin (also known as mecobalamin, or MeCbl) has the molecular formula C63H91CoN13O14P and is notable as a rare example of an enzyme that contains metal-alkyl bonds. Methylation is the donation of a methyl group to a substrate, and methylcobalamin can function as the donor molecule. Proper DNA replication and cell division require methylation. For this reason, and others, the current invention includes cyanocobalamin and methylcobalamin.
Adenosylcobalamin (also known as cobamamide, AdCbl, or dibencozide) comprises more than 70 percent of the cobalamins in the brain. Adenosylcobalamin functions in reactions in which hydrogen groups and organic groups exchange places. Adenosylcobalamin is the major form in cellular tissues, especially energy-hungry muscles, where it is retained in the mitochondria. Adenosylcobalamin is the coenzyme for the mitochondrial enzyme methylmalonyl CoA mutase. Problems with methylmalonyl CoA mutase can lead to methylmalonic aciduria and dysfunction of the mitochondria. In one preferred embodiment of the current invention, adenosylcobalamin is included to prevent dysfunction of the mitochondria in the brain.
The mitochondrion (plural mitochondria) is the “cell's powerhouse”. Most of the organism's stored energy is converted into a usable chemical energy known as adenosine triphosphate (ATP) in the mitochondria. The citric acid cycle or Krebs cycle generates GTP which becomes ATP. Problems with the mitochondria can cause them to die. Problems with the mitochondria, which are also involved in cell signaling, cell death, and cell differentiation, can disrupt the functioning of the cell, tissue and organ in which they survive. It is an organelle with its own strand of DNA, distinct from DNA in the nucleus. Mitochondria are found inside most animal cells. Populations of mitochondria per cell range from one to thousands. Mitochondria living in our cells may be hitch-hiking, symbiotic descendants of bacteria that provided some benefits to us, indeed mitochondrial DNA resembles bacterial DNA. We certainly provided a safe living cell as home with all the warmth and nutrients to these bacteria. When one realizes that the basic chemical structure of cobalamins can only be synthesized by bacteria, it is not hard to see a critical connection and history between mitochondria and cobalamins.
Consistent with the idea that certain types of headache are a result of insufficient energy production by the mitochondria are reports of headache remedies that lessen the brain's demand for energy including relaxation techniques, meditation, and calming affirmations while hypnotized. Also consistent are reports that providing more oxygen to an individual can ameliorate headaches, such treatments include repeated deep breathing and hyperbaric oxygen. Other consistent findings are that regular exercise can both prevent headaches and that exercise can increase the number of mitochondria in the brain. Conversely, strenuous physical activity by people who are not accustomed to it can reduce oxygen concentrations in the brain and have been reported to trigger a benign exertion headache. Likewise carbon monoxide (which binds up hemoglobin) and tobacco smoke can reduce oxygen and are associated with headache. Brain scans called fMRI detect where there is increased blood flow in the brain, which is a surrogate indicator for where there is increased brain activity. Such fMRI scans show that three of the highest energy demanding functional areas of our brains are those areas which process vision, smell and hearing. Accordingly the mitochondrial dysfunction theory of headache is consistent with the hypersensitivity of headache sufferers to bright lights, bad smells, and loud noises. Indeed, visual disturbances known as aura can occur an hour or so prior to the onset of a headache.
The brain's electrical activity correlates to changes in cerebral blood flow and cerebral metabolic rate of oxygen. Rises in cerebral metabolic rate of oxygen are controlled by the ATP turnover, which depends on the energy used for the Na, K-ATPase to re-establish ionic gradients, while cerebral blood flow responses are controlled by mechanisms that depend on Ca(2+) rises in neurons. (Lauritzen M, Neuroimage, 2012 Aug. 15; 62(62(2):1040-50.) Caffeine acts as a stimulant because it constricts the brain's blood vessels and many analgesics contain caffeine to fight headaches, especially vascular headaches including migraines. Other products, such as adenosine, have the opposite effect because they dilate blood vessels in the brain and the increased blood flow can lead to a headache. Vasodilation may be part of a headache, yet it is not required for migraine symptoms to manifest. Vasodilation and the brief vasoconstriction that generally precedes it are not the root causes of vascular headaches, as once believed.
The current invention teaches away from the prior art in its findings. The seemingly contradictory idea that headaches are caused by insufficient metabolism of oxygen in the mitochondria, and that increasing blood flow is also a cause of headaches can be reconciled as follows: Blood vessels over essentially all of the brain are normally constricted in a resting, non-headache state, and it is only at the local functional area(s) in the brain where current neurological processing is taking place that momentary vasodilation of the blood vessels (i.e. increases in local cerebral blood flow) occur. (This increased local blood flow can be seen in fMRI images that detect the iron in hemoglobin being fed to the high activity locations.) This local spike in cerebral blood flow delivers a quick, just-in-time oxygen supply to permit a local increase in the cerebral metabolic rate of oxygen. Ameliorating headaches by restricting blood flow all over the brain (increasing mean arterial pressure) is analogous to keeping all the fire hydrants in a city sealed shut except that one hydrant in front of a burning building where opening just that one hydrant provides sufficient pressure to blast the water out.
Hours or days prior to the onset (aura) of a migraine attack, a headache sufferer often experiences a set of symptoms known as prodrome consistent with the current invention's teachings of mitochondrial dysfunction or underperformance in the brain and muscles. Prodrome's symptoms include mood changes, muscle stiffness, yawning (which is a call for more oxygen), fatigue and food (nutrition) cravings.
The current inventor contends that the root cause of many headaches and body pains is inadequate energy (ATP) production in the mitochondria needed to fuel the energy-hungry brain and muscle cells (and not the inflammatory response as per conventional wisdom), and that surprisingly the current invention can provide the micronutrients needed as raw materials to permit the optional functioning of mitochondria.
A non-obvious mechanism of action disclosed in the current invention is that increased mitochondrial concentrations of adenosylcobalamin (and also coenzyme Q10, magnesium, L-carnitine, and riboflavin) prevent or lessen the severity of a cellular energy crisis in which mitochondrial function declines. Such a decline can be due to alternating inner membrane potential, imbalanced trans-membrane ion-transport, and an overproduction of free radicals. (Zhuo M L, Huang Y, Liu D P, Liang C C (April 2005). “KATP channel: relation with cell metabolism and role in the cardiovascular system”. Int. J. Biochem. Cell Biol. 37 (4): 751-64.) In such a situation, mitochondrial K(ATP) channels open and close to regulate both internal Ca2+ concentration and the degree of membrane swelling. This helps restore proper membrane potential, allowing further H+ outflow, which continues to provide the proton gradient necessary for mitochondrial ATP synthesis. Without aid from the potassium channels, the depletion of high energy phosphate would outpace the rate at which ATP could be created against an unfavorable electrochemical gradient. (Xu M, Wang Y, Ayub A, Ashraf M (September 2001). “Mitochondrial K(ATP) channel activation reduces anoxic injury by restoring mitochondrial membrane potential”. Am. J. Physiol. Heart Circ. Physiol. 281 (3): H1295-303.)
An ATP-sensitive potassium channel is a type of potassium channel that is gated by ATP. Simply stated, levels of ATP influence constriction and dilation of blood vessels which have receptors for ATP known as P2x-R. Many vascular headaches, including migraine, begin with a brief vasoconstriction immediately followed by vasodilation, resulting in a throbbing headache. The current invention therefore surprisingly prevents headaches by providing the micronutrients needed for the mitochondria to function properly.
Any shortage or deficiency of adenosylcobalamin and/or the other micronutrients disclosed in the current invention will impair or inhibit mitochondrial functioning. Additionally, increasing amounts of adenosylcobalamin and/or the other micronutrients disclosed herein will accelerate the chemical reactions in the mitochondria, thereby permitting the mitochondria to metabolize more chemical energy over a given period of time.
One example of the utility of the current invention is its amelioration of mitochondrial dysfunction in the hypothalamus, a hormone secreting region of the brain which is associated with cluster headaches.
One especially preferred embodiment of the current invention is a once-daily dissolving that is placed on the tongue and swallowed, and contains combinations of cyanocobalamin, methylcobalamin, and adenosylcobalamin in amounts that are effective in defending the individual against headache and body pain; and the current invention also includes one or more of the following substances or metabolites and salts thereof: magnesium, coenzyme Q10, L-carnitine, and riboflavin.
Magnesium ions are important to the production of nucleic acid, DNA, and RNA, and the catalytic action of many enzymes. Of special relevance to the current invention are the magnesium-dependant enzymes associated with the conversion of adenosine triphosphate (ATP) into adenosine diphosphate (ADP) in the mitochondria. Phosporylation is an important process that occurs in the mitochondria. For this reason, one particularly preferred embodiment of the current invention includes elemental magnesium, magnesium oxide, magnesium gluconate, magnesium citrate, magnesium oxide, magnesium orotate, magnesium malate, and combinations thereof in the formulation in amounts ranging from about 10 mg to about 500 mg per portion.
Proper functioning of the mitochondria requires coenzyme Q10 (CoQ10), also known as ubiquinone or 1-4-benzoquinone. In one preferred embodiment, coenzyme Q10 is included in the formulation in amounts ranging from about 10 mg to about 500 mg per portion.
Riboflavin (vitamin B2) has an important function in energy metabolism. Flavin mononucleotide (FMN) and flavin adenine dinucleotide (FAD) function as coenzymes for a wide variety of oxidative enzymes and remain bound to the enzymes during the oxidation-reduction reactions. Reduction of isoalloxazine ring (FAD, FMN oxidized form) yields the reduced forms of the flavoproteins (FMNH2 and FADH2). For this reason, one particularly preferred embodiment of the current invention includes riboflavin in the formulation in amounts ranging from about 0.1 mg to about 300 mg per portion.
Levocarnitine (or L-carnitine) plays an important role in energy metabolism by helping the transport of fatty acids from the cytosol into the mitochondria. Also, it helps remove toxic chemical byproducts from the mitochondria so they do not accumulate. In one preferred embodiment of the current invention, L-carnitine, acetyl-L-carnitine (L-acetylcarnitine), L-propionyl carnitine, or L-carnitine fumarate, and combinations thereof is included in doses between 1 mg and 400 mg per portion.
One especially preferred embodiment of the current invention is a once-daily dissolving medication that is placed on the tongue and swallowed, and contains combinations of cyanocobalamin, methylcobalamin, adenosylcobalamin, magnesium, coenzyme Q10, and riboflavin in amounts that are effective in defending the individual against headache and body pain.
One particularly preferred embodiment of the current invention is a once- or twice-daily dissolving that is placed on the tongue and swallowed. Each dosage's approximate contains are: 1.1 mg of cyanocobalamin, 1.1 mg of methylcobalamin, 1.1 mg of adenosylcobalamin, 5 mg of coenzyme Q10, and 1.2 mg of riboflavin.
In one preferred embodiment, the current invention includes one or more of the following plants or extracts thereof: feverfew ( Tanacetum parthenium, Chrysanthemum parthenium, Pyrethrum parthenium ), kudzu ( Pueraria lobata ), capsicum ( solanaceae ), butterbur ( Petasites hybridus ), ginger ( zingiber officinale ) and ginko ( ginko biloba ).
In the current invention, formulation of dissolving medication can employ hydrophilic polymers that rapidly dissolve in the mouth, preferably on top of the tongue. The cyanocobalamin, methylcobalamin, and adenosylcobalamin permeate the skin of the mouth and, in a certain percentage, are ingested for absorption by the gut, especially the ileum. In one preferred embodiment of the current invention, formulation of dissolving medication involves the application of both aesthetic and performance characteristics such as polymers, plasticizers, active pharmaceutical ingredients, sweetening agents, saliva stimulating agents, flavoring agents, coloring agents, stabilizing and thickening agents. In the current invention, formulation of dissolving medication can employ polymers such as maltodextrin, microcrystalline cellulose and piroxicam made with a hot extrusion technique. To make the medication more flexible; plasticizer excipients such as propylene glycol, glycerol, dimethyl phthalate, diethyl phthalate, dibutyl phthalate, triacrtin, castor oil, triethyl citrate, tributyl citrate, acetyl citrate in the current invention. In one preferred embodiment of the current invention Stevia (steviol glycoside) is used to sweeten the medications.
In one particularly preferred embodiment, the headache medication is delivered to the headache sufferer in a dissolving medication placed in the mouth. The dissolving medication is a thin film delivery technology, and is also referred to as a dissolving film or an oral strip. The current invention defines a dissolving strip as a thin film delivery means to administer active agent(s) via absorption in the mouth. This absorption can be in the mouth as a whole (buccally) on top of the tongue (supralingually), or under the tongue (sublingually) followed up by swallowing.
The skin, including the surface of the tongue, provides a physical barrier that can interfere with the absorption of active drug ingredients. Although cyanocobalamin, methylcobalamin, and adenosylcobalamin are known to permeate the skin in the mouth, a penetration enhancer can increase their transdermal delivery in one preferred embodiment. Penetration enhancers that can increase transdermal delivery and can be used preferably in various embodiments of the current invention include but are not limited to: dimethyl isosorbide, alpha bisobola, sulphoxides (e.g. dimethylsulphoxide), azones (e.g. laurocapram), pyrrolidones (e.g. 2-pyrrolidone), alcohols and alkanols (e.g. ethanol and decanol), glycols (e.g. propylene glycol), surfactants, terpenes, fatty acids, fatty acid esters, fatty alcohols, fatty alcohol esters, biologics, enzymes, amines, amides, complexing agents, macrocyclics, classical surfactants and the like. Gels and creams with a Lamellar or liquid crystal structure also enhance penetration of active ingredients.
When considering the various embodiments of the invention described herein, those knowledgeable in the art will appreciate that these are illustrative only. Such embodiments do not limit the scope of the invention. Those knowledgeable in the art involved will appreciate that many variations, substitutions, equivalents, and like modifications may be made within the scope of the present invention.
SUMMARY OF THE INVENTION
Consistent with original study findings on almost 2,000 people, most of whom were in a Phase III placebo-controlled clinical study, the present invention is directed to safe and effective cyanocobalamin, methylcobalamin, and/or adenosylcobalamin containing, orally-dissolving medications to reduce the frequency and severity of pains in the head and body in humans and for enhancing the normal functioning of the human body by boosting the human defense against headaches and body pains.
A non-obvious mechanism of action disclosed in the current invention is that higher concentrations of adenosylcobalamin (and other disclosed compounds) in the mitochondria prevent or lessen the severity of a cellular energy crisis in which mitochondrial function declines. Mitochondria convert sugars into chemical energy the cell can use called ATP. Levels of ATP also function to constrict and dilate blood vessels. Many vascular headaches, including migraine, begin with a brief narrowing of the blood vessels (vasoconstriction) followed by an opening up blood vessels resulting in a throbbing headache. The current invention therefore surprisingly prevents headaches by providing the micronutrients needed for the mitochondria to function properly.
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The current invention discloses novel approaches to help individuals defend against headaches and body pains with orally-delivered cyanocobalamin, methylcobalamin, adenosylcobalamin, and combinations thereof. Original clinical research conducted by the inventor on almost 2,000 humans yielded surprising and unexpected results showing differences in the frequency and severity of pains in the head and the body favoring cyanocobalamin patients over placebo. In one FDA-approved Phase III study on 1,551 patients, 4.4 percent of headaches and body pains were rated as “Severe” in the cyanocobalamin, group versus 11.5 percent in the placebo group. Once inside the body, cyanocobalamin is converted to methylcobalamin and adenosylcobalamin, but not to hydroxocobalamin. The current invention provides the patient's mitochondria with sufficient concentrations of essential micronutrients to survive, increase in number and manufacture the chemical energy (ATP) that is required to prevent the brief vasoconstriction followed by vasodilation associated with headache and body pain.
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PRIORITY CLAIM
This application claims priority from Provisional Application Ser. No. 61/328,889 filed Apr. 28, 2010.
FIELD AND BACKGROUND OF INVENTION
The invention is generally related to floating offshore structures and more particularly to the centerwell arrangement of a spar type hull.
There are a number of spar hull designs available in the offshore oil and gas drilling and production industry. These include the truss spar, classic spar, and cell spar. The term spar hull structure described herein refers to any floating structure platform, which those of ordinary skill in the offshore industry will understand as any floating production and/or drilling platform or vessel having an open centerwell configuration.
A spar hull is designed to support a topsides platform and riser system used to extract hydrocarbons from reservoirs beneath the seafloor. The topsides support equipment to process the hydrocarbons for export to transport pipelines or to a tanker for transport. The topsides can also support drilling equipment to drill and complete the wells penetrating the reservoir. The product from these wells is brought up to the production platform on the topsides by risers. The riser systems may be either flexible or steel catenary risers (SCRs) or top tensioned risers (TTRs) or a combination of both.
The catenary risers may be attached at any point on the spar hull and routed to the production equipment on the topsides. The routing may be on the exterior of the hull or through the interior of the hull. The TTRs are generally routed from wellheads on the seafloor to the production equipment on the topsides platform through the open centerwell.
These TTRs may be used for either production risers to bring product up from the reservoir or as drilling risers to drill the wells and provide access to the reservoirs. In some designs where TTRs are used, either buoyancy cans or pneumatic-hydraulic tensioners can support (hold up) these risers. When buoyancy cans are used, the buoyancy to hold up the risers is supplied independently of the hull and when tensioners are used these tensioners are mounted on the spar hull and thus the buoyancy to hold up the risers is supplied by the spar hull. In either method of supporting the risers, TTRs are generally arranged in a matrix configuration inside an open centerwell. The spacing among the risers in this centerwell location is set to create a distance among the risers that allows manual access to the production trees mounted on top of the risers.
The spar type structure which supports the topsides comprises a hard tank and other structural sections such as a truss and a soft tank or the hull can be completely enclosed as a cylinder. The hard tank supplies the majority of the buoyancy to support the hull structure, risers, and topsides platform. The hard tank is compartmentalized into a plurality of chambers among which the ballast can be shifted to control the hull's stability.
The centerwell configuration forms an open volume in the center of the hard tank referred to as the open centerwell. Since the centerwell is open to the sea it does not contribute to the hull structure's buoyancy. This offers a potential to displace the sea water in the centerwell and capture the buoyancy. The primary advantage of capturing this buoyancy is that the diameter of the hard tank can be reduced. This offers specific benefits in construction, transportation and installation of the spar hull.
SUMMARY OF INVENTION
The present invention addresses the shortcomings in the known art and is drawn to a spar hull open centerwell arrangement wherein an adjustable buoyancy centerwell device (ABCD) unit is disposed within the open centerwell of the structure. The ABCD is rigidly connected to the interior walls of the hard tank and defines an adjustable buoyancy compartment device within the centerwell. The ABCD is a water and airtight buoyancy chamber that allows the interior ballast to be changed as required.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming part of this disclosure. For a better understanding of the present invention, and the operating advantages attained by its use, reference is made to the accompanying drawings and descriptive matter, forming a part of this disclosure, in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, forming a part of this specification, and in which reference numerals shown in the drawings designate like or corresponding parts throughout the same:
FIG. 1 is a sectional view of a typical truss spar with an open centerwell.
FIG. 2 schematically illustrates the installation of the invention during construction of the spar.
FIG. 3 is a sectional view of a spar hard tank with the invention installed.
FIG. 4 is a side sectional view of a spar hard tank with the invention installed.
FIG. 5 is a sectional view that illustrates an alternate shape of the invention installed in a spar.
FIGS. 6-8 illustrate alternate arrangements of the invention.
FIG. 9 is a graph that compares spar hull diameter of the prior art and a spar hull with the invention.
FIG. 10 is a graph that compares strake size on spar hulls with and without the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a sectional view of a truss spar 10 with a traditional open centerwell 12 . It is seen that the risers 14 are received in the open centerwell 12 . As described in the background above, the traditional open centerwell 12 is open to the sea water 28 . The truss section 30 extends downward from the hard tank 18 . A soft tank 32 at the lower end of the truss section 30 is used to adjust buoyancy as needed.
FIG. 2 illustrates the invention 16 , generally referred to as the adjustable buoyancy centerwell device (ABCD), being lifted into place during construction of the spar 10 . Due to the size (typically 80-150 feet in diameter and as much as 200-300 feet long), the spar hard tank 18 is typically built in sections with the spar 10 in the horizontal position. Thus, the ABCD 16 is more easily installed when the spar is on its side and the centerwell 12 is easily accessible. There are various construction methods to install the ABCD, depending on the construction facility and capabilities. As seen in FIGS. 2 and 3 , the ABCD 16 is sized to have outer dimensions that are less than the inner dimensions of the centerwell in the completed spar. When installed and held in position, this defines a space 20 between the outer surface of the ABCD 16 and the inner surface of the centerwell 12 . The ABCD 16 is a rigid structure made of suitable material for the offshore environment, such as steel, and is closed at the bottom to prevent entry of sea water and provide additional buoyancy to the spar structure. The ABCD 16 may be provided with a plurality of separate water tight and air tight chambers 26 for selectively adjusting the buoyancy as required during drilling and production operations offshore.
FIG. 3 illustrates the ABCD 16 installed in the hard tank 18 of a spar structure. A plurality of shear plates 22 are rigidly attached between the ABCD 16 and hard tank 18 to hold the ABCD 16 in place and define the space 20 between the ABCD 16 and the hard tank 18 . The space 20 provides room for risers 14 . The spacing between the risers 14 is indicated by numeral 24 .
FIG. 4 is a partial side sectional view that illustrates the ABCD 16 installed in the spar. For ease of illustration, the risers are not shown in this drawing figure.
FIG. 5 illustrates an alternate embodiment wherein the centerwell 12 of the spar and the ABCD 16 are both circular in cross section.
FIG. 6 shows an alternate embodiment in which the space 20 for risers is provided on only two sides of the ABCD 16 . In this embodiment, the ABCD 16 is rectangular in shape with two opposing sides that have outer dimensions less than the inner dimensions of the centerwell 12 and the remaining two opposing sides of the ABCD 16 have outer dimensions that closely match the inner dimensions of the centerwell 12 .
FIG. 7 shows an alternate embodiment in which three spaces 20 are provided for risers. This is similar to the embodiment of FIG. 6 , with an extra space in the center. This will require either the use of two separate ABCD units 16 attached to the centerwell 12 or a single ABCD unit 16 that includes a center cut out to provide a space for the risers.
FIG. 8 shows an alternate embodiment in which the space 20 for the risers is provided across the center instead of the perimeter. Again, this will require either the use of two separate ABCD units 16 attached within the centerwell 12 or a single ABCD unit 16 that includes a center cut out to provide a space for the risers. As a single unit ABCD 16 , it will have outer dimensions that closely match the inner dimensions of the centerwell 12 and a cut out across the center to provide a space for the risers.
The configuration of FIG. 3 may also be used to store fluids and other materials inside the ABCD 16 . This provides for fluid storage inside the spar hard tank 18 and protects the fluid storage container (ABCD 16 ) from collision while maintaining the traditional spar architecture.
The configuration of FIG. 6 may also be used for fluid storage inside the ABCD 16 . In this configuration the ABCD storage unit 16 is connected to internal centerwell bulkheads while the hard tank 10 provides buoyancy compartments in the normal manner.
The invention provides several advantages over the known art, including increased buoyancy, reduced size and weight (reduced hull diameter), and simple and effective means to adjust the buoyancy of the platform as conditions change. The effect of these advantages is explained below.
Construction and delivery of the spar includes a number of phases where the spar hull is in the horizontal position. The hull can be transported on a heavy lift vessel and brought to a near shore shallow water location where it is floated off the transport vessel. Alternatively, the hull can be built near its deployment site and transferred to the water without transportation. In either case it is typical that the hull is temporarily moored to a dock or quayside for additional work while in the horizontal position before being towed to the installation site in deep open water further offshore. The water depth in the vicinity of docks suitable for building such a structure, such as a shipyard, is normally shallow, in the range of 40 to 45 feet. It is critical that the hull not contact the seabed during this operation. The reduced hull diameter provides the advantage of floating capability in such shallow dock areas.
Most spars, whether from U.S. Pat. No. 4,702,321 (known in the industry as the Classic Spar) or from U.S. Pat. No. 5,558,467 (known in the industry as the Truss Spar), are equipped with helical strakes on the exterior of the hull. The purpose of these strakes is to reduce the motions caused by vortex shedding. In general practice the distance the strakes extend off the spar wall is 13% to 15% of the hard tank diameter. Spar hulls constructed to date have a hull diameter from 80 to 150 feet. This means that the strake will extend radially from the hull a distance of approximately 10.4 to 22.5 feet, depending on the diameter of the hull. This strake height is a consideration when towing the hull in shallow water or near a quayside used in the construction of the spar hull. When the spar diameter is large or the water is shallow, the strake can come into contact with the seabed. In cases where the strake will contact the seabed, the solution is to cut the strake to provide the necessary clearance. The consequence of cutting the tip of the strake is diminished effectiveness in reducing the motions caused by vortex shedding. If the standard strake size is to be retained, then the consequence is the need to attach the strake or strakes in deeper water away from the construction yard, which increases the complexity and cost of the work. Reducing the diameter of the hull reduces the height of the strake and provides increased clearance under the keel.
The diameter of a spar hull is highly dependent on the payload it is supporting. Some advantage can be taken by lengthening the spar hull. However, to illustrate the effectiveness of the ABCD on reducing the hull diameter, presume the overall length of the Spar is held constant at 555 feet. The diameter of a Truss Spar of this length and having an open centerwell required to support a range of topside weights is shown in the graph of FIG. 9 . The same graph shows the diameter of the spar when the ABCD of the invention is used.
The graph of FIG. 10 compares the strake heights on the hulls. The graph shows that strake height is reduced by approximately two feet for the Spars with the ABCD of the invention.
A valve tree may be mounted on top of a top tensioned riser (TTR). The purpose of the tree is to provide access to the reservoir wells to carry out interventions that stimulate and control the well as part of normal operations. The access port to the wells is at this tree. When the tree is mounted on a well head on the sea floor, it is known as a wet tree. In the wet tree case, an additional vessel known as a mobile offshore drilling unit (MODU) is connected to the subsea tree to gain access to the well to carry out the intervention. When the tree is mounted on top of the TTR, it is known as a dry tree and interventions can be carried out directly from the vessel supporting the TTRs and therefore the MODU is not required. The economic advantages of the dry tree over the wet tree are well known in the industry.
In the traditional open centerwell, the TTRs are arranged in a matrix formation. A skidding apparatus that traverses the centerwell in two directions is used to move the intervention equipment above the trees and enter the wells. In the traditional open centerwell, the space within the centerwell is occupied by the risers and cannot be otherwise utilized. When the ABCD is installed in the centerwell, the risers are re-arranged to occupy the gap on the perimeter of the ABCD as illustrated in FIG. 3 . Arranging the risers in this pattern offers a number of advantages to the overall design of the hull. For example, it allows access to the space within the centerwell above the ABCD which can be utilized for other functions such as installation of drilling or production equipment, onboard storage, or as a general lay-down area.
While specific embodiments and/or details of the invention have been shown and described above to illustrate the application of the principles of the invention, it is understood that this invention may be embodied as more fully described in the claims, or as otherwise known by those skilled in the art (including any and all equivalents), without departing from such principles.
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A spar hull centerwell arrangement wherein an adjustable buoyancy centerwell device (ABCD) is disposed within the centerwell of the structure. The adjustable buoyancy centerwell device is rigidly connected to the interior walls of the hard tank and defines an adjustable buoyancy centerwell device within the centerwell. The adjustable variable buoyancy unit is a water and airtight buoyancy chamber that allows the interior ballast to be changed as required. This device can also be used as a storage unit for on board fluids and other produced hydrocarbons.
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FIELD OF THE INVENTION
[0001] The invention relates generally to self-inflating tires and, more specifically, to a pump mechanism and pressure regulator for such tires.
BACKGROUND OF THE INVENTION
[0002] 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 dependent 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.
SUMMARY OF THE INVENTION
[0003] The invention provides in a first aspect a self-inflating tire assembly, including a tire mounted to a rim, the tire having a tire cavity, first and second sidewalls extending respectively from first and second tire bead regions to a tire tread region; an air passageway having an inlet end and an outlet end, the air passageway being composed of a flexible material operative to open and close when the tire rotates, wherein the outlet end is in fluid communication with the tire cavity; the inlet control valve having a regulator body having an interior chamber; a pressure membrane being mounted on the inlet control valve to enclose the interior chamber, wherein the pressure membrane has a lower surface that is positioned to open and close the outlet port mounted in the interior chamber, wherein the pressure membrane is in fluid communication with the tire cavity pressure; wherein the body of the inlet control valve has a first and second flexible duct, wherein said first and second flexible ducts each have an internal passageway; wherein the first flexible duct has a first end connected to an inlet filter assembly and a second end is connected to the interior chamber of the inlet control valve, wherein the second flexible duct has a first end connected to the outlet port of the inlet control valve, and a second end in fluid communication with the inlet end of the air passageway.
Definitions
[0004] “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.
[0005] “Asymmetric tread” means a tread that has a tread pattern not symmetrical about the center plane or equatorial plane EP of the tire.
[0006] “Axial” and “axially” means lines or directions that are parallel to the axis of rotation of the tire.
[0007] “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.
[0008] “Circumferential” means lines or directions extending along the perimeter of a surface, perpendicular to the axial direction.
[0009] “Equatorial Centerplane (CP)” means the plane perpendicular to the tire's axis of rotation and passing through the center of the tread.
[0010] “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.
[0011] “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.
[0012] “Lateral” means an axial direction.
[0013] “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.
[0014] “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.
[0015] “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.
[0016] “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.
[0017] “Peristaltic” means operating by means of wave-like contractions that propel contained matter, such as air, along tubular pathways.
[0018] “Radial” and “radially” means directions radially toward or away from the axis of rotation of the tire.
[0019] “Rib” means a circumferentially extending strip of rubber on the tread which is defined by at least one circumferential groove and either a second such groove or a lateral edge, the strip being laterally undivided by full-depth grooves.
[0020] “Sipe” means small slots molded into the tread elements of the tire that subdivide the tread surface and improve traction, sipes are generally narrow in width and close in the tires footprint as opposed to grooves that remain open in the tire's footprint.
[0021] “Tread element” or “traction element” means a rib or a block element defined by having shape adjacent grooves.
[0022] “Tread Arc Width” means the arc length of the tread as measured between the lateral edges of the tread.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention will be described by way of example and with reference to the accompanying drawings in which:
[0024] FIG. 1 is an isometric view of tire and rim assembly showing a pump and regulator assembly.
[0025] FIG. 2 is a front view of the pump and regulator assembly as shown from inside the tire of FIG. 1 .
[0026] FIG. 3 is an exploded view of the regulator assembly.
[0027] FIG. 4 is a section view of FIG. 2 in the direction 4 - 4 showing the regulator in the open position during operation.
[0028] FIG. 5 is a section view of FIG. 2 in the direction 4 - 4 showing the regulator in the closed position during operation.
[0029] FIG. 6 is a front view of a second embodiment of a regulator assembly as shown from inside the tire of FIG. 1 .
[0030] FIG. 7 is an exploded view of the second embodiment of the regulator assembly.
[0031] FIG. 8 is a section view of FIG. 6 in the direction 8 - 8 showing the regulator in the open position during operation.
[0032] FIG. 8 a is the same as FIG. 8 , except that the coil spring has been replaced with a leaf spring.
[0033] FIG. 9 is a section view of FIG. 6 in the direction 8 - 8 showing the regulator in the closed position during operation.
[0034] FIG. 10 is a view from inside the tire during operation.
[0035] FIG. 11 is an exploded view of a pump outlet valve.
[0036] FIG. 12 a is a cross-sectional view of the pump outlet valve in the closed position.
[0037] FIG. 12 b is a cross-sectional view of the pump outlet valve during the cracking open position.
[0038] FIG. 12 c is a cross-sectional view of the pump outlet valve in the open position.
[0039] FIG. 13 is a cross-sectional view of the lower tire sidewall.
[0040] FIG. 14 is a front view of the regulator and pump assembly illustrating a pump length of about 170 degrees.
[0041] FIG. 15 is a front view of the regulator and pump assembly illustrating a pump length of about 350 degrees.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Referring to FIGS. 1 and 2 , a tire assembly 10 includes a tire 12 , a pump assembly 14 , and a tire rim 16 . The tire and rim enclose a tire cavity 40 . As shown in FIGS. 1-2 , the pump assembly 14 is preferably mounted into the sidewall area 15 of the tire, preferably near the bead region.
Pump Assembly 14
[0043] The pump assembly 14 includes an air passageway 43 which may be molded into the sidewall of the tire during vulcanization or formed post cure. When the air passageway is molded into the tire sidewall as shown in FIG. 2 , the air passageway has an arc length L as measured by an angle Ψ that is measured from the center of rotation of the tire. In a first embodiment, the angle Ψ may range, and is preferably in the range of about 15-50 degrees or optionally, an angular length sufficient to extend the length of the tire footprint Z, as shown in FIG. 10 . The air passageway has an arc length L that may extend in a circumferential direction, or any direction. The arc length L may range, and is preferably about the length of the tire footprint Z, as shown in FIG. 10 . The length is typically about 20-40 degrees when the shorter length is used. Alternatively, the pump tube length may be any desired length, typically 20 degrees or more. The pump air passageway 43 is comprised of a tube body formed of a resilient, flexible material such as plastic, 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 may be utilized. The tube may be a discrete tube that is inserted into the tire during tire manufacturing, or the tube may be molded into shape by the presence of a removable strip that forms the passageway when removed.
[0044] As shown in FIG. 2 , the pump passageway 43 has an inlet end 42 connected to an inlet fitting 100 , and an outlet end 44 that is connected to an outlet valve 200 . The inlet fitting 100 is in fluid communication with an inlet control valve 300 . The inlet control valve 300 is in fluid communication with an inlet filter assembly 450 .
Inlet Control Valve
[0045] A first embodiment of an inlet control valve 300 is shown in FIGS. 2-5 . The inlet control valve 300 functions to regulate the flow of air to the pump 14 . The inlet control valve 300 has a central housing 310 that houses an interior chamber 320 . The interior chamber 320 has a central opening 312 . Opposite the central opening 312 is an outlet port 330 . The outlet port is raised from the bottom surface 313 and extends into the interior of the chamber 320 . The outlet port is positioned to engage a pressure membrane 550 .
[0046] The pressure membrane has an upper surface 551 that is substantially planar. The pressure membrane has a lower surface 553 wherein a plug 555 extends from the lower surface. The pressure membrane further has an annular sidewall 556 which extends downwardly from the upper surface, forming a lip 557 . The lip 557 is preferably annular, and snaps in an annular cutout 559 formed on the outer housing 310 . The pressure membrane is a disk shaped member made of a flexible material such as, but not limited to, rubber, elastomer, plastic or silicone. The outer surface 551 of the pressure membrane is in fluid communication with the pressure of the tire chamber 40 . The lower surface 553 of the pressure membrane is in fluid communication with the interior chamber 320 . The plug 555 is positioned to close the outlet port 330 . A spring 580 is positioned in the interior chamber 320 to bias the pressure membrane 550 in the open position. The spring has a first end 582 that is received about the plug 555 . The spring has a second end 584 that is wrapped around the outer surface of the outlet port 330 . A first washer 586 may be received between the spring first end 582 and the pressure membrane 550 . A second washer 588 may be received between the spring second end 584 and the bottom of the chamber 313 . Thus the balance of pressure forces on each side of the pressure membrane actuates the pressure membrane plug 555 to open and close the outlet port 330 . A membrane support member 590 is received over the pressure membrane 550 . The membrane support member 590 has a plurality of holes 592 in the outer surface 591 of the lid, to allow the pressure membrane to be in fluid communication with the tire cavity 40 . The membrane support member 590 is formed of a rigid material, and the support member allows a preloading of the spring via the pressure membrane.
[0047] Extending from the central housing 310 is a first and second flexible duct 400 , 500 , positioned on either side of the central housing 310 . Each flexible duct 400 , 500 may be integrally formed with the central housing as shown, or be a discrete part connected to the central housing 310 . Each flexible duct 400 , 500 has an internal passageway 404 , 504 for communicating fluid.
[0048] The internal passageway 404 of the first flexible duct 400 has a first opening 402 that is located inside the interior chamber 320 . The internal passageway 404 of the first flexible duct 400 has a second end 406 that is in fluid communication with an inlet filter assembly 450 . The inlet device 450 supplies outside filtered air to the regulator via the first flexible duct 400 , and is described in more detail below.
[0049] The internal passageway 504 of the second flexible duct 500 is shown integrally formed with the outlet port 330 of the interior chamber 320 . The internal passageway 504 has a second end 506 in fluid communication with an inlet fitting 100 . The inlet fitting 100 may be a hollow screw such as a banjo screw. The inlet fitting 100 has an internal passageway 102 with inlet holes 104 that communicate flow to the inlet 42 of the pump passageway 43 . The inlet fitting 100 may comprise a screw with an internal passageway, and has an outer threaded surface 106 that is received in a sleeve 110 . The sleeve 110 has a bore that extends completely therethrough. The sleeve is mounted in the tire.
[0050] A second embodiment of the inlet control valve 1100 is shown in FIGS. 6-9 . The inlet control valve 1100 is the same as 300 except for the following differences. The membrane 1102 does not have a plug 555 on the lower surface. The membrane has a non-planar upper surface with a recessed interior portion 1104 . The recessed interior portion extends into the interior of the interior chamber and is positioned to open and close the outlet passageway 330 . A coil spring 580 is positioned to bias the pressure membrane in the open position. The coil spring 580 may be replaced with a leaf spring 583 as shown in FIG. 8A .
Inlet Filter Assembly
[0051] The inlet filter assembly 450 is shown in FIG. 4 . The inlet filter assembly 450 includes an insert sleeve 452 that is hollow and has an internal threaded bore 454 . The insert sleeve 452 is inserted into the tire, typically in the sidewall 15 . The insert sleeve 452 may be inserted into the tire post cure or may be molded into the tire as shown in FIG. 2 . An air passage screw 460 has an outer threaded body 463 that is screwed into the internal threaded bore 454 of the insert sleeve. The air passage screw 460 has an internal passageway 462 having an opening 464 . A filter 470 is inserted through opening 464 and is received in the internal passageway 462 . A filter cap 480 has a threaded end 482 that is received in the opening 464 of the air passage screw 460 . The filter cap is positioned on the outside surface of the tire, typically on the tire sidewall as shown in FIG. 1 . The filter cap has a plurality of holes 484 for allowing the flow of air into the inlet filter 470 . Outside air enters hole 484 and then through the filter cap into and through filter 470 . The filter air exits the filter 470 into the internal passageway 462 of the air passage screw 460 . The air exits the internal passageway 462 through exit hole 490 and then into the inlet end 406 of the first flexible duct 400 . The inlet end of the flexible duct 400 has a circular flange 495 surrounding a hole 410 through which the air passage screw is inserted. The exit hole 490 is located in a circumferential groove 491 to facilitate fluid communication with inlet hole 406 of the first flexible duct 400 . The circular flange 495 functions like a sealing gasket if it is made of a flexible soft material like rubber.
Pump Outlet Check Valve
[0052] As described above, a first end 42 of the pump is connected to a regulator and a check valve. The second end 44 of the pump is connected to a pump outlet valve 200 . The pump outlet valve is shown in FIGS. 11 , 12 A-C. The pump outlet valve 200 includes an insert sleeve 202 that is inserted into the tire on an interior surface, typically the inner sidewall as shown in FIG. 2 . The insert sleeve 202 has an internal threaded bore 204 . The insert sleeve 202 may be molded into the tire 12 or inserted post cure. The insert is installed in the tire area so that the internal bore 204 is in fluid communication with the pump outlet end 44 . A valve body 210 has an outer threaded surface 212 that is received within insert 202 . The valve body 210 has a central passage 215 that has a first opening 218 that is in fluid communication with the insert sleeve bore 204 and the pump passageway 43 outlet end 44 when inserted into the tire. The central passage 215 has an outlet end 217 that is in fluid communication with the tire cavity. The valve body has a shaped head 222 such as a hexagonal shaped head bore 223 for receiving a mating tool such as an allen wrench useful for tightening the valve body 210 inside the sleeve 202 . The central passage 215 further includes a retainer slot 230 for receiving flexible stopper 240 . The flexible stopper 240 is preferably made of a resilient material such as rubber, silicone, or an elastomer. The flexible stopper 240 has a disk shaped lower end 242 , and two opposed legs 244 which extend from the lower end 242 . Each leg 244 has a shoe 250 which has a curved enlarged shape and is made of a resilient material. As shown, the shoe is a semi-circle, although other shapes would work for the invention. Although the flexible stopper 240 is shown with two legs 244 , the stopper could have a single leg 244 with a shoe thereon, and the shoe could be annular with holes that allow passage of air therethrough.
[0053] The flexible stopper is mounted inside the central passage so that each shoe 250 of the flexible stopper is received in the annular retainer slot 230 , and the disk lower end 242 is positioned to open and close the pump end 44 .
[0054] FIGS. 12A-C illustrate the pump outlet valve 200 installed and operational. FIG. 12C illustrates flow from the pump outlet 44 to the pump outlet valve 200 . The disk lower end 242 of the flexible stopper 240 does not seal the pump outlet 44 when the flow direction is towards the pump outlet valve 200 . The flow travels through the central passage 215 , around and through the legs 244 and exits the passage outlet 217 to the tire cavity. FIG. 12A illustrates the disk lower end 142 of the flexible stopper 140 sealing the pump end 44 so that flow is blocked from flowing to the tire cavity 40 . FIG. 12B illustrates the disk lower end 142 of the flexible stopper 140 being lifted by the valve cracking pressure when the pump starts pumping.
[0055] An additional check valve like the check valve 200 may be optionally used between the pump inlet passageway 42 and the outlet of the regulator.
System Operation
[0056] As will be appreciated from FIG. 2 , the inlet control valve 300 is in fluid communication with the inlet end of the pump passageway 43 . As shown in FIG. 10 , as the tire rotates, a footprint is formed against the ground surface. A compressive force F is directed into the tire from the footprint and acts to flatten the pump passageway 43 . Flattening of the pump passageway 43 forces the compressed air towards the pump outlet device 200 . Due to the increase in pressure at the pump outlet 44 , the pressure unseats the disk 242 from the opening of the pump outlet 44 , which allows the pumped air to exit the pump outlet device through passage 215 into the tire cavity 40 , as shown in FIG. 12C .
[0057] The inlet control valve 300 controls the flow of outside air into the pump. If the tire pressure is low, the membrane 550 in the inlet control valve 300 is responsive to the tire pressure in the tire cavity 40 . If the tire cavity pressure falls below a preset threshold value, the plug of the membrane will unseat from the central outlet port 330 . Outside air will enter the filter assembly 450 , exit through the filter and enter the first flexible duct 400 , as shown in FIGS. 4 and 8 . The flow then exits the first flexible duct and enters the chamber and then into the second flexible duct, through the inlet fitting 100 and then into the pump inlet. The flow is then compressed through the pump and then exits the pump outlet valve into the tire cavity. The pump will pump air with each tire rotation. The pump passageway 43 fills with air when the pump system is not in the footprint.
[0058] If the tire pressure is sufficient, the inlet control valve will block flow from exiting the inlet control valve, as shown in FIGS. 5 and 9 . The pressure membrane is responsive to the cavity tire pressure and engages the central port 330 forming a seal which prevents air flow from passing through the inlet control valve. The pressure membrane material properties are adjusted to have the desired tire pressure settings.
[0059] The location of the pump assembly in the tire will be understood from FIGS. 1 and 13 . In one embodiment, the pump assembly 14 is positioned in the tire sidewall, radially outward of the rim flange surface in the chafer 600 . So positioned, the air passageway 43 is radially inward from the tire footprint and is thus positioned to be flattened by forces directed from the tire footprint as described above. Although the positioning of the air passageway 43 is specifically shown in a chafer 600 of the tire near the bead region, it is not limited to same, and may be located at any region of the tire that undergoes cyclical compression. The cross-sectional shape of the air passageway 43 may be elliptical or round.
[0060] As described above, the length L of the pump passageway may be about the size of the tire's footprint length Z. However, the invention is not limited to same, and may be shorter or longer as desired. See FIG. 14 which illustrates an approximate 170 degree length, FIG. 15 which illustrates an approximate 340 degree length. As the length of the pump increases, the pump passageway will need to substantially open and close like a peristaltic pump.
[0061] The pump assembly 14 may also be used with a secondary tire pressure monitoring system (TPMS) (not shown) of conventional configuration that serves as a system fault detector. The TPMS may be used to detect any fault in the self-inflation system of the tire assembly and alert the user of such a condition.
[0062] 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 a inlet control valve. The inlet control valve regulates the inlet air flow to the air tube and the outlet air flow to the tire cavity.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is referencing a continuation of Provisional application No. 61/153,280 filed Feb. 17, 2009
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] n/a
REFERENCE TO SEQUENCE LISTING
[0003] n/a
BACKGROUND OF THE INVENTION
[0004] Bicycle enthusiasts and children alike have a need to be lit up at night for visibility and safety. In some areas this is not just a safety concern but an issue of legal compliance. Custom car enthusiasts and average drivers both enjoy lighting elements that set them apart from the crowd. The lighting devices that are currently on the market are largely LED, or gas neon tubes. Although there exists “plug and play” EL wire units that come with a battery inverter and a length of EL wire, said “plug and play” kits do not take into account certain elements that the present invention overcomes by its configuration and/or modular ability to be expandable.
BRIEF SUMMARY OF THE INVENTION
[0005] The first obstacle overcome by the present invention is to conform the EL wire or illuminated filament to the unique design of a bicycle frame or the interior/exterior of a car. A single wire cannot be easily wound around the entirety of the surface a vehicle owner may want to light. The present invention solves this by providing a circuit that splits lengths of EL wire or illuminated filament to correspond to specific areas of a bicycle frame or car interior/exterior. The circuit splits are done in a modular fashion combining at connection points to allow customization and expansion.
[0006] The second obstacle overcome by the present invention is that vehicles have moving parts, such as the steering column and shocks on a bicycle, and the doors and steering wheel on a car. EL wire is durable but will break and disintegrate if applied in these high movement areas. This obstacle is overcome by the present invention by combining the connection points that make the present invention modular with the high movement areas as the connection points are flexible lead wire and can be long enough to provide proper slack depending on the nature of the vehicle area.
[0007] The third obstacle taken into account in the present invention is weather. Standard EL wire is water resistant, but standard EL wire connectors are not and will short circuit if for example: bicycling in the rain or in outdoor storage conditions. The present invention solves this obstacle by using waterproofed connectors or by applying a method of waterproofing to standard connections.
[0008] A fourth issue solved by the present invention is attaching the EL wire to the bicycle frame or car interior/exterior. Several methods of bracket systems are set forth by the present invention that can be adapted in a variety of ways to achieve just about any design element wished to be illuminated in EL wire. The brackets can be adapted to be specific shapes and designs or logos, or be open ended for the end user to design their own shapes. These brackets can be attached to the bicycle frame or car in a number of ways.
[0009] Any user of the prior art will see how the present invention solves the obstacles set forth and the scope of modification while staying within the spirit of the invention.
[0010] Furthermore, although the focus of the invention is the easy application of electroluminescent lights to a vehicle, the modular nature, the configuration, and bracket system may make the current invention applicable to a multitude of surfaces defined only by the end users imagination.
BRIEF DISCRIPTION OF DRAWINGS
[0011] FIG. 1 is a typical bicycle frame.
[0012] FIG. 2 is a schematic of the present invention, preferred embodiment to fit bicycle frame.
[0013] FIG. 3 is a bicycle wheel with a schematic of an embodiment of the invention in a spiral to fit bicycle tire.
[0014] FIG. 4 is a bicycle wheel with a schematic of an embodiment of the invention in a radial to fit bicycle tire.
[0015] FIG. 5 is a large view of a bracket 117 designed to clip EL wire to a bicycle spoke.
[0016] FIG. 6 is an overview of a car interior and a schematic of an embodiment o f the invention designed to fit a car interior.
[0017] FIG. 7 is a car steering wheel and a schematic of an embodiment of the invention designed to fit a car steering wheel.
[0018] FIG. 8 is a bracket designed to keep EL wires in place on a bicycle frame, two views.
[0019] FIG. 9 is a bracket designed to keep EL wires in a fixed straight channel with an adhesive surface, two views.
[0020] FIG. 10 is a bracket designed to bend EL wires in a fixed angle channel with an adhesive surface, two views.
[0021] FIG. 11 is a bracket designed to bend EL wires in a variety of fixed angles, or to cross two wires in a fixed cross channel with an adhesive surface, two views.
[0022] FIG. 12 is a bracket designed to bend EL wires in a variety of fixed shapes and designs, with a variety of wire clips or fixed channels, two views. Designed to fit a bicycle frame or dashboard.
[0023] FIG. 13 is a bracket designed as a bicycle grip, with fixed channels to hold EL wire. Two designs.
[0024] FIG. 14 is a molded design of a possible embodiment of a bracket system containing an array of LED's and EL wires extruding from it.
[0025] FIG. 15 is a molded design of a possible embodiment of a bracket system containing EL wire wound inside and extruding to frame mold shape.
[0026] FIG. 16 is a molded design of a possible embodiment of a bracket system containing an array of LED's and EL wires wound inside a transparent or translucent mold shape.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 1 is an illustration of the basic sections of a bicycle frame. It is intended to be viewed in tandem with FIG. 2 to reference what sections of the present invention correspond to specific sections of the bicycle frame. 101 is the area under a bicycle seat, or a typical seat pack designed to strap under a bicycle seat. 102 is the top bar of a bicycle frame. Although depicted is a male bike, it is referencing the corresponding bar on a female bicycle frame as well. 103 are the handle bars and steering column on a bicycle frame. 104 are the front shocks and front wheel frame bars of a bicycle. 105 is the bottom bar of the mainframe of a bicycle. 106 are the back shocks and back wheel frame bars of a bicycle. 107 is a reference to both tires on a bicycle.
[0028] FIG. 2 is a schematic of the preferred embodiment of the invention. 111 represents a length of EL wire or illuminated filament. 108 represents a solar cell or kinetic generator. 109 represents the battery storage and electrical inverter. 108 and 109 would fit on the bicycle at section 101 FIG. 1 inside a weatherproof seat pack or weatherproofed in a unit together and clipped under bicycle seat frame. 110 represents the symbol used in the schematic for a water resistant male/female coupling connector. 112 represents a Y split connector. Said connector starts with a water resistant male connector and takes the single circuit starting at the electrical inverter and splits it to two wires ending in two water resistant female plug ends. The lead wire included in 112 gives extra length to the flexible wire to be positioned at the moving parts of the bicycle frame at sections 106 , 103 and 104 in FIG. 1. 112 also allows expansion of the circuit to two new sections. In this preferred embodiment the first instance of 112 splits the circuit into section 113 and 114 . 113 is a section starting with a water resistant male connector end then splits into two circuits each including several inches of lead wire then ending in a length of EL wire with a water resistant cap at the end. 113 is intended to be attached to the two back bicycle wheel frame bars of section 106 in FIG. 1. 114 is a section starting with a water resistant male connector end then splits to two circuits each including several inches of lead wire then continuing in a length of EL wire with a water resistant female connector at the end of each EL wire. The two lengths of EL wire in section 114 could be different lengths and not both EL wires need to end in a female connector, but instead one could be just a water proof cap. 114 is intended to be secured to the bicycle frame at sections 102 and 105 of FIG. 1 but can be arranged as determined by the end user keeping in mind moving parts of the bicycle frame. At least one female connector end of 114 is intended to be secured near the steering column of the bicycle frame 103 FIG. 1 so that the next instance of a Y split connector 112 can be secured with enough slack for the steering to not be impeded and to split the circuit to accompany sections 115 and 116 . Sections 115 and 116 are similar in circuit to each other and 113 . They all split the current from a water resistant male connector end to two circuits each including several inches of lead wire then ending in a length of EL wire with a water resistant cap at the end. 115 is intended to be secured to the bicycle frame front wheel bars 104 FIG. 1. 116 is intended to be secured to each side of the handlebars 103 FIG. 1. 113 115 and 116 could all be the same length of lead wire and EL wire for easy compatibility or could be specifically designed lengths as to conform more precisely to a specific bicycle frame, style, or design. A properly built circuit as described here in FIG. 2 powered by the appropriate power inverter will light all the EL wire in the circuit brightly and provide enough slack in lead wire areas so as to not interfere with the normal operation of a bicycle. A properly built circuit as described here in FIG. 2 could be disconnected and reconnected in a variety of ways as determined by the end user, and have additional circuit arrays available to replace or add to the circuit of the preferred embodiment. Any standard or custom clip or bracket that achieves securing the wires in the intended place can be used to secure the present invention to a bicycle frame. FIG. 8 is the preferred embodiment of a bracket to secure EL wires to a bicycle frame with ease and precision. The electric inverter 109 is graded as by how much wire it can power, and can be upgradable to power further expansions of the present invention and/or as described in the other embodiments in the FIG. 12 , FIG. 13 , FIG. 14 , FIG. 15 , and FIG. 16 drawings. Include FIG. 3 , FIG. 4 , and FIG. 5 , for the full embodiment of the present invention intended to light a bicycle frame.
[0029] FIG. 3 is an illustration of a bicycle tire with an embodiment of the invention attached to the spokes in a spiral fashion. 209 is a battery driver inverter powered by small batteries such as watch sizes or AAAs. It is preferred that this driver has a motion detection switch to only light tires when in action as to save battery charge. The battery driver inverter could have any number of effects including but not limited to strobe, flash, or sound activated. 211 is the circuit starting with the battery inverter to several inches of lead wire, ending in a length of EL wire to be enough to arrange in a spiral around the spokes of section 107 FIG. 1 . The end of the EL wire should be weather capped. 117 is a preferred embodiment of a clip channel to attach the EL wire to the spokes securely in the direction intended. Any standard or custom clip or bracket that achieves securing the wires in the intended place can be used to secure present invention to bicycle frame.
[0030] FIG. 4 is an illustration of a bicycle tire with an embodiment of the invention attached to the spokes in a radial fashion. 209 is a battery driver inverter powered by small batteries such as watch sizes or AAAs. It is preferred that this driver has a motion detection switch to only light tires when in action as to save battery charge. The battery driver inverter could have any number of effects including but not limited to strobe, flash, or sound activated. 311 is the circuit starting at the battery inverter to several inches of lead wire with small sections of EL wire connected to the lead wire every few inches. This is arranged in a fashion as to where the lead wire will be attached from a point near the axle of the tire and extend out each separate length of EL wire along a spoke and the end of each EL wire will attach at a point near the inner wall of the tire in a radial pattern. 117 is a preferred embodiment of a clip channel to attach the EL wire to the spokes securely in the direction intended. Any standard or custom clip or bracket that achieves securing the wires in the intended place can be used to secure present invention to bicycle frame.
[0031] FIG. 5 is a close up view of an example of a preferred embodiment of a bracket designed to clip to a bicycle spoke and fasten an EL wire. 117 A shows a view of the bracket with a channel clip to arrange an EL wire in a straight line. 117 B shows a side view of the bracket featuring a spoke clip on a swivel as to move the direction of the channel clip.
[0032] FIG. 6 is a schematic of an embodiment of the present invention adapted to fit a car interior. 208 is a solar panel. 309 is a battery storage and electrical inverter designed to be used standalone, or in conjunction with the car's battery. This electrical inverter could be a multichannel sequencer or sound activated driver for special effects. 210 is the symbol used throughout the schematic to represent a weather proofed male/female connector coupling. 120 is a length of EL wire to be used on the dashboard area, 121 is a length of EL wire to be used on the interior of the car doors. 122 is a length of EL wire to be used on or around the car seats. 123 is a length of EL wire to be used in, on, or around the car interior center console. 212 is a possible placement for a standard Y split connector. 124 is a length of EL wire to be used on, or around the back seats and back window of the car interior. Extra Y split connectors 212 or extra lengths of wire could be used easily to expand on this basic circuit, or to change out areas for further customization. A simple rearrangement of the circuit of this embodiment could make it appropriate for car exterior use. Any standard or custom clip, adhesive, or bracket that achieves securing the wires in the intended place can be used to secure this embodiment of the present invention to car interior/exterior. FIG. 9 FIG. 10 . FIG. 11 and FIG. 12 are examples of preferred embodiments of brackets that would improve easy installation and customization.
[0033] FIG. 7 is a car steering wheel with a schematic of an embodiment of the present invention. This embodiment includes a battery driver inverter 409 powered by small batteries such as watch batteries or AAAs. It is preferred that this driver has a motion detection switch to only light tires when in action as to save battery charge. The battery driver inverter could have any number of effects including but not limited to strobe, flash, or sound activated. The wire could alternately be powered by the main car electrical inverter 309 , FIG. 6 if plenty of lead wire was secured in the proper fashion as to not interfere with driving. 125 is a length of EL wire appropriate to wind around, or attach around, a car steering wheel.
[0034] FIG. 8 is a bracket used in the preferred embodiment of the present invention designed to strap around any section of bicycle frame. This bracket could be made of any durable moldable material. 126 is a clip channel designed with a radius as to secure any standard size of EL wire used by present invention. 126 A is an alternate view of the EL wire clip channel array. 127 is a strap and secure point for the bracket. The strap and secure point can be any such securing method such as: zip tie, hook and loop, button, tab, buckle. 127 A is the same strap and secure point in an alternate view.
[0035] FIG. 9 is a bracket used in an embodiment of the present invention designed to secure an EL wire in a fixed direction onto a car interior surface. 128 is a straight channel clip designed with a radius as to secure any standard size of EL wire used by present invention. 128 A is an alternate view of the straight channel clip. 129 is the flat bottom surface of the bracket to be affixed with an industrial strength adhesive.
[0036] FIG. 10 is a bracket used in an embodiment of the present invention designed to secure and bend EL wires in a fixed angle channel onto a car interior surface. 130 is a fixed angle channel clip designed with a radius as to secure any standard size of EL wire used by present invention. 130 A is an alternate view of the straight channel clip. 129 is the flat bottom surface of the bracket to be affixed with an industrial strength adhesive.
[0037] FIG. 11 is a bracket used in an embodiment of the present invention designed to bend EL wires in a variety of fixed angles, or to cross two wires in a fixed cross channel and secure them to a car interior surface. 131 is a cross channel clip designed with a radius as to secure any standard size of EL wire used by present invention. 131 A is an alternate view of the cross channel clip. 129 is the flat bottom surface of the bracket to be affixed with an industrial strength adhesive.
[0038] FIG. 12 is a bracket used in an embodiment of the present invention designed to bend EL wires 411 , 411 A in a variety of fixed shapes and designs, with a variety of wire clips or fixed channels 226 , 226 A. Designed to fit a bicycle frame or dashboard the surface shape 132 , 132 A can be any durable flexible material shaped to fit a bicycle bar in a tubular fashion or flat for a car interior. The surface shape 132 can house the EL wire channel clips 226 in a sturdy fixed way that can affix wires in just about any basic shape or logo depending on placement and number of channel clips 226 . This bracket construct can be attached to a bicycle bar or a car interior by 227 , 227 A which would be straps and secure points for a bicycle, or suction cups/adhesive surface for a car. Such a bracket could be included as part of an embodiment of the present invention and/or as an expansion unit with EL wire already wired into it, or as a blank design expansion piece for the end user to apply EL wire into the channel clips 226 manually.
[0039] FIG. 13 is a bracket used in an embodiment of the present invention designed as a bicycle grip with fixed channels to hold EL wire 511 . 133 is one design embodiment. 233 is another design embodiment. 134 is an LED element wired at the end of the EL wire 511 . Such an embodiment of the present invention could be included and/or part of an expansion unit. This embodiment would be fashioned as a cushioned bicycle grip with EL wire 511 already embedded in the grip, or with blank channels that the end user could apply EL wire to manually.
[0040] FIG. 14 is a molded design of a possible embodiment of a bracket system containing an array of LED's 234 and EL wires 611 extruding from it. In this embodiment the molded design is that of a sunflower in a transparent or translucent material. This embodiment of a lighted molded bracket could be included as part of an embodiment of the present invention and/or as an expansion unit. It is designed to be strapped to the handlebars but could be modified to fit another area of a bicycle, dashboard, car interior, or car exterior. 136 is a weather proofed male plug to power the molded bracket and is designed to plug into any of the weather proofed female plugs in any other part of the present invention.
[0041] FIG. 15 is a molded design of a possible embodiment of a bracket system containing EL wires 711 extruding from it in select places so as to outline the mouth and eyes only of an alien head. In this embodiment the design is molded in an opaque, transparent or translucent material. This embodiment of a lighted molded bracket could be included as part of an embodiment of the present invention and/or as an expansion unit. It is designed to be strapped to the handlebars but could be modified to fit another area of a bicycle, dashboard, car interior, or car exterior. 136 is a weather proofed male plug to power the molded bracket and is designed to plug into any of the weather proofed female plugs in any other part of the present invention.
[0042] FIG. 16 is a molded design of a possible embodiment of a bracket system containing an array of LED's 334 and EL wires 811 molded into it. In this embodiment the molded design is that of a skull and crossbones in a transparent or translucent material. The LEDs 334 are to light up the eyes and the EL wire lights up the mold from the inside. This embodiment of a lighted molded bracket could be included as part of an embodiment of the present invention and/or as an expansion unit. It is designed to be strapped to the handlebars but could be modified to fit another area of a bicycle, dashboard, car interior, or car exterior. 136 is a weather proofed male plug to power the molded bracket and is designed to plug into any of the weather proofed female plugs in any other part of the present invention.
[0043] While the present invention has been described in what are presently considered to be its most practical and preferred embodiments or implementations, it is to be understood that the invention is not to be limited to the particular embodiments disclosed hereinabove. On the contrary, the present invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the claims included, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as are permitted under the law.
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A modular electroluminescent lighting kit to apply to a bicycle, car, or other vehicle for increased safety, visibility and design style. The kit is comprised of a battery driver which can be further powered by solar or kinetic devices, an EL wire or other illuminated filament configuration that conforms to the frame of the bicycle or form of the vehicle interior/exterior taking into account the areas of said vehicles that have moving parts. The kit includes basic or custom brackets to affix the wires in place in any design configuration that pleases the end user. The kit may be designed to be upgradable in modular stages and including but not limited to LED devices, motion sensing stand-alone wheel lighting, or plastic molded mountable lighting devices.
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BACKGROUND OF THE INVENTION
This invention relates to thin film circuit fabrication, and in particular to a method for fabricating resistors and capacitors on a single substrate.
Fabrication of thin film resistors and capacitors on a single insulating substrate has been known for many years. Typically, the resistors comprise a layer of tantalum nitride which is deposited by sputtering, followed by chemical etching to form the desired pattern. The capacitors are typically formed by depositing a layer of tantalum which is etched to define the anode, followed by anodization of a portion of the layer to form the capacitor dielectric. The capacitor counter-electrode is then formed over the dielectric by depositing and patterning layers which are typically nickel-chromium and gold. These steps are performed in a variety of combinations in order to achieve maximum processing efficiency and compatibility between the components. (See, e.g. U.S. Pat. No. 3,607,679, issued to Melroy et al and U.S. Pat. No. 3,718,565, issued to Pelletier.)
At some point in the processing, it is necessary to stabilize the resistor films by heating in an oxidizing atmosphere. In prior art processes, this step was usually performed prior to completion of the capacitors, otherwise the capacitor dielectric would be degraded resulting in excessive leakage currents. While prior art processes were adequate, the stabilization problem in part necessitated a departure from an optimized sequence which would involve formation of all resistors and capacitors followed by stabilization. In cases where stabilization was prescribed after all resistors and capacitors were formed, the capacitor dielectric had to be formed with a high voltage anodization to insure no degradation (see, U.S. Pat. No. 4,251,326, issued to F. R. Arcidiacono, et al.
The problem of stabilization has recently been exacerbated by the need to further miniaturize thin film components to conserve space. This is especially important where thin film resistors and capacitors are formed over a silicon substrate including active silicon devices. In such circuits, capacitors should be anodized at low voltages less than 100 volts to form a very thin dielectric (less than 1700 Angstroms) in order to achieve high capacitance density. Such thin dielectrics cannot stand up to the high temperatures and times required to stabilize the resistors (typically 350 degrees C. for one hour). However, it appears that the fabrication technique may not be economically attractive unless both the resistors and capacitors can be formed completely prior to stabilization.
It is therefore an object of the present invention to provide a stabilization process which would permit prior complete formation of resistors and capacitors so that processing is optimized. It is a further object of the invention to provide a stabilization process which is compatible with both thin film resistors and low voltage anodization thin film capacitors.
SUMMARY OF THE INVENTION
These and other objects are achieved in accordance with the invention which is a method for fabricating a thin film circuit on an insulating substrate. A thin film resistor and a thin film capacitor are formed on the substrate. After complete formation of such components, stabilization is effected by heating in an atmosphere comprising high pressure steam. Such an atmosphere permits stabilizing the resistors at a sufficiently low temperature and/or time so as not to significantly adversely affect capacitor performance.
BRIEF DESCRIPTION OF THE DRAWING
These and other features will be delineated in detail in the following description. In the drawing:
FIGS. 1-6 are cross-sectional views of a portion of a thin film circuit in various stages of fabrication in accordance with one embodiment of the invention;
FIG. 7 is a cross-sectional view of an apparatus useful for practicing one embodiment of the invention;
FIG. 8 is a graph of resistance change as a function of time for various stabilization conditions in accordance with the invention; and
FIG. 9 is a graph of resistance change as a function of resistor aging time for prior art thermally stabilized resistors compared to resistors stabilized in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
The invention will be discussed with reference to the fabrication of an RC circuit, a portion of which is shown in FIGS. 1-6. It will be realized that the resistor and capacitor are part of a larger circuit which includes other elements. In the case of RC components formed over a silicon wafer, such additional elements would include active devices within a silicon substrate which are omitted here for the sake of generality.
The sequence of steps illustrated is basically that described in U.S. Pat. No. 4,251,326 issued to Arcidiacono, et al, cited supra, for forming RC components on ceramic substrates. It will be appreciated that the invention is not limited to this particular RC fabrication sequence.
First, a layer, 11, of alpha tantalum was formed on an insulating substrate 10. The substrate can be the standard ceramic substrate of conventional RC circuits or an insulating layer overlying an active silicon substrate. The layer 11 was deposited by RF sputtering to a thickness of approximately 3000 Angstroms. Thicknesses in the range 2000-4000 Angstroms are typical. The layer had a nitrogen doping of approximately 30 atomic percent.
Next, as shown in FIG. 2, the tantalum layer was formed into a pattern, which included a capacitor anode portion 12. This was accomplished by standard photolithographic techniques.
Then, as shown in FIG. 3, fabrication of the capacitors continued by selectively oxidizing a portion of the anode to give a layer, 13, of Ta 2 O x N y . The oxide can be formed using a suitable mask (not shown) such as photoresist or titanium and oxidizing electrolytically in a solution such as 0.01 percent phosphoric or citric acid. With an applied voltage of 50 volts oxide thicknesses were typically 850 Angstroms.
Next as shown in FIG. 4, a layer, 14, comprising tantalum nitride was deposited over the circuit by magnetically enhanced sputtering. The layer was typically 400 Angstroms thick. The capacitor counter-electrode and electrical interconnections were formed by depositing successive layers of titanium, palladium, and gold, shown as composite layer 16, and etching the appropriate patterns as shown in FIG. 5. The thicknesses of the metal layers were typically 2000 Angstroms for titanium, 2500 Angstroms for palladium, and 20,000 Angstroms for gold. Subsequent to defining these electrodes and interconnects, the resistors, 15, were patterned using standard techniques.
The circuit of FIG. 6 was then subject to a stabilization process in accordance with the invention. FIG. 7 illustrates a typical apparatus which was employed to practice the method. The apparatus is a commercially available reactor sold by Koehler under the designation "oxidation stability bomb." The reactor comprises a cylindrical casing, 20, and a screw-on cover, 21, made of stainless steel and capable of withstanding pressures of 2500 psi. The circuits 23 were placed in a nichrome basket, 22, which was supported by wire support 26. Deionized water, 24, was included in the bottom of the reactor. An O-ring, 25, formed a pressure seal for the reactor.
In subsequent stability runs, a similar apparatus sold by Parr Instrument Company under the designation "General Purpose Bomb No. 4602" was utilized. This particular apparatus would probably be advantageous in commercial manufacture since it included pressure fittings to facilitate temperature and pressure measurements as well as an electric heater with temperature control in which the bomb was inserted. In any event, it should be apparent that the apparatus in FIG. 7 is merely illustrative and any reactor which is capable of withstanding high pressure may be utilized.
In accordance with one embodiment of the method of the invention, sufficient water was added to the reactor to insure saturation at the particular stabilization temperature employed. The amount of water needed for saturation can be determined from tables available in the literature. For example, Keenan and Keyes, Thermodynamic Properties of Steam (First Ed., John Wiley and Sons) at pages 28-33 contains tables showing the specific volume of water which will saturate at various temperatures. Knowing this and the volume of the reactor, the minimum weight of water needed for saturation can be calculated. In this particular example, the volume of the reactor was 190 cm 3 and the amount of water added for a 300 degree stabilization was 30 cm 3 .
After the water was added, the circuits were loaded into the basket, and the reactor was sealed and placed in a standard forced convection air oven heated to the desired stabilization temperature. Temperatures for different runs ranged from 250-350 degrees C. and times ranged from 1/4-30 hours. In this particular example, the temperature was approximately 300 degrees C. and time of stabilization was approximately one hour. (Times specified herein do not include a period of approximately 50 minutes required for the circuit to reach the stabilization temperature.) The pressure in the reactor at such temperature reached approximately 1246 psi. At temperatures of 250-350 degrees C., pressures will range from approximately 590-2400 psi. Temperatures, times, and pressures outside the ranges given above might be employed if desired for certain applications. For best results, stabilization should be at the minimum time and temperature which will stabilize the resistors so that capacitors are not degraded. For resistance changes of approximately 100 percent during stabilization, 300 degrees C. for one hour appears optimum. A preferred range appears to be 250-350 degrees C. for 10 min-20 hours to achieve resistance changes within the range 50-200 percent during stabilization.
Subsequent to stabilization, the circuits were annealed at 100 degrees C. for approximately 4 hours. This step is not essential, but may be useful for obtaining optimum resistance aging characteristics. Useful annealing ranges are 85-120 degrees C. for 15 min-10 hours.
Resistance values of individual resistors having an initial value of 150Ω/□ and stabilized by the above method were measured. The results are illustrated in the graph of FIG. 8 which shows resistance change as a function of time for resistors stabilized at 350 degrees C. (Curve A), 300 degrees C. (Curve B), 275 degrees C. (Curve C) and 250 degrees C. (Curve D). It was discovered that these resistance change curves were roughly parallel to those of other resistors stabilized in air except they were displaced by approximately 50 degrees C. Thus, for example, resistors stabilized at 300 degrees C. for one hour in steam showed approximately the same resistance changes as resistors stabilized at 350 degrees C. for one hour in air. This displacement is apparently due to an accelerated oxidation rate in the high pressure steam atmosphere which is approximately six times faster than the rate in air at the same temperature.
Resistors stabilized in steam were also thermally aged subsequent to stabilization to determine resistance changes. Initial resistance value was 300Ω/□. FIG. 9 shows thermal aging effects for a resistor stabilized at 300 degrees C. for one hour in steam in accordance with the invention (Curve E) compared with a resistor stabilized at 350 degrees C. for one hour in air (Curve F). Both resistors were aged at 150 degrees C. It will be noted again that the curves are roughly parallel, but the initial resistance change for steam stabilized resistors was larger. This initial resistance change can be decreased by annealing subsequent to the steam stabilization as previously described. Even without an annealing step, the aging of the steam stabilized resistors is still less than 0.1 percent at 65 degrees C. for 20 years. Thus, although aging of steam stabilized resistors is different from air stabilized resistors, change in resistance is well within the limit for precision resistors.
Individual capacitors anodized at 50 volts and undergoing stabilization in accordance with the above-described embodiment were tested for capacitance, dissipation factor, and leakage. After approximately 20 hours of storage time, median values were 8170 pf capacitance, 0.0018 dissipation factor and 0.25 nanoamps leakage at 12 volts. Thus, the steam stabilization produced acceptable capacitors. Consequently, one of the important advantages of the inventive method is that it can be used to stabilize resistors and capacitors simultaneously whereas in the standard prior art process, resistors typically had to be stabilized at times and temperatures which would cause capacitor degradation.
While the inventive method has been described with the use of a saturated steam environment in accordance with one embodiment, one could reduce the humidity if desired. Resistance characteristic curves will be essentially like those of FIG. 8 but displaced. For example, at 300 degrees C. a resistance change produced in saturated vapor in one hour took 1.5 hours in 50 percent relative humidity and 4 hours in 25 percent relative humidity. Further, although steam alone was described, other materials such as oxygen might be added to the stabilization environment.
Various additional modifications will become apparent to those skilled in the art. All such variations which basically rely on the teachings through which the invention has advanced the art are properly considered within the spirit and scope of the invention.
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Disclosed is a method for fabricating a circuit including thin film resistors (15) and capacitors (12, 13, 14, 16) on a single substrate whereby stabilization is effected after all such components are completely formed. A high pressure steam atmosphere is utilized for stabilization so that the resistors can be stabilized at lower temperatures and/or times and the capacitors are not degraded.
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CROSS-REFERENCED TO RELATED APPLICATION
[0001] This application is a U.S. National Stage filing under 35 U.S.C. §371 and 35 U.S.C. §119, based on and claiming priority to PCT/GB2014/050030 for “GROUP DELAY CORRECTION IN ACOUSTIC CROSS-OVER NETWORK” filed Jan. 7, 2014, claiming priority to GB patent application no. 1300215.9 filed Jan. 7, 2013.
FIELD OF INVENTION
[0002] The present invention relates to methods for equalising the group delay of a sound reproduction system, in particular a system comprising acoustic transducers with at least one crossover between lower- and higher-frequency transducers.
BACKGROUND TO THE INVENTION
[0003] Multi-way loudspeakers that use two or more drive units to convey a range of audio frequencies require filters at the crossover points to ensure a well formed magnitude response. However, these filters may combine to introduce a raised group delay on certain frequencies which may cause a smearing of the perceived sound.
[0004] Several methods are known that avoid uneven group delay through a crossover, including the use of first-order crossover responses or those derived using a subtractive method [Small, R. H., “Constant Voltage Crossover Design”, Proc IREE Australia, Vol 31 No 3, 1970 March, pp. 66-73], the use of a filler-driver [Baekgaard, E, “A Novel Approach to Linear Phase Lousdpeakers using Passive Crossover Networks”, J. Audio Eng. Soc, Vol 25, No 5, pp 284-294] and linear-phase crossovers normally derived using digital signal processing (DSP).
[0005] Methods are also known for smoothing the group delay introduced by a crossover system by applying a complementary all-pass correction [Linkwitz, S. H., “Active Crossover Networks for Non-Coincident Drivers”, J. Audio Eng Soc, Vol 24 No 1/2, 1976 January/February, pp. 2-8].
[0006] An acoustic transducer normally has a natural low-frequency cut off and the combination of a transducing element on a baffle or in an enclosure exhibits a high-pass frequency response which may be modelled as a high-pass filter system. This high-pass response can present significant or uneven group delay. The increase in low frequency group delay near system cut-off may be of the order of the period of the cut-off frequency. If left uncorrected, a listener can observe the low frequency components of a composite sound signal arriving after their higher frequency counterparts.
[0007] According to the overall design of the transducer and enclosure, the low-frequency response can exhibit slower-roll off (in an over-damped system), a second-order high-pass response in a closed-box system, a fourth-order high-pass in a system incorporating a vent, auxiliary radiating element or coupled cavity, or any of these in conjunction with an additional auxiliary filter which preconditions the audio so as to provide low-frequency extension, optimise alignment, or introduce intermediate or higher-order high-pass responses. In general, systems will exhibit a raised group delay at some low frequencies as a result of the overall system design and that delay bump will tend to be lower in proportion to the order of the overall system acoustic response. For this reason, for certain high-quality applications closed-box loudspeakers have hitherto been preferred over vented or higher-order designs.
[0008] The high-pass response of a loudspeaker system can be modelled as a filter which may in turn be factored into a cascade of first and second-order elements, some of which will relate to the mechanical properties of the transducer in its enclosure and others to pre-processing of the signal. It is also known that a higher-order response, such as sixth-order Butterworth, can be designed in four ways which combine pairs of its second-order factors to synthesise the mechanical system, while the third can be an auxiliary filter; normally the combinations are selected to provide the smallest enclosure volume. [Thiele, A. N. (1973). “Loudspeakers, Enclosures and Equalisers,” Proc. IREE, 34(11), pp. 425-448.]
[0009] Non-real-time methods are known, whereby audio can be pre-processed in reverse time through an all-pass filter having the same phase response as the total system; this audio when later reproduced results in a uniform group delay response.
[0010] However, it is not always convenient to pre-process the audio and particularly is inconvenient to do so for different designs.
[0011] It is not possible to use a real-time causal stable filter to impart a negative delay to compensate for unwanted group delay. However, an all-pass filter which has a flat magnitude response may be used to add group delay at a specific range of frequencies. A method that adds a series of all-pass filters to carry out limited equalisation is described in M. F. Quélhas, A. Petraglia, and M. R. Petraglia, “Efficient group delay equalization of discrete-time IIR filters”, European Signal Processing Conference, pp. 125-127, 2004. However, this approach alone does not provide sufficient means for equalising the group delay of the entire multi-way loudspeaker.
[0012] In real-time, to obtain a uniform group delay it is necessary to delay the entire audio so that no part arrives earlier than the latest component arriving from the overall system; that maximum group delay is normally associated with the system low-frequency high-pass response and may be several tens of milliseconds.
[0013] In principle, an all-pass filter can be designed to correct for a high-pass response. However, to cover the frequency range from below 100 Hz to above 20 kHz would require a very large number of filters (of the order of five hundred second order all-pass filters evenly spaced across the required frequency range) and risk the accumulation of considerable noise.
[0014] Real-time techniques involving reverse block processing of a signal have also been described that do provide an opportunity for equalising the group delay, such as in Adam, V. and Benz, S., “Correction of crossover phase distortion using reversed time all-pass IIR filter”, Audio Engineering Society, 122 nd Convention, Paper 7111, 6 pp., 2007. However, for precise high-sample-rate systems these approaches require very large buffers to ensure that filter states converge at the block or buffer boundaries. This method also imposes a significant start-up delay on the audio whilst adequate buffers are filled and such delay may for example be incompatible with associated video.
[0015] As will be appreciated from the above discussion, there is a need for a practical method for implementing group delay equalisation of multi-way loudspeakers with low additional latency.
SUMMARY OF THE INVENTION
[0016] According to a first aspect of the present invention, there is provided a method for equalising the overall group delay in the response of an acoustic transducer system having a crossover between a lower-frequency range and a higher-frequency range, the method comprising the steps of:
applying correction to a signal in the lower-frequency range, including the crossover region, to substantially equalise the group delay for the lower-frequency range; and, applying a signal delay to a signal in the higher-frequency range to bring it into closer alignment with the equalised lower-frequency range signal.
[0019] According to a second aspect of the present invention, a computer program product comprises computer executable code which when executed on a processor of an acoustic transducer system causes the system to perform the method of the first aspect.
[0020] According to a third aspect of the present invention, an acoustic transducer system is adapted to perform the method of the first aspect.
[0021] The present invention relates to methods for equalising the variation of group delay with frequency in sound reproducing systems which comprise one or more transducers that together reproduce a lower-frequency range and one or more other transducers that reproduce an overlapping or adjoining upper-frequency range, and where the two ranges are unified by a crossover means. Such systems may be assembled as multiple transducer combinations in one overall baffle or enclosure or in a headphone or as combinations of separately housed woofer and higher-range loudspeakers.
[0022] In one embodiment of the invention the method adjusts the signals fed to a lower-frequency reproducing combination using all-pass filters to normalise the group delay over that frequency range, while simpler time-delay means adjust the signals fed to corresponding upper-frequency combination(s). The invention thus equalises the group delay of a sound reproduction system comprising acoustic transducers with at least one crossover between lower-frequency and higher-frequency transducers and which can operate in real-time with low latency.
[0023] Within a multi-way system incorporating more than one crossover, the methods may be applied more than once; for example first correcting group-delay irregularity in a combination of mid-range and tweeter and then correcting overall group-delay irregularity between that combination and an associated woofer.
[0024] The methods of the present invention may be implemented as signal-processing elements within a multi-way loudspeaker system or as signal-processing elements within separate loudspeaker systems, including separate woofer with satellite combinations including where the numbers of satellites and woofers are not necessarily equal, in such a way that the overall response achieves the desired corrected group delay.
[0025] The methods may also be used within a controller or pre-processor device, including within a surround-sound or home-theatre decoder, processor or receiver, to adjust signals fed to multiple loudspeakers so as to equalise variations in group delay in the resulting sound. The methods may also be applied to the design of a signal-processor which uses internal band-split and recombination to more efficiently provide compensation for a loudspeaker system where there is no access to the crossover.
[0026] The methods described may also be used in the design of a multi-way acoustic reproducer to enable more uniform group delay where the underlying acoustic design would otherwise be less appropriate.
[0027] In some embodiments of the invention the correction is incorporated at the design stage so as to enable adequate system performance to be achieved from a transducer system whose natural group-delay response would otherwise be unacceptable, for example as might result if: (i) a high-order system design such as 10 th order was used to extend the response of a smaller cabinet, or (ii) where methods of extending the acoustic low-frequency response of a mid-range system otherwise confused the crossover design.
[0028] The methods described may be implemented as analogue or digital processing means to obtain the low-frequency all-pass response while the delay for the upper section can use acoustic, analogue or digital memory or other means.
[0029] The methods described may also be implemented in software as an improvement to existing systems using a digital signal processor (DSP).
[0030] Although the present invention does not relate to correction of crossovers as such, it does facilitate additional methods for optimising the design of a crossover by virtue of the near-uniform group delay realised using the invention.
[0031] In a first embodiment of the invention a series of all-pass filters are designed to equalise the group delay of the low frequency signal within a multi-way loudspeaker up to and somewhat above the relevant cross-over frequency. As the frequency range between the system roll-off and the crossover may be only a few octaves, this correction can be accomplished using a relatively small number of all-pass filter elements. The all-pass system is designed so as to present uniform delay to relevant frequencies when combined with the low-frequency transducer system. The signal fed to the higher-frequency signal paths can then be delayed appropriately by other means and this may then result in an overall system which provides consistent group delay across the entire frequency range, and consequently present a cleaner overall sounding result.
[0032] A second embodiment of the invention utilises a reverse block processing technique providing a means to filter the low-frequency audio signal backwards, effectively implementing an apparent negative group delay on the forward signal.
[0033] Because this processing need only be applied to the lower-frequency section of a multi-way system, problems of state convergence can be overcome by down-sampling the low frequency signal prior to application of a series of equalising all-pass filters. Overall audio alignment with the high-frequency system is obtained through pure delay methods within the high frequency signal paths.
[0034] A third embodiment of the invention employs a pre-processor with one input and one output per loudspeaker system and which is designed to provide a signal which equalises the low-frequency group delay of an external loudspeaker. The process uses band-split means to divide the signal into a low-frequency part within which path all-pass filters can be used to provide an appropriate group delay and into a high-frequency part which path contains a pure delay. Upper and lower ranges are then recombined by a band-join method, which may be a simple addition, to provide the pre-compensated signal.
[0035] The computer program product of the second aspect of the invention may implemented as an update or enhancement to an existing digital signal processor (DSP) loudspeaker system, or else as an update or enhancement to an existing multichannel or stereo audio processor.
[0036] An acoustic transducer system according to the third aspect of the invention may comprise low and upper range sections of a multi-way loudspeaker or other transducer combination. Alternatively, or additionally, it may comprise any frequency-adjacent pair of driver ranges in a multi-way system, not including the lowest-frequency range, such as between tweeters or between a mid-range and tweeter combination.
[0037] In some embodiments the acoustic transducer system may comprise a low-frequency system in a separate enclosure or cabinet, such as a sub-woofer, in combination with one or more loudspeakers, wherein there exists a crossover, whether acoustic or by filter means.
[0038] In some embodiments the acoustic transducer system may comprise signal processing within an associated element for performing the method in conjunction with a combination of loudspeaker systems or other transducers, including surround processors, home theatre receivers and similar devices, which may include bass management, crossover and alignment methods.
[0039] In some embodiments the acoustic transducer system may comprise a compensating signal-processing device, wherein lower-frequency range and higher-frequency range paths are internal and created by bandsplit means, but wherein the post-correction recombination of low and high-frequency signals occurs in signal processing by bandjoin means, so as to provide a composite signal corrected for the acoustic transducer system where there is no access to any crossover or where the system is full-range.
[0040] As will be appreciated by those skilled in the art, the present invention is capable of various implementations according to the application. Moreover, the invention facilitates other design options for the acoustic transducer system, for example relating to the form of the crossover, which may take advantage of the group delay correction afforded by the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Examples of the present invention will be described in detail with reference to the accompanying drawings, in which:
[0042] FIG. 1 shows a basic flow diagram of a multi-way loudspeaker, in this case a three-way loudspeaker comprising three driver units;
[0043] FIG. 2 is an example of low frequency group delay for second, fourth, sixth, eighth and tenth-order loudspeakers;
[0044] FIG. 3 shows two examples all pass filters and their combined group delay;
[0045] FIG. 4 shows a partial group delay equalisation using eight all-pass filters and the perceived overall delay once delay lines have been applied;
[0046] FIG. 5 shows a flow diagram of a three-way loudspeaker incorporating a series of all pass filters on the low frequency or woofer drive unit, and a delay line for the remaining signal paths to align the overall group delay of the system;
[0047] FIG. 6 illustrates a method for breaking up an audio signal into blocks for reverse block processing, wherein each block is processed as an individual step;
[0048] FIG. 7 shows a flow diagram for a three-way loudspeaker system that performs reverse-block processing on the low-frequency signal path so that a sequence of all-pass filters can be used to negate the overall group delay. A pure delay is used in the high-frequency paths to align the loudspeaker outputs; and,
[0049] FIG. 8 shows a flow diagram for a pre-processor unit that carries out a bandsplit on the input signal, corrects the group delay on the low-frequency path and applies a compensatory pure delay to the high-frequency path, before recombining at the output via a bandjoin process.
DETAILED DESCRIPTION
[0050] The present invention may be implemented in a number of different ways according to the acoustic transducer system being used. The following describes some example implementations with reference to the figures.
All-Pass Filter Correction
[0051] A multi-way loudspeaker consists of two or more sets of drive units, where each set may consist of one or more loudspeaker driver units and may be considered the end point of a different signal path. The flow diagram in FIG. 1 shows one such possible three-way loudspeaker system in which the audio signal 1 is passed through a different filter set for each drive unit. A low pass filter 4 and an aux filter 5 to extend the bass response is used for the woofer driver 8 signal; a band pass filter 3 for the mid-range 7 drive unit signal; and a high pass filter 2 for the tweeter 6 signal.
[0052] Each drive unit in a multi-way loudspeaker operates over a different but overlapping frequency range. Consequently, for an ideal loudspeaker each signal path should be filtered to ensure the crossover point of each drive unit combine such that the overall magnitude and phase response of the entire loudspeaker meets a desired response.
[0053] FIG. 2 shows the dominating low frequency characteristics of the group delay for various three-way loudspeaker cabinets. The significant group delay, most visible in this example around 25 Hz, will cause low frequency sounds to arrive after their associated high frequency components or transients, blurring and generally degrading the overall auditory result.
[0054] A known method for adjusting the group delay of a system without altering the overall magnitude response is through the use of all-pass filters as described in M. F. Quélhas, A. Petraglia, and M. R. Petraglia, “Efficient group delay equalization of discrete-time IIR filters”, European Signal Processing Conference, pp. 125-127, 2004. The transfer function of a second order digital all-pass filter may be defined as:
[0000]
A
(
z
)
=
b
+
az
-
1
+
z
-
2
1
+
az
-
1
+
bz
-
2
[0055] The parameters a and b are chosen according to the requirements of the filter, where
[0000]
a
=
-
2
r
·
cos
(
2
π
f
c
F
s
)
[0000] and b=r 2 . Where r corresponds to the radius of the filter pole (the zero radius being given as 1/r) with r<1 required to ensure a stable causal filter, f c is the centre frequency, and F s is the sampling frequency.
[0056] FIG. 3 shows an example of the overall group delay obtained from two second order all-pass filters with F s of 96000 Hz, f c equal to 100 Hz and 200 Hz, and r corresponding to 0.995 and 0.996, respectively.
[0057] Ideally, a set of all-pass filters with a negative group delay would be required to equalise the group delay of a loudspeaker cabinet, such as those shown by the curves in FIG. 2 . However, although it is possible to design an all-pass filter to have a negative group delay, the filter will be acausal making the entire system unstable.
[0058] An alternative solution would require hundreds of all-pass filters to create a flat positive group delay across the entire frequency range from low to high. This number of filters would generally be impractical in terms of real-time implementation and introduce significant build-up of noise.
[0059] Consequently, the first embodiment of this invention applies a sequence of all-pass filters to the low frequency path to equalise the group delay response of the loudspeaker to a frequency sufficiently beyond the crossover frequency of the woofer signal path. For instance, assuming an 8 th order Linkwitz-Riley low-pass roll off for the woofer, the magnitude response will be 24 dB down half an octave above the crossover frequency, at which point the waveform will be sufficiently reduced to ensure negligible group delay interference. FIG. 4 shows the group delay of a set of eight equalising second order all-pass filters as well as the group delay for the loudspeaker system and the combined group delay.
[0060] The full group delay equalisation is now achieved by delaying the signal in additional signal paths, which correspond to the mid-range and tweeter feeds in the current example. In this example, delay is introduced within memory buffers of a DSP system. As shown by the flow diagram of FIG. 5 , the buffers implement a pure delay 9 which corresponds to the equalised low-frequency system group delay.
[0061] Thus, in the first embodiment of the invention a series of all-pass filters are applied to equalise or the low-frequency path using positive group delays to a target uniform delay level and accomplished in such a way as to provide an appropriate phase at the cross-over frequency, and then an equivalent delay is inserted into the remaining audio paths, which in this embodiment corresponds to the mid-range and tweeter feeds.
[0062] Although illustrated as correction between a woofer and mid-range section, an equivalent embodiment would correct between a woofer system and a one-way or multi-way upper frequency reproducer. This method can also be applied to flatten the group delay of a midrange-tweeter system which in turn can be combined with a woofer using the same method.
Steps:
[0000]
Using an iterative process to apply and adjust a series of all pass filters, equalise the group delay response of the low frequency component of the loudspeaker to a positive time delay across the frequency range of interest.
Extend the equalisation up to and beyond the crossover frequency of the low frequency drive unit.
Implement delay within the remaining high frequency loudspeaker feeds, e.g., mid-range and tweeter.
Ensure the overall loudspeaker response knits well at the crossovers, adjusting the filters and delay lines appropriately.
Reverse Block Processing
[0067] An alternative approach to compensate for positive group delay using all-pass filters is to process a signal in reverse. A series of all-pass filters with positive group delay may be constructed that normalise the group delay of the low frequency signal path of a multi-way loudspeaker. Once calculated these filters may be applied to a known signal in reverse time before audition. However, for a real-time system this is impractical. Hence, a second embodiment of the invention makes use of reverse block processing enabling the additive group delay of all-pass filters to be effectively subtracted from the low-frequency signal path in real-time, which when combined with pure delay methods for the high frequency signal paths can effectively equalise the entire system.
[0068] One such application of reverse-block processing is portrayed in FIG. 6 , in which two or more buffers may be used to facilitate the process. The system will present an initial start-up delay whilst the buffers fill for the first time, which may be compensated for via a pure delay within the high-frequency paths. The buffers may be treated as a form of Last In First Out (LIFO) buffer, as they are filled with the forward signal but the filters are applied starting with the last sample first.
[0069] Processing of the first buffer, A, may commence as soon as buffer B has been filled, or at least the region occupied by the overlap, B 1 to B j . Where 1<j<<n, with j corresponding to the sample offset of the overlap region within a block buffer of length n. This overlap is necessary to ensure filter states have stabilised sufficiently to provide accurate filtering of buffer A to prevent discontinuities in the processed signal at the block boundaries.
[0070] A third buffer may be used allowing filtering of the region from B j backwards to A 1 , whilst additional audio is buffered in a block C in preparation for the next processing step, namely filtering of block B (samples C j to B 1 ). Once a block has been filtered it may be passed to the output path for audition, and the corresponding buffer freed for reuse.
[0071] Unless additional buffers are used to allow for error checking, the overlap region of length j should be of sufficient size to ensure that filter states stabilise. However, for high sample rate signals a large and generally impractical number of samples will be required for filter state stabilisation to attain an acceptable level for a high precision system. Such large numbers of samples would require a suitably fast processor, large buffers and long delays on system start whilst the buffers fill.
[0072] A solution is provided, as shown in FIG. 7 , by down-sampling 11 the low-frequency signal (which has already been suitably low-pass filtered 4 ) by an integer factor N prior to reverse-block processing 12 and all-pass filtering 10 . After this, the processed signal may be up-sampled 13 again, if required. Down-sampling reduces the frequency range over which the signal relates and as such the states of the equivalent lower sample rate all-pass filters stabilise significantly faster than the original high sample rate versions.
[0073] This second embodiment of the invention uses a method of reverse-block processing a lower frequency signal with a series of all-pass filters designed such that they compensate for the positive group delay of the system. To facilitate filter state convergence at buffer or block boundaries the signal may be down-sampled prior to group delay correction via the all-pass filters. Finally the corrected signal may be up-sampled to return it to the original sample rate. The higher frequency signal paths utilise a pure delay equivalent to the time taken for a sample to pass through the low-frequency filter process, including down-sampling, reverse-processing, all-pass filtering, and up-sampling.
Steps:
[0000]
Down-sample the low-frequency signal.
Reverse-block process the down-sampled low-frequency signal.
Apply a cascade of all-pass filters designed to match the system group delay, thus cancelling the positive group delay in reverse time.
If necessary, prior to output up-sample the low-frequency signal back to its original or a different sample rate.
Apply a pure delay to the high-frequency signal paths corresponding to the time delay imposed on the low-frequency signal path by buffering during reverse-block processing.
Pre-Processing
[0079] A third embodiment of the invention, as shown in FIG. 8 , considers a pre-processor with one input and one output per loudspeaker system and which is designed to provide a signal which equalises the low-frequency group delay of an external loudspeaker. The process envisaged uses a bandsplit means 14 to divide the signal into a low-frequency part, as indicated by LF in FIG. 8 , and a high-frequency part, HF. The low-frequency path passes through a group delay correction block 15 that implements all-pass filters in the manner of embodiment 1 or embodiment 2. Similarly, the high-frequency path contains a pure delay 9 , which is appropriate to the first or second embodiments of the invention.
[0080] The processed upper and lower ranges are then recombined by a band-join method 16 , which may be a simple addition, to provide the pre-compensated signal 17 .
Steps:
[0000]
Band-split the audio signal into low and high-frequency components.
Apply group delay correction methods to the low-frequency signal path. This may utilise all-pass filters and a down-sampling/up-sampling stage as described in embodiment 1, or reverse-block processing from embodiment 2 of the invention.
Apply a pure delay to the high-frequency component equivalent to the delay either required or imposed by the processing on the low-frequency path depending on the use of embodiment 1 or embodiment 2 of the invention.
Recombine the group delay corrected low-frequency and high-frequency components of the audio signal using a band-join process.
|
Methods are provided for equalising the group delay of a sound reproduction system, in particular a system comprising acoustic transducers with at least one crossover between a lower-frequency and a higher-frequency range. A correction is applied to a signal in the lower-frequency range, including the crossover region, to substantially equalise the group delay for the lower-frequency range, and a signal delay is applied to a signal in the higher-frequency range to bring it into closer alignment with the equalised lower-frequency range signal. The methods may be implemented in the design of an acoustic transducer system and also via a computer program product, which can be implemented as an update or enhancement to an existing digital signal processor loudspeaker system.
| 7
|
This is a division of U.S. application Ser. No. 307,646 filed Feb. 7, 1989, now U.S. Pat. No. 4,988,705 which is a division of U.S. application Ser. No. 017,027, filed Feb. 17, 1987 (now U.S. Pat. No. 4,810,708), which is a continuation-in-part of U.S. application Ser. No. 861,788, filed May 15, 1986 (now abandoned), which in turn is a continuation-in-part of U.S. application Ser. No. 744,865, filed Jun. 13, 1985 (now abandoned).
BACKGROUND OF THE INVENTION
The present invention relates to novel polycyclic compounds which are useful in the treatment of allergic diseases, inflammation, peptic ulcers, hypertension, hyperproliferative skin diseases and in suppressing the immune response.
SUMMARY OF THE INVENTION
The invention in its chemical compound aspect involves a compound having the structural formula I ##STR1## or a pharmaceutically acceptable salt or solvate thereof, wherein:
in formula I:
the dotted lines (---) represent optional double bonds;
W is ##STR2## T and V may be the same or different and each represents H, OH, alkyl, alkoxy, phenyl or substituted phenyl;
in addition, T may also be F, Cl, or Br;
X and M may be the same or different and each independently represents --CH(R a )-- or --NA-- when the dotted line --- attached thereto does not represent a double bond; or X and M each independently represents ═CH-- or ═N-- when the dotted line --- attached thereto represents a double bond; or when M is N and the dotted lines --- in ring t both represent double bonds, X and T together with the carbon atom of the ring t therebetween may also represent a group ##STR3## wherein X is a carbon atom and Q 0-3 represents zero, 1, 2 or 3 Q substituents as defined below;
each A is independently selected from H, alkyl, CH 2 CH 2 OH, COR b , COOR e , SO 2 R b or (CH 2 ) s R c ;
Z is O, S, N--R e or N(OR i );
B is alkyl, alkenyl [provided k is not zero], NH 2 , COOR e , O(CO)R e , or an aryl group selected from phenyl, naphthyl, indenyl, indanyl, phenanthridinyl, pyridinyl, pyrimidinyl, pyrazinyl, pyridazinyl, 1,2,4-triazinyl, furanyl, thienyl, benzofuranyl, indolyl, imidazolyl, pyrazolyl, triazolyl, or thiazolyl any of which aryl groups may be substituted with up to three of any of the following substituents, Q: halogen, hydroxy, nitro, alkyl, CH 2 OH, trifluoromethyl, cyano, N(R f ) 2 , cycloalkyl, alkoxy, alkenyloxy, alkynyloxy, S(O) r R e , NHSO 2 R e , NHSO 2 CF 3 , NHCOCF 3 , SO 2 NH 2 , SO 2 NHR e , SO 2 N(R e ) 2 COR h , O--D--COR h , or NHCOR d ;
R a is H, OH, alkyl, phenyl, substituted phenyl, phenylalkyl or substituted phenylalkyl;
R b is H, alkyl, phenyl, substituted phenyl, or N(R e ) 2 ;
R c represents carboxyl or N(R i ) 2 ;
R d represents H, alkyl, alkoxy, COR j , or NHR k ;
each R e independently represents alkyl, phenyl, substituted phenyl, benzyl or substituted benzyl;
each R f independently represents H or alkyl;
R h represents OH, NH 2 or OR e ;
each R i independently represents H or alkyl;
R j represents OH or alkoxy;
R k represents H or alkyl;
D represents alkylene;
k is 0, 1 or 2;
r is 0, 1 or 2; and
s is 1, 2, 3, 4 or 5;
in formula II:
the dotted line --- represents an optional double bond;
Y and Y' are both H or, when --- represents a double bond, Y and Y' together with the carbon atoms to which they are attached may also represent a phenyl ring which may be substituted with up to 3 substituents independently selected from hydroxy, alkoxy, alkyl or halo; and
m and n may be the same or different and are 0, 1, 2, 3 or 4, provided that the sum of m and n is 1, 2, 3 or 4;
in formula III:
the dotted line --- represents one optional double bond or two optional non-cumulated double bonds;
one of a, b, and c is N (if the dotted line --- attached thereto represents a double bond), N + O - (if the dotted line attached thereto represents a double bond), O, S(O) r , N--R m , or N--CO--R n , or d is N (if the dotted line --- attached thereto represents a double bond), --NR m , or N--CO--R n , and each of the other three may be the same or different and each represents CH 2 or CH (if the dotted line --- attached thereto represents a double bond);
r is as defined above;
R m represents H, alkyl, acyl, benzyl or substituted benzyl; and
R n represents phenyl, substituted phenyl, alkoxy, phenoxy, substituted phenoxy, phenylalkoxy, or substituted phenylalkoxy;
in formula IV:
R 1 and R 2 may be the same or different and each is selected from H (provided both are not H), alkyl, phenyl, substituted phenyl, hydroxy, COOR e , O(CO)R e , cyano, carboxyl, CONH 2 , CON(R e ) 2 , CONHR e , or OR e ; or R 1 and R 2 are attached to the same carbon atom of the ring ##STR4## and together represent a carbonyl oxygen or a ketal thereof selected from ##STR5## or R 1 and R 2 together with two adjacent carbon atoms of the ##STR6## ring represent an epoxide, aziridine, furane, thiophene, pyrrole, N-alkylpyrrole, isopyrrole, 3-isopyrrole, pyrrolidine, triazole, triazolidine, isoxazole, isothiazole, isoxazolidine, isoxazoline, pyrazole, N-alkylpyrazole, pyrazoline, or pyrazolidine ring;
R w and R y may be the same or different and each represents alkyl; and
R e is as defined above;
in formula V:
R 3 , R 4 , R 5 and R 6 may be the same or different and are hydrogen or alkyl; and
g is 1 or 2;
in formula VI:
the dotted line represents an optional double bond between e and f or between f and g as defined below:
e, f and g are defined as follows:
(i) e represents O, S(O) r , N--R m or N--COR n , and f and g both represent CR p (if the dotted line between f and g represents a double bond) or CHR p ; or
(ii) f represents O, S(O) r , N--R m or N--COR n , and e and g both represent CHR p ; or
(iii) g represents N (if the dotted line between f and g represents a double bond), f represents CR p , and e represents CHR p ; or
(iv) g represents N--R m or N--COR n , and e and f both represent CR p (if the dotted line between e and f represents a double bond) or both represent CHR p ;
each R p is independently selected from H, alkyl, acyl or COOR f ; and
R f , R m , R n and r are as defined above; and
in formula VII:
one of J and L is CHR q and the other is CR r R s or, when --- represents a double bond between J and L, one of J and L is CR q and the other is CR r ;
R q represents H, COOR t , or alkyl;
R r and R s may be the same of different and each is selected from H, alkyl, acyl, --COOR e , O(CO)R e , --CN, phenyl, sufonyl, substituted phenyl sulfonyl, alkyl sulfonyl, nitro; or R q and R r together with the carbon atoms to which they are attached represent a carbocyclic ring having from 5 to 8 carbon atoms optionally containing one carbon-carbon double bond or represent a heterocyclic ring selected from ##STR7## R e is as defined above; and R t represents H, alkyl, phenyl, substituted phenyl, benzyl or substituted benzyl.
In formula I, k is preferably zero, the dotted lines in ring t preferably represent double bonds and M is preferably N. T and V are preferably H, Z is preferably O, and X is preferably CH. B in formula I is preferably phenyl or phenyl substituted with up to 3 Q substituents as defined above. Substituent Q is preferably present in the 2-, 3- or 4-; 2- and 3-; 2- and 4-; 2- and 5-; 3- and 4-; or 3-and 5- positions.
A preferred subgenus of formula II has structural formula ##STR8## wherein B, m, and n are as defined above.
A second preferred subgenus of formula II has structural formula ##STR9## wherein Q 0-3 represents up to three Q substituents as defined above. Q preferably represents a 3--Cl, 3--CH 3 S or 3--NO 2 substituent in such formula.
A third preferred subgenus of formula II has structural formula ##STR10## wherein Q 0-3 represents up to three Q substituents as defined above. Q preferably is absent or represents a 3--CF 3 , 3--S--CH 3 , 4--CH 3 or 3--NO 2 phenyl substituent in a such formula.
In formula III, a, c and d preferably are CH 2 , the dotted lines --- preferably do not represent double bonds, and b preferably represents O, S(O) r , N--R m or N--CO--R n wherein r, R m and R n are as defined above. More preferably, b is N--R m and R m is acyl, e.g., acetyl.
A preferred subgenus of formula III has structural formula ##STR11## wherein the dotted lines represent optional double bonds; Q 0-3 represents up to three Q substituents as defined above; and E represents N + --O - when the dotted line attached to E represents a double bond or E represents N--R m or N--CO--R n (wherein R m and R n are as defined above) when the double bond represented by the dotted line attached to E is absent.
A preferred subgenus of the compounds having ring W represented by formula is represented by the formula ##STR12## wherein B and R 1 are as defined above. In such formula IVa, R 1 is preferably COOR e wherein R e is as defined above, R e preferably being C 2 H 5 and B preferably being 3-chlorophenyl. Alternatively, R 1 in formula IVa is preferably CH 3 and B preferably represents 3-chlorophenyl, 3-methoxyphenyl, 3-methylthiophenyl or 3-nitrophenyl group.
In formula VI, e and f preferably represent CH 2 and the dotted lines do not represent double bonds, with g being defined as above. The letter g preferably represents N--R m , more preferably N--CH 3 while B preferably represents phenyl or substituted phenyl such as 3-trifluoromethylphenyl.
In formula VII, the dotted line preferably does not represent a double bond and J and L together preferably represent a heterocyclic ring ##STR13## wherein R t is phenyl. Alternatively, the dotted line preferably does not represent a double bond and J and L both preferably represent CHCOOCH 3 .
Preferred compounds of the invention include ##STR14## or a pharmaceutically acceptable salt thereof. Compound A is particularly useful in the treatment of allergic reactions, while Compounds B, C and D are particularly useful in the treatment of inflammation.
When utilized herein, the terms below have the following scope:
halo-represents fluoro, chloro, bromo and iodo;
alkyl (including the alkyl portion of alkoxy, phenylalkyl, phenylalkoxy and alkylsulfonyl) and alkylene--represent straight and branched carbon chains and contain from 1 to 6 carbon atoms;
alkenyl--represents straight and branched carbon chains having at least one carbon to carbon double bond and contain from 2 to 6 carbon atoms;
alkenyloxy and alkynyloxy--represents straight and branched carbon chains having at least one carbon-to-carbon double or triple bond, respectively, and contains from 3 to 6 carbon atoms, with the proviso that the oxygen atom is not bound to an olefin or acetylenic carbon atom thereof;
cycloalkyl--represents saturated carbocyclic rings having from 5 to 8 carbon atoms;
substituted phenyl, substituted phenylalkyl, substituted phenoxy, substituted phenylalkoxy, and substituted benzyl--represents phenyl, phenylalkyl, phenoxy, phenylalkoxy and benzyl groups wherein the phenyl ring thereof is substituted with up to 3 substituents Q as defined above, with the Q substituents being the same or different with there are 2 or 3 Q substituents; and
acyl--represents a group alkyl--CO-- wherein alkyl is as defined above.
The invention also involves a pharmaceutical composition which comprises a compound having structural formula I in combination with a pharmaceutically acceptable carrier.
The invention further involves methods for treating allergic reactions, inflammation, peptic ulcers, hypertension and hyperproliferative skin diseases (e.g., psoriasis, lichenified eczema or seborrheic dermatitis) and for suppressing the immune response in a mammal which comprises administering the above defined pharmaceutical composition to said mammal in an amount effective to achieve such purposes.
DESCRIPTION OF THE INVENTION
The group B in formula I may represent various aromatic and heterocyclic rings. These rings may be attached to the group --(CH 2 ) k -- (or to the N atom of the middle ring of structural formula I if k is zero) via any of the available substitutable atoms of such B aromatic or heterocyclic aromatic ring. Examples of suitable aryl heterocyclic groups B include 2-, 3- or 4-pyridinyl, 2- or 3-furanyl, 2- or 3-thienyl, 2, 4- or 5-thiazolyl, 2-, 4- or 5-imidazolyl, 2-, 4-, 5- or 6-pyrimidinyl, 2- or 3-pyrazinyl, 3- or 4-pyridazinyl, 3-, 5- or 6- [1,2,4-triazinyl], 2-, 3-, 4-, 5-, 6- or 7-benzofuranyl, 2-, 3-, 4-, 5-, 6- or 7-indolyl, or 3, 4- or 5-pyrazolyl.
Also, in formula IV, when R 1 and R 2 together represent a heterocyclic ring system, all possible orientations of the heteroatoms in such rings are intended. For example, R 1 and R 2 together with the adjacent carbon atoms of the ring ##STR15## to which they are attached may form a furanyl ring with the oxygen atom thereof in any possible position in the furanyl ring.
As noted above, the compounds of the invention may include up to three Q substituents on an aromatic "B" group depending upon the available sites for substitution. In compounds where there is more than one such Q substituent, they may be the same or different. Thus, compounds having combinations of different Q substituents are contemplated within the scope of the invention. Examples of suitable Q substituents include hydroxy, methyl, chloro, bromo, nitro, cyclohexyl, allyloxy, 2-propynyloxy, methylthio, methylsulfonyl, carboxy, acetoxymethoxy, acetylamino, methylsulfonylamino and the like.
Where two substituents appear on the same group, e.g. R e in SO 2 N(R e ) 2 or R f in N(R f ) 2 , such substituents may be the same or different. The same is true when a particular substituent (such as R e ) appears in two or more positions in a compound of formula I. For example, when in formula I, Z is NR e , ring W is formula II, and R 1 represents COOR e , the R e groups may be the same or different.
Certain compounds of the invention may exist in isomeric forms. The invention contemplates all such isomers both in pure form and in admixture, including racemic mixtures.
The compounds of the invention of formula I can exist in unsolvated as well as solvated forms, including hydrated forms, e.g., hemihydrate. In general, the solvated forms, with pharmaceutically acceptable solvents such as water, ethanol and the like are equivalent to the unsolvated forms for purposes of the invention.
Certain compounds of the invention will be acidic in nature, e.g. those compounds which possess a carboxyl or phenolic hydroxyl group. These compounds may form pharmaceutically acceptable salts. Examples of such salts are the sodium, potassium, calcium, aluminum, gold and silver salts. Also contemplated are salts formed with pharmaceutically acceptable amines such as ammonia, alkyl amines, hydroxyalkylamines, N-methylglucamine and the like.
Certain compounds of the invention also form pharmaceutically acceptable salts, e.g., acid addition salt and quaternary ammonium salts. For example, the pyrido- or pyrazino- nitrogen atoms may form salts with strong acid, while compounds having basic Q substituents such as amino groups also form salts with weaker acids. Examples of suitable acids for salt formation are hydrochloric, sulfuric, phosphoric, acetic, citric, oxalic, malonic, salicyclic, malic, fumaric, succinic, ascorbic, maleic, methanesulfonic and other mineral and carboxylic acids well known to those in the art. The salts are prepared by contacting the free base form with a sufficient amount of the desired acid to produce a salt in the conventional manner. The free base forms may be regenerated by treating the salt with a suitable dilute aqueous base solution such as dilute aqueous sodium hydroxide, potassium carbonate, ammonia and sodium bicarbonate. The quaternary ammonium salts are prepared by conventional methods, e.g., by reaction of a tertiary amino group in a compound of formula I with a quaternizing compound such as an alkyl iodide, etc. The free base forms differ from their respective salt forms somewhat in certain physical properties, such as solubility in polar solvents, but the salts are otherwise equivalent to their respective free base forms for purposes of the invention.
The compounds of the invention which possess an aromatic ring nitrogen atom, as defined above, may also form quaternary salts at an aromatic ring nitrogen atom.
All such acid, base and quaternary salts are intended to be pharmaceutically acceptable salts within the scope of the invention and all acid and base salts are considered equivalent to the free forms of the corresponding compounds for purposes of the invention.
The following processes A. to D. may be employed to produce various compounds in accordance with formula I. Processes A. to C. produce compounds of formula I where ring W is in accordance with formulas II, III, IV, V and VI, Z is O, and the dotted lines in ring t represent double bonds:
A. A compound of formula X ##STR16## is reacted with a compound of formula XI ##STR17## wherein M, T, V, X, k, and B are as previously defined, ring W is in accordance with formulas II to VI, and L 1 is a leaving group to produce a compound of formula I, a compound of formula Ia, ##STR18## or a mixture of compounds of formulas I and Ia, and if only a compound of formula Ia is produced, followed by converting the compound of formula Ia to a compound of formula I by treatment of the compound of formula Ia with strong acid; or if a mixture of compounds of formulas I and Ia was produced, optionally followed by treatment of the mixture with strong acid to convert the compound of formula Ia to a compound of formula I.
The starting materials having structural formula X and XI are known in the art. L 1 can be, for example, phenoxy, alkoxy, phenylalkoxy, etc. Compounds in accordance with formula X having --OH in the position of L 1 can be converted to compounds wherein L 1 is phenoxy, alkoxy or phenylalkoxy, by standard methods. Compounds of formula X wherein X and M are N, i.e., 2-substituted amino-3-pyrazine carboxylate esters may be prepared by known methods. For example, 2-phenylamino-3-pyrazine carboxylic acid is known from C.A., 75 20154e (1971).
The ketones XI, may be prepared by standard procedures or by obvious variations thereof. Other ketones having structural formula XI such as cyclopentanone, cyclohexanone and the like are available commercially.
The reaction of the compounds of formulas X and XI may be carried out by contacting X and XI in a non-reactive solvent in the presence of a basic reagent, preferably at an elevated temperature for a sufficient amount of time until the reaction is substantially completed. The progress of the reaction may be monitored by thin layer chromatography, if desired. Suitable non-reactive solvents for purposes of the reaction are tetrahydrofuran, toluene, dimethylsulfoxide, N,N-dimethylformamide and the like. Suitable basic reagents are lithium bistrimethylsilylamide, sodium amide and the like. Other suitable basic reagents and solvents will suggest themselves to those skilled in the art.
The reaction of X and XI may yield compounds of formula I, compounds of formula Ia, or a mixture of the two. If only a compound of formula Ia is formed, it may be converted to a compound of formula I by treatment with a strong acid such as p-toluenesulfonic acid in boiling toluene. Other strong acids such as sulfuric acid, aqueous hydrobromic acid, etc. may be used.
B. A compound of formula XII ##STR19## is reacted with a compound of formula XIII ##STR20## wherein M, T, V, X, k, and B are as previously defined, ring W is in accordance with formulas II to VI, L 2 is a leaving group and L 3 is a leaving group (which also acts as an activating group in formula XIII), to produce a compound of formula I, a compound of formula Ib ##STR21## or a mixture of compounds of formulas I and Ib, and if only a compound of formula Ib is produced, followed by converting the compound of formula Ib to a compound of formula I by treatment of the compound of formula Ib with strong acid, or if a mixture of compounds of formulas I and Ib was produced, optionally followed by treatment of the mixture with strong acid to convert the compound of formula Ib to a compound of formula I.
Compounds of formula XII are known or may be prepared by known methods. The choice of leaving groups L 2 is not critical. L 2 may, for example, be Cl, Br or --OSO 2 R, wherein R is phenyl, alkyl, --CF 3 , etc. For example, known compounds of the formula ##STR22## may be converted to compounds of the formula ##STR23## for example, by reaction with SOCl 2 or POCl 3 or PCl 5 to produce compounds of formula XIIb. Compounds of formula XIIb are reacted with an appropriate primary amine, the ester group is then hydrolyzed off with, for example, base, and then the resulting compound is reacted to form the acid chloride, e.g. with thionyl chloride. For example, the following reaction scheme illustrates this process: ##STR24##
L 3 is a leaving group, preferably a tertiary amino leaving group, e.g., of the formula ##STR25## wherein R u and R v are alkyl, arylalkyl, heteroarylalkyl, or R u and R v , together with the nitrogen atom to which they are attached may form a 5 to 8 membered saturated ring, e.g., pyrrolidine, piperidine, or morpholine. Many enamine compounds of formula XIII are known. Others may be made by known procedures, e.g., J. Am. Chem. Soc. 76, 2029 (1954). L 3 may also be, for example, SCH 3 , e.g. from the enamine 1-methyl-2-methylmercapto-2-pyrroline.
The reaction of compounds of formulas XII and XIII is carried out in solvent, e.g., dichloromethane, benzene, toluene, etc., at temperatures ranging from -10° C. to the boiling point of the solvent. The reaction proceeds in the presence of at least 2 moles of tertiary amine base, of which one mole must be of compound formula XIII. The additional base can be extra compound XIII or a different base such as, for example, triethylamine, diisopropylethylamine, etc.
The reaction of XII and XIII may yield compounds of formula I, formula Ib, or a mixture of the two. If only a compound of formula Ib is formed, it may be converted to a compound of formula I by treatment with a strong acid such as p-toluene-sulfonic acid in boiling toluene. Other strong acids, such as sulfuric acid, aqueous hydrobromic acid, etc., may be used.
C. A compound of formula XIV ##STR26## is reacted with a compound of formula XV ##STR27## wherein M, T, V, X, k, and B are a previously defined, ring W is in accordance with formulas II to VI, L 4 is a leaving group and L 5 is a leaving group, to produce a compound of formula I, a compound of formula Ic ##STR28## or a mixture of compounds of formulas I and Ic, and if only a compound of formula Ic is produced, followed by converting the compound of formula Ic to a compound of formula I by treatment with non-nucleophilic strong acid, or if a mixture of compounds of formulas I and Ic was produced, optionally followed by treatment of the mixture with non-nucleophilic strong acid to convert the compound of formula Ic to a compound of formula I.
Compounds of formula XIV may be made by the following reaction: ##STR29##
In formula XIVa, L 6 and L 4 are leaving groups such as Cl, Br, alkoxycarbonyloxy, phenoxy, benzyloxy, trifluoromethoxy, etc.
In formulas XIVb, L 5 is the same as L 3 from formula XIII. The reaction of compounds XIVa and XIVb takes place in solvent, e.g., CH 2 Cl 2 , CHCl 3 , CCl 4 , benzene, toluene, etc., at -10° C. to about 25° C., preferably at about 0° C. This reaction like process B described above requires at least 2 moles of base of which one mole must be a compound of formula XIVb.
The primary amines of formula XV are well known and commercially available or can be made by conventional means.
The reaction of compounds XIV and XV takes place in solvent, e.g., benzene, toluene, xylene, etc. at elevated temperatures up to the boiling point of the solvent. Alternatively, the reaction can be carried out in the solvent and 1 equivalent of a strong, non-nucleophilic, preferably anhydrous acid such as p-toluenesulfonic acid, trifluoromethanesulfonic acid, etc.
The reaction of compounds XIV and XV may yield compounds of formula I, formula Ic, or a mixture of the two. If only a compound of formula Ic is formed, it may be converted to a compound of formula I by treatment with a non-nucleophilic strong acid, preferably an anhydrous acid. Preferred acids for this purpose are p-toluenesulfonic acid and trifluoromethanesulfonic acid. Of course others may be used. The reaction takes place in solvent, e.g. benzene, toluene, CH 2 Cl 2 , etc. at elevated temperatures, preferably the boiling point of the solvent. Of course, this step may be omitted if the reaction of compounds XIV and XV is carried out in presence of the acid.
D. To produce a compound of formula I wherein Z is O, the dotted lines in ring t represent double bonds, and W is ##STR30## wherein J and L and the dotted line are as previously defined, a compound of formula XXI ##STR31## wherein M, T, V, X, k, and B are as previously defined, is reacted with a compound having the formula XXIIa or XXIIb ##STR32## to form compounds of formula I wherein W is of formula VII and the dotted line in formula VII represents a single bond, or with a compound of formula XXIIc
J.tbd.L XXIIc
to form compounds of formula I wherein W is of formula VII and the dotted line in formula VII represents a double bond. In formula XXIIb, L 7 and L 8 are leaving groups, e.g., halo, preferably bromo.
Compounds of formula XXIIa, XXIIb and XXIIc are well known or can be prepared by conventional methods. A process for making compounds in accordance with formula XXI is described later.
The reaction of compounds XXI with XXIIa, XXIIb, or XXIIc takes place in solvent, for example, ethyl acetate, benzene, CHCl 3 , at elevated temperatures, preferably the boiling point of the solvent. If a compound of formula XXIIb is employed, the reaction should take place in the presence of a base such as pyridine.
In the above processes, especially in processes A, B, and C, it is desirable and sometimes necessary to protect the groups in column 1 of the following table. Conventional protecting groups are operable. Preferred protecting groups appear in column 2 of the table.
______________________________________1. Group to beProtected 2. Protected Group______________________________________COOH COOalkyl, COObenzyl, COOphenyl ##STR33## ##STR34## ##STR35## ##STR36##OH ##STR37##NHR, wherein R is any substituent on an amino group allowed by the ##STR38##NH.sub.2 ##STR39##______________________________________
Of course other protecting groups well known in the art may be used. After the reaction or reactions, the protecting groups may be removed by standard procedures well known in the art.
Compounds of formula I produced by processes A, B, C, or D may be converted to other compounds of formula I or to solvates or pharmaceutically acceptable salts by standard techniques. Examples of such conversions follow.
To make a compound of formula I wherein Z is O, the dotted lines in ring t represent double bonds and W is ##STR40## wherein R 1 and R 2 together with two adjacent carbon atoms on the ring represent aziridine, a compound of formula XVI ##STR41## wherein M, T, V, X, k, and B are as previously defined and W 1 is ##STR42## wherein L 9 is alkyl or alkoxy, is reacted with alkali metal hydroxide to produce a compound of formula XVII ##STR43## wherein W 2 is ##STR44## The reaction is carried out in solvent, e.g., ethanolwater.
Compounds of formula XVI are produced by the following reaction sequence ##STR45## wherein W 3 is ##STR46##
Other suitable bases that may be used in the last step are NaH and lithium diisopropylamide. The reaction may be carried out in a non-nucleophlic aprotic solvent such as tetrahydrofuran or benzene. Since a mixture of compounds in accordance with formula XVII is produced, pure compounds may be isolated if desired by using standard techniques.
To make compounds of formula XVII, wherein W 2 is ##STR47## the position of the hydroxyl on formula XVIIa is shifted by standard techniques so that the starting compound has the formula XVIIe ##STR48## The above described reaction sequence is then followed.
To produce a compound of formula I wherein Z is O, the dotted lines in ring t represent double bonds, and W is ##STR49## wherein R 1 and R 2 together with two adjacent carbon atoms on the ring represent an epoxide ring, a compound of formula XVIII ##STR50## wherein W 4 is ##STR51## is reacted with a per acid to produce a compound of formula XIX ##STR52## wherein W 5 is ##STR53##
The production of compounds of formula XVIII has been described in the previous process.
Per acids that may be reacted with compounds of formula XVIII include, for example, meta-chloroperbenzoic acid, peracetic acid, and trifluoroperacetic acid. The reaction takes place at 0° C. to room temperature in solvents such as CHCl 3 , CH 2 Cl 2 , etc.
To produce a compound of formula I wherein Z is O, the dotted lines in ring t represent double bonds, and W is ##STR54## wherein E is N + --O - , a compound of formula XX ##STR55## is reacted with H 2 O 2 in the presence of sodium tungstate catalyst.
Compounds of formula XX may be made by processes A, B, or C. The reaction of compound XX with H 2 O 2 takes place in water, as solvent, in the presence of sodium tungstate catalyst at 0° to 25° C.
To make a compound of formula I wherein the dotted lines in ring t are not double bonds and wherein M and X are the same of different and are CH(R a ) or NH, i.e., as in formula XXV below, a compound of formula XXIV ##STR56## (wherein X and M are the same or different and are C(R a ) or N and wherein B, k and W are as previously defined) is hydrogenated to form a compound of formula XXV ##STR57##
The reaction with hydrogen gas may be carried out over 10% Pd/C catalyst in glacial acetic acid or other suitable solvent at about room temperature. The pressure may range from 1 to 4 atmospheres or higher. The temperature may range from room temperature to 100° C. or higher.
To form a compound of formula I wherein at least one of M and X represents N(A) wherein A is as defined previously but other than hydrogen, and the dotted lines in ring t are not double bonds, a compound of formula XXV ##STR58## wherein at least one of M and X is NH and W is as defined previously, is reacted with a compound of formula XXVI
L.sup.10 A.sup.1 XXVI
wherein L 10 is a leaving group and A 1 is a radical in accordance with the previous definitions of A, but other than hydrogen.
In formula XXVI, if A 1 is alkyl, L 10 may be iodine, chlorine, bromine, etc. The reaction of XXV with XXVI requires a base, e.g., NaH, and a solvent, e.g., dimethylformamide. The temperature can range from 0° to 50° C.,
If A 1 is other than alkyl, L 10 is preferably chlorine or bromine, the solvent is toluene, CH 2 Cl 2 or benzene, and the base is pyridine or triethylamine. The temperature may be 0° to 50° C.
To make a compound of formula I wherein Z is S a compound of formula I wherein Z is O is reacted with P 2 S 5 or Lawesson's reagent, or other reagent capable of introducing sulfur in place of oxygen.
The reaction may take place at elevated temperature in pyridine or other suitable solvent. Lawesson's reagent has the formula ##STR59##
Numerous conversions of a compound of formula I to another compound of formula I are possible. Many of the examples illustrate such conversions.
Compounds wherein Z represents NR e or N(OR i ) may be prepared by reacting the compounds wherein Z is oxygen first with an oxaphile such as SOCl 2 , POCl 3 , PCl 5 , etc., and then with the appropriate amine or hydroxylamine.
The compounds of this invention can be used to treat allergies and their preferred use is for treating allergic chronic obstructive lung diseases. Chronic obstructive lung disease as used herein means disease conditions in which the passage of air through the lungs is obstructed or diminished such as is the case in asthma, bronchitis and the like.
The anti-allergy method of this invention is identified by tests which measure a compound's inhibition of anaphylactic bronchospasm in sensitized guinea pigs having antigen-induced SRS-A mediated bronchoconstriction. Allergic bronchospasm was measured in actively sensitized guinea pigs by a modification of the procedure of Konzett and Rossler, Arch. Exptl. Pathol. Pharmakol., 194, pp. 71-74 (1940). Male Hartley guinea pigs were sensitized with 5 mg ovalbumin injected ip and 5 mg injected sc in 1 ml saline on day 1 and 5 mg ovalbumin injected ip on day 4. The sensitized animals were used 3-4 weeks later. To measure anaphylactic bronchospasm, sensitized guinea pigs were fasted overnight and the following morning were anesthetized with 0.9 ml/kg ip of dialurethane. The trachea and jugular vein were cannulated and the animals were ventilated by a Harvard rodent respirator. A side arm to the tracheal cannula was connected to a Harvard pressure transducer to obtain a continuous measure of intratracheal pressure. An increase in intratracheal pressure was taken as a measure of bronchoconstriction. Each guinea pig was injected iv with 1 mg/kg propranolol, 5 mg/kg indomethacin and 2 mg/kg mepyramine given together in a volume of 1 ml/kg. Fifteen minutes later, the animals were challenged with antigen (0.5 per cent ovalbumin) delivered as an aerosol generated from a DeVilbiss Model 65 ultrasonic nebulizer and delivered through the tracheal cannula for 30 seconds. Bronchoconstriction was measured as the peak increase in intratracheal pressure occurring within 15 minutes after antigen challenge. For example, the compound 10-(3-chlorophenyl)-6,7,8,9-tetrahydrobenzo[b] [1,8]-naphthyridin-5(10H)-one (Compound B), was found to inhibit anaphylactic bronchospasms in such test procedure when given at an oral dose of 0.2 mg/kg. Said compound was also found to inhibit allergen-induced SRS-A and histamine release from sensitized guinea pig lung tissue.
The compounds are effective non-adrenergic, non-anticholinergic antianaphylactic agents. The compounds may be administered by any conventional mode of administration for treatment of allergic reactions employing an effective amount of a compound of formula I for such mode. For example, when administered orally they are active at doses from about 0.2 to 10 mg/kg of body weight; when administered parenterally, e.g., intravenously, the compounds are active at dosages of from about 0.1 to 5 mg/kg body weight; when administered by inhalation (aerosol or nebulizer) the compounds are active at dosages of about 0.1 to 10 mg per puff, one to four puffs may be taken every 4 hours.
The compounds of this invention are also useful for the treatment of inflammation; thus, they are useful for the treatment of: arthritis, bursitis, tendonitis, gout and other inflammatory conditions. The anti-inflammatory use of the compounds of the present invention may be demonstrated by the Reversed Passive Arthus Reaction (RPAR)-PAW technique as set forth below using male Lewis rats (obtained from Charles River Breeding Laboratories) weighing 180-220 grams. The potency of the compounds is determined using indomethacin as the standard. On the basis of the test results, an oral dosage range of about 5 milligrams per kilogram of body weight per day to about 50 milligrams per kilogram of body weight per day in divided doses taken at about 4 hour intervals is recommended, again with any of the conventional modes of administration for treatment of inflammation being suitable.
The dosage to be administered and the route of administration depends upon the particular compound used, the age and general health of the patient and the severity of the inflammatory condition. Thus, the dose ultimately decided upon must be left to the judgment of a trained physician. The anti-inflammatory activity may be demonstrated by the following test procedures:
REVERSED PASSIVE ARTHUS REACTION (RPAR) ANIMALS, MATERIALS AND METHODS
Male Lewis inbred albino rats weighing 180-220 grams obtained from Charles River Breeding Laboratories are used in these experiments. The rats are housed 3 animals/cage and food and water are allowed ad libitum. The animals are numbered 1-3 in each cage and color marked for identification purposes.
All reagents and drugs are prepared just prior to the study. Crystallized and lyophilized bovine serum albumin (BSA), obtained from Sigma Chemical Company, is solubilized without shaking in cold sterile pyrogen free saline (10 mg/ml). Lyophilized anti-bovine serum albumin (IgG Fraction), obtained from Cappel Laboratories, is suspended in sterile distilled water and diluted with cold pyrogen free saline (PFS) just prior to use. The final concentration of anti-bovine serum albumin is 0.5 mg/ml of PFS. Both BSA and anti-BSA solutions are iced during use. Drugs are suspended or solubilized in an aqueous solution of methyl cellulose (MC) with a homogenizer just prior to administration.
Groups of animals (6/group) are dosed with drug in MC by gavage one hour prior to sensitization with BSA. Controls are given MC alone and drug-standard is usually included in each assay for verification purposes. Drugs are prepared so as to provide a dose for a 200 gram animal which is equivalent to the mg/kg dose for the experiment. Thus each rat receives an oral dose in a volume of approximately 2.0 cc. One hour after dosing the animals are lightly anesthetized with ether and sensitized by injecting into the penile vein 0.2 ml of PFS containing 0.1 mg of BSA. One hour later they are injected in the plantar region of one hind paw with 0.1 ml of PFS containing 0.1 mg of the anti-bovine serum albumin. Immediately after the subplantar injection, the injected paw is dipped (up to the lateral maleolus) into the mercury well of a plethysmograph. The volume of mercury displaced is converted to weight and recorded. This value is considered to be the control paw volume for the animal. Paw volumes are also recorded with a plethysmograph during the development of the inflammation at 2 and 4 hours post-challenge. Compounds B, C and D provided ED 50 values of about 0.4, 0.1 and 0.4 mg/kg, respectively, p.o. in this procedure.
Another procedure for testing for acute anti-inflammatory activity measures the reverse passive Arthus reaction in the pleural cavity of rats as described in Myers et al, Inflammation, Vol. 9, No. 1, 1985, pp. 91-98. Compounds B and C provide ED 50 values of about 0.4 mg/kg and 0.1 mg/kg, respectively, p.o. in such procedure.
The compounds of this invention are also useful in the treatment of peptic ulcers. They display chemotherapeutic activity which enables them to relieve the symptoms of peptic ulcer disease, stress ulceration, and promote healing of gastric and/or duodenal ulcers. The compounds are also useful as conjunctive therapeutic agents for coadministration with such anti-inflammatory/analgesic agents as aspirin, indomethacin, phenylbutazone, ibuprofen, naproxen, tolemtin and other agents. The compounds of this invention prevent the untoward side effects of irritation and damage to the gastrointestinal tract caused by such agents. The anti-ulcer activity of the compounds of this invention is identified by tests which measure their cytoprotective effect in rats.
The compounds of this invention may be evaluated for their antiulcer activity characteristics by the procedures which measure the cytoprotective effect in rats e.g., as described in Chiu et al., Archives Internationales de Pharmacodynamie et de Therapie, 270, 128-140 (1984). Compound A at 10 mg/kg provided an 82% inhibition of Indomethacin-induced gastric ulcers.
In the treatment of peptic ulcer disease, and the prevention and treatment of drug-induced gastric ulceration, the active compounds of this invention can be administered in conventional unit dosage forms such as tablets, capsules, pill, powders, granules, sterile parenteral solutions or suspensions, suppositories, mechanical delivery devices, e.g., transdermal, and the like. The compounds of this invention may be administered at doses of about 0.3 to about 30 mg/kg, preferably, from about 2 to about 15 mg/kg, of body weight per day. Preferably, the total dosages are administered 2-4 divided doses per day.
The compounds of the invention are also useful as antihypertensive agents in the treatment of hypertension. The compounds effectively lower blood pressure in spontaneously hypertensive rats (SHR), an animal model of human essential hypertension, without affecting the blood pressure of normotensive rats. This activity may be demonstrated by the procedure described below.
Male spontaneously hypertensive rats or normotensive Sprague-Dawley rats were used. Blood pressure is measured according to standard procedures as described in detail in Baum T., Sybertz E. J., Watkins R. W., et al., Antihypertensive activity of SCH 31846, a non-sulfhydryl angiotensin-converting enzyme inhibitor. J. Cardiovas. Pharmacol. 5:655-667, 1983.
Animals are allowed at least 1.5-2 hours equilibration prior to experimentation. Test drugs are administered orally in a methylcellulose vehicle in a volume of 2 ml/kg and blood pressure is monitor for 4 hours following dosing. Compound A above at oral dosages of 10 and 30 mg/kg, reduced blood pressure significantly by -21±4 (mean ±SEM) and -35±4 mm Hg, respectively, in the spontaneously hypertensive rats. In contrast, Compound A did not lower blood pressure in the normotensive Sprague Dawley rats. Compounds B and C at an oral dosage of 30 mg/kg lowered blood pressure by -19±2 and -24±2 mm Hg, respectively, in the SHR and caused negligible changes in blood pressure of normotensive Sprague Dawley rats.
The dosage range for the antihypertensive method of the invention may vary from about 3 to about 100 mg/kg, preferably about 10 to about 30 mg/kg per day, in divided doses if desired. The dose will be varied depending on a number of factors, including inter alia the hypertensive disease being treated, the patient, the potency of the particular compound employed, etc. The compounds of formula I can be administered by conventional modes, e.g. orally, intraveneously, etc., in any conventional form for such purpose such as solutions, capsules, tablets, pills, powders, sterile parenteral solutions or suspensions, transdermal compositions or the like.
The compounds of formula I are useful in the treatment of hyperproliferative skin disease, e.g., psoriasis, in mammals, e.g., humans, which may be demonstrated by the Arachidonic Acid Mouse Ear Test as described below.
ARACHIDONIC ACID MOUSE EAR TEST, MATERIALS AND METHODS
Charles River, female, CD, (SD) BR mice, 6 weeks old, are caged 8/group and allowed to acclimate 1-3 weeks prior to use.
Arachidonic acid (AA) is dissolved in reagent grade acetone (2 mg/0.01 ml) and stored at -20° C. for a maximum of 1 week prior to use. Inflammatory reactions are induced by apply 10 ml of AA to both surfaces of one ear (4 gm total).
Test drugs are dissolved in either reagent grade acetone or aqueous ethanol (only if insoluble in acetone) at the same doses selected by Opas et al., Fed. Proc. 43, Abstract 2983, p. 1927 (1984) and Young et al., J. Invest. Dermatol. 82, pp. 367-371 (1984). These doses are employed to ensure maximum responses and to overcome any difference in topical absorption which could occur with any drug applied in an aqueous ethanol vehicle. The test drug is applied 30 minutes prior to challenge with AA.
The severity of the inflammation is measured as a function of increased ear weight. A 6 mm punch biopsy is removed 1 hour after AA challenge and weighed to the nearest 0.1 mg. Mean ± standard error and all possible comparisons are made via Duncan's Multiple Range Statistic.
Compounds A, B, and C provided ED 50 values of 0.15 mg, 0.07 mg and 0.01 mg, respectively in the above test procedure.
As a result of the topical administration of a compound of formula I, a remission of the symptoms of the psoriatic patient, in most cases, can be expected. Thus, one affected by psoriasis can expect a decrease in scaling, erythema, size of the plaques, pruritus and other symptoms associated with psoriasis. The dosage of medicament and the length of time required for successfully treating each individual psoriatic patient may vary, but those skilled in the art of medicine will be able to recognize these variations and adjust the course of therapy accordingly.
Included within the invention are preparations for topical application to the skin whereby the compounds having structural formula I are effective in the treatment and control of skin diseases characterized by rapid rates of cell proliferation and/or abnormal cell proliferation, e.g., psoriasis.
In a preferred method of treating hyperproliferative skin diseases, a pharmaceutical formulation comprising a compound of formula I, (usually in concentrations in the range of from about 0.001 percent to about 10 percent, preferably from about 0.1 percent to about 5 percent) together with a non-toxic, pharmaceutically acceptable topical carrier, is applied several times daily to the affected skin until the condition has improved. Topical applications may then be continued at less frequent intervals (e.g. once a day) to control mitosis in order to prevent return of severe disease conditions.
The compounds of the invention are also useful in the treatment of autoimmune and other immunological diseases including graft rejection in which T cell proliferation is a contributing factor to the pathogenesis of disease. The effectiveness of these compounds as immunosuppressing agents may be demonstrated by the following tests which involve the inhibition of T cell functions using these compounds.
GRAFT VS. HOST REACTION (GVHR)
To induce a GVHR, C57 B1/6XA/J(F6AF1) male mice were injected intravenously with parental (C57B1/6J) spleen and lymph node cells. The compound (Compound A) was then administered orally for 10 days beginning on the day prior to the cell transfer. On the day following the last treatment, the animals were sacrificed, and their spleens were excised and weighed. The enlargement of the spleen of the host is a result of a GVHR. To some extent it is the host's own cells which infiltrate and enlarge the spleen although they do this because of the presence of graft cells reacting against the host. The amount of spleen enlargement, splenomegaly, is taken as a measure of the severity of the GVHR.
In carrying out the GVHR the animal in the experimental group is injected with parental cells, cells of the same species but of different genotype, which cause a weight increase of the spleen. The animal in the control group is injected with syngeneic cells, genetically identical cells which do not cause a weight increase of the spleen. The effectiveness of the compounds administered to the mice in the experimental group is measured by comparing the spleen weight of the untreated and treated GVH animal with that of the syngeneic control. Compound B reduced spleen weight by 12%, 29% and 100% at doses (mg/kg) of 25, 50 and 100, respectively, as compared to the untreated animals; while Compound C reduced spleen weight by 46%, 129% and 100% at doses (mg/kg) of 25, 50 and 100, respectively, compared to untreated animals.
SPLENIC ATROPHY
The immunosuppressive activity of the compounds may also be shown by a decrease in spleen weight after dosing BDF 1 mice orally with the drug for seven (7) consecutive days. The mice are sacrificed on the eighth day. The percent decrease in spleen weight is measured for each dosage level. In this procedure, Compound B provided a 27%, 25% and 24% spleen weight decrease at dosage levels at 25, 50 and 100 mg/kg, respectively; while Compound C provided a 31%, 35% and 33% spleen weight decrease at dosage levels of 25, 50 and 100 mg/kg, respectively.
As noted above, the subject compounds possess acute anti-allergy and anti-inflammatory activities. For example, Compounds B and C have ED 50 values of less than about 0.5 mg/kg and 5 mg/kg, respectively, p.o. in tests measuring the inhibition of anaphylactic bronchospasm in sensitized guinea pigs having antigen-induced bronchoconstriction and ED 50 values of about 0.4 mg/kg and 0.1 mg/kg, respectively, p.o. in tests measuring the reverse passive Arthus reaction in the pleural cavity of rats (as described by Myers et al., Inflammation, Vol. 9, No. 1, 1985, pp. 91-98). Compounds B and C have ED 50 values of greater than about 50 mg/kg and 25 mg/kg, respectively, in the GVHR test as described above. These results for Compound B and C and similar results obtained for other compounds of formula I tested to date indicate that an immunosuppressive effective dose for such compounds is several times or more their anti-inflammatory and anti-allergy effective doses.
The usual dosage range for the immunosuppressive method of the invention with the compounds of formula I in a 70 kg mammal is an oral dose of about 0.1 to 250 mg/kg, preferably 0.1 to 150 mg/kg, in 3 or 4 divided doses per day. Of course, the dose will be regulated according to the potency of compound employed, the immunological disease being treated, and the judgment of the attending clinician depending on factors such as the degree and the severity of the disease state and age and general condition of the patient being treated.
To treat immunological diseases, the active compounds of formula I can be administered in unit dosage forms such as tablets, capsules, pills, powders, granules, sterile parenteral solutions or suspensions, suppositories, transdermal compositions and the like. Such dosage forms are prepared according to standard techniques well known in the art.
Some of the compounds of this invention are also useful in preventing cardiac anaphylaxis.
For preparing pharmaceutical compositions from the compounds described by this invention, inert, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, dispersible granules, capsules, cachets and suppositories. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders or tablet disintegrating agents; it can also be an encapsulating material. In powders, the carrier is a finely divided solid which is in admixture with the finely divided active compound. In the tablet the active compound is mixed with carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired. The powders and tablets preferably contain from 5 to about 70 percent of the active ingredient. Suitable solid carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethyl-cellulose, a low melting wax, cocoa butter and the like. The term "preparation" is intended to include the formulation of the active compound with encapsulating material as carrier providing a capsule in which the active component (with or without other carriers) is surrounded by carrier, which is thus in association with it. Similarly, cachets are included. Tablets, powders, cachets and capsules can be used as solid dosage forms suitable for oral administration.
For preparing suppositories, a low melting wax such as a mixture of fatty acid glycerides or cocoa butter is first melted, and the active ingredient is dispersed homogeneously therein as by stirring. The molten homogeneous mixture is then poured into convenient sized molds, allowed to cool and thereby solidify.
Liquid form preparations include solutions, suspensions and emulsions. As an example may be mentioned water or water-propylene glycol solutions for parenteral injection. Liquid preparations can also be formulated in solution in polyethylene glycol and/or propylene glycol, which may contain water. Aqueous solutions suitable for oral use can be prepared by adding the active component in water and adding suitable colorants, flavors, stabilizing, sweetening, solubilizing and thickening agents as desired. Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, i.e., natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose and other well-known suspending agents.
Formulations for topical application, e.g., for use in treating hyperproliferative skin diseases, may include the above liquid forms, creams, aerosols, sprays, dusts, powders, lotions and ointments which are prepared by combining an active ingredient according to this inventions with conventional pharmaceutical diluents and carriers commonly used in topical dry, liquid, cream and aerosol formulations. Ointment and creams may, for example, be formulated with an aqueous or oily base with the addition of suitable thickening and/or gelling agents. Such bases may, thus, for example, include water and/or an oil such as liquid paraffin or a vegetable oil such as peanut oil or castor oil. Thickening agents which may be used according to the nature of the base include soft paraffin, aluminum stearate, cetostearyl alcohol, propylene glycol, polyethylene glycols, woolfat, hydrogenated lanolin, beeswax, etc.
Lotions may be formulations with an aqueous or oily base and will, in general, also include one or more of the following, namely, stabilizing agents, emulsifying agents, dispersing agents, suspending agents, thickening agents, coloring agents, perfumes and the like.
Powders may be formed with the aid of any suitable powder base, e.g., talc, lactose, starch, etc. Drops may be formulated with an aqueous base or non-aqueous base also comprising one or more dispersing agents, suspending agents, solubilizing agents, etc.
The topical pharmaceutical compositions according to the invention may also include one or more preservatives or bacteriostatic agents, e.g., methyl hydroxybenzoate, propyl hydroxybenzoate, chlorocresol, benzalkonium chlorides, etc.
The topical pharmaceutical compositions according to the invention may also contain other active ingredients such as antimicrobial agents, particularly antibiotics, anesthetics, analgesics and antipruritic agents.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for either oral or parenteral administration. Such liquid forms include solutions, suspensions and emulsions. These particular solid form preparations are most conveniently provided in unit dose form and as such are used to provide a single liquid dosage unit. Alternatively, sufficient solid may be provided so that after conversion to liquid form, multiple individual liquid doses may be obtained by measuring predetermined volumes of the liquid form preparation as with a syringe, teaspoon or other volumetric container. When multiple liquid doses are so prepared, it is preferred to maintain the unused portion of said liquid doses at low temperature (i.e., under refrigeration) in order to retard possible decomposition. The solid form preparations intended to be converted to liquid form may contain, in addition to the active material, flavorants, colorants, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents and the like. The solvent utilized for preparing the liquid form preparation may be water, isotonic water, ethanol, glycerine, propylene glycol and the like as well as mixtures thereof. Naturally, the solvent utilized will be chosen with regard to the route of administration, for example, liquid preparations containing large amounts of ethanol are not suitable for parenteral use.
Preferably, the pharmaceutical preparation is in unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, for example, packeted tablets, capsules and powders in vials or ampoules. The unit dosage form can also be a capsule, cachet or tablet itself or it can be the appropriate number of any of these in packaged form.
When administered parenterally, e.g. intravenously, the compounds are administered at a dosage range of about 1-30 mg/kg of body weight in single or multiple daily doses.
The quantity of active compound in a unit dose of preparation may be varied or adjusted from 1 mg to 100 mg according to the particular application and the potency of the active ingredient. The compositions can, if desired, also contain other therapeutic agents.
The dosages may be varied depending upon the requirements of the patient, the severity of the condition being treated and the particular compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day if desired.
The following examples are intended to illustrate, but not to limit, the present invention.
PREPARATIVE EXAMPLE 1
Dissolve 2-chloronicotinoyl chloride (0.10 mole) in CHCl 3 (90 ml). Add the resulting solution to a 5° C. solution of triethylamine (0.10 mole) and an enamine, 1-(1-pyrrolidinyl)-1-cyclopentene (0.10 mole), dissolved in CHCl 3 (90 ml). Allow C-acylation to proceed for 21 hrs., while the temperature of the reaction mixture rises to 25° after the second hour. Monitor the course of the reaction by thin-layer chromatography as needed. Wash the resulting solution with water, aqueous NaHCO 3 solution, and with water. After drying, carefully evaporate solvent to obtain the enaminoketone, (2-chloro-3-pyridinyl) [2-(1-pyrrolidinyl)-1-cyclopenten-1-yl]methanone, m.p. 102.5°-104.0° C., after recrystallization from ethyl acetate. This compound is referred to in Examples 1 and 3 below as Compound 1.
By employing the acid chloride and enamine listed in Columns 1 and 2 of Table 1 below, the compounds listed in Column 3 are prepared. In some instances CH 2 Cl 2 is used in place of CHCl 3 and the reaction time is varied. 2-Chloronicotinoyl and 2-chloro-3-pyridazinylcarbonyl chloride are available from Chemo Dynamics Inc., whereas the Aldrich Chemical Co. supplies certain enamines, e.g. 1-pyrrolidino-1-cyclopentene, 1-morpholino-1-cyclohexene, and 1-pyrrolidino-1-cyclohexene. Other enamines employed here and elsewhere in the following examples are prepared according to J. Am. Chem. Soc. 76, 2029 (1954) or other methods. For example, the indicated enamines may be prepared by the methods disclosed in the articles listed after each: 2-(1-pyrrolidino)-indene, J. Org. Chem. 26, 3761 (1961); 1-methyl-2-methylmercapto-2-pyrroline, Org. Syn. 62, 158 (1984) and Liebigs Ann. Chem. 725, 70 (1969); 4-carbethoxy-1-(1-pyrrolidino)-cyclohexene, 1,2-dicarbethoxy-4 -(1-pyrrolidino)-4-pyrroline, 1-acetyl-3-(1-pyrrolidino)-2-pyrroline, and 1-acetyl-4-(1-pyrrolidino)-1,2,5,6-tetrahydropyridine, J. Am. Chem. Soc. 76, 2029, (1954); and 5,6-dihydro-4-(1-pyrrolidino)-2H-thiopyran, Zh. Organ. Khim., 1, 1108 (1965). The following ketone starting materials for the enamines may be prepared, for example, by the methods disclosed in the articles listed after each: 4-carbethoxycyclohexanone, Synth. Commun. 15, 541 (1985); 1,2-dicarbethoxy-4-pyrrolidinone, J. Org. Chem. 38, 3487 (1973); 1-acetyl-3-pyrrolidinone, J. Med. Chem. 5, 762 (1962).
TABLE 1__________________________________________________________________________ ##STR60## Col. 2 ##STR61## Col. 4 Product m.p. °C. (solvent ofX M L.sup.4 Enamine G crystallization)__________________________________________________________________________N N Cl ##STR62## ##STR63## 110-112 (CCl.sub.4 -Pet. ether)CH CH Br " " oilCH N Cl ##STR64## ##STR65## oilCH N Cl ##STR66## ##STR67## oilCH N Cl ##STR68## ##STR69## 168-172° (CH.sub.3 COOC.sub.2 H.sub.5)__________________________________________________________________________ .sup.1 X, M and L.sup.4 same as in column 1. .sup.2 Referred to as Compound 2 in Example 2 below.
PREPARATIVE EXAMPLE 2
Add equimolar amounts of ethyl glycinate hydrochloride, triethylamine, and (2-chloro-3-pyridinyl)-[2-(1-pyrrolidinyl)-1-cyclopenten-1-yl]methanone to t-butyl alcohol (170 ml per 0.020 mole of amine). Reflux the resulting mixture for 34 hrs, monitoring the reaction by thin-layer chromatography as needed. Cool the reaction mixture, and evaporate solvent. Wash a CHCl 3 solution of the residue with water and with saturated aqueous NaCl solution. After drying the organic solution, evaporate the solvent to obtain the resulting enaminoketone, (2-chloro-3-pyridinyl)[2-(1-ethoxycarbonylmethanaminyl)-1-cyclopenten-1-yl]methanone, m.p. 114.5°-117.5° C., after recrystallization from isopropanol.
EXAMPLE 1
Dissolve the primary amine, 3-nitroaniline, and the enaminoketone (Compound 1 above) in benzene containing anhydrous p-toluenesulfonic acid. Let the molar ratio of the primary amine to enaminoketone be about 1.25 and that of acid to enaminoketone be 1. Use enough benzene to give a solution that is initially 1M in enaminoketone. Reflux the resulting solution 26 hours, and monitor the course of the reaction by thin-layer chromatography as needed. Cool the reaction mixture, evaporate the solvent, and dissolve the residue in CHCl 3 . Wash the CHCl 3 solution with water, aqueous NaHCO 3 solution, dilute aqueous HCl solution, and with water. After drying the CHCl 3 solution, evaporate solvent to obtain the resulting naphthyridinone, 9-(3-nitrophenyl)-6,7,8,9-tetrahydro-5H-cyclopenta[b][1,8]-naphthyridin-5-one, m.p. 276°-277° C., after recrystallization from CH 3 CN.
EXAMPLE 2
Dissolve 3-chloroaniline (0.0733 mol) and the enaminoketone (Compound 2 in Table 1 above) (0.0539 mol) in benzene (50 ml) containing p-toluenesulfonic acid monohydrate (0.0523 mol). Reflux the solution for 18 hours, removing water with a Dean Stark trap. Cool the resulting mixture and evaporate the solvent, dissolving the residue in CHCl 3 . Wash the CHCl 3 solution with water, 2N HCl, water, in NaHCO 3 , and with water. Dry and filter the CHCl 3 solution, and evaporate the solvent to give 10-(3-chlorophenyl)-6,7,8,9-tetrahydrobenzo[b][1,8]napthyridin-5(10H)-one, m.p. 195°-198° C. after crystallization from CH 3 CN.
By employing the primary amine the enaminoketone as indicated in Columns 1 and 2 of Table 2 below, the naphthyridinones or pyrazinopyridones as indicated in Column 3 of Table 2 are prepared by basically the same methods as described in Examples 1 and 2.
TABLE 2__________________________________________________________________________ Col. 3 Product.sup.3 Col. 1 Primary Amine B in NH.sub.2B ##STR70## ##STR71## Col. 4 Product m.p. °C. (solvent of crystallization)__________________________________________________________________________ ##STR72## H CH Cl ##STR73## ##STR74## 321-324 (CH.sub.3 CN) ##STR75## H CH Cl " " 306-308 (CH.sub.3 CN) ##STR76## H CH Cl " " 230-233 (CH.sub.3 CN) ##STR77## H CH Cl " " 303-306 (CH.sub.3 CN) ##STR78## H CH Cl " " 287-290 (CH.sub.3 CN) ##STR79## H CH Cl " " 294-296 (CH.sub.3 CN) ##STR80## H CH Cl ##STR81## ##STR82## 270-273 (CH.sub.3 CN)C.sub.2 H.sub.5 O(CO)CH.sub.2 * * * * " 151-153.5 (CH.sub.3 CN) ##STR83## H CH Cl " " 212-215 (CH.sub.3 CN) ##STR84## H CH Cl " " 242-244.5 (CH.sub.3 CN) ##STR85## H CH Cl " " 210.5-213.5 (CH.sub.3 CN) ##STR86## H N Cl ##STR87## ##STR88## 278-280 (CHCl.sub.3 /CH.sub.3 COCH.sub.3) ##STR89## H N Cl " " >300 (d) (CHCl.sub.3 /CH.sub.3 COCH.sub.3) ##STR90## H N Cl " " >300 (d) (CH.sub.3 COCH.sub.3) ##STR91## H N Cl " " >300 (d) (CH.sub.3 COCH.sub.3) ##STR92## H CH Cl ##STR93## ##STR94## 255-259 (1,4-dioxane) ##STR95## H CH Cl ##STR96## ##STR97## 256.5-260 (CH.sub.3 CN) ##STR98## H CH Cl ##STR99## ##STR100## 207-209 (CH.sub.3 CN) ##STR101## H CH Cl " " 221-223 (CHCl.sub.3 /CH.sub.3 COCH.sub.3) ##STR102## H CH Cl " " 185-187 (CH.sub.3 CN) ##STR103## H CH Cl " " 201-203 (CH.sub.3 COCH.sub.3) ##STR104## H CH Cl " " 192-194 (CH.sub.3 CN) ##STR105## H CH Cl ##STR106## ##STR107## 230-233 (CH.sub.3 CN) ##STR108## H CH Cl ##STR109## ##STR110## 265-267 (1,4-dioxane) ##STR111## H CH Cl ##STR112## ##STR113## 238- 239.5 (CH.sub.3 CN) ##STR114## H CH Cl " " >350 (DMF) ##STR115## H CH Cl ##STR116## ##STR117## 235-238.5 (CH.sub.3 COOC.sub.2 H.sub.5 /CH.sub.3 OH) ##STR118## H CH Cl ##STR119## ##STR120## 245.5-248 (CH.sub.3 CN) ##STR121## H CH Cl ##STR122## ##STR123## 225-230 (eluent on silica gel column is 1% CH.sub.3 OH in CHCl.sub.3) ##STR124## H CH Cl ##STR125## ##STR126## 201-203 (CH.sub.3 CN) ##STR127## CH.sub.3 CH Cl ##STR128## " 218-220,5 (CH.sub.3__________________________________________________________________________ CN) .sup.3 B same as in column 1 and X and V same as in column 2. *Prepared using the compound of Preparative Example 2.
By employing the primary amines and enaminoketones as indicated in Columns 1 and 2 of Table 3 below, the compounds of Column 3 may also be prepared by basically the same method.
TABLE 3__________________________________________________________________________ Col. 3 Product.sup.4 Col. 1 Primary Amine B in NH.sub.2B ##STR129## ##STR130##__________________________________________________________________________ ##STR131## H CH Cl ##STR132## ##STR133## ##STR134## H N Cl " " ##STR135## H CH Cl " " ##STR136## H CH Cl " " ##STR137## H CH Cl " "__________________________________________________________________________ .sup.4 B same as in column 1 and X and V same as in column 2.
EXAMPLE 3
Mix aniline and the enaminoketone (Compound 1 above) in a molar ratio of 1.25:1, and heat the mixture 51 hours at 110° C. and 24 hours at 125° C. Cool the resulting mixture, dissolve it in CHCl 3 , and treat the CHCl 3 solution as described in Example 1 above to produce 9-phenyl-6,7,8,9-tetrahydro-5H-cyclopenta[b]-[1,8]naphthyridin-5-one, m.p. 235°-237° C., after recrystallization from CH 3 CN.
By employing the primary amines and enaminoketones as indicated in Columns 1 and 2 of Table 4 below, the compounds listed in Column 3 thereof are prepared by basically the same method varying the reaction time from 4.5-100 hrs. and the temperature from 110°-130° C. as necessary. If the amine used in this example is hydrazine, then use a molar ratio of hydrazine to enaminoketone of 8.5:1.
TABLE 4__________________________________________________________________________ Col. 3 Product.sup.5 Col. 1 Primary Amine NH.sub.2(CH.sub.2).sub.kB kB ##STR138## ##STR139## Col. 4 Product m.p. °C. (solvent of crystallization)__________________________________________________________________________0 NH.sub.2 CH Cl ##STR140## ##STR141## 206-210 (d) (CH.sub.3 CN) ##STR142## CH Cl " " 261-264 (CH.sub.3 CN) ##STR143## CH Cl " " 177-178.5 (CH.sub.3 CN) ##STR144## CH Cl " " 259.5-261 (CH.sub.3 CN) ##STR145## CH Cl " " 242-243 (CH.sub.3 COOC.sub.2 H.sub.5)__________________________________________________________________________ .sup.5 B and k same as in column 1 and X same as in column 2.
EXAMPLE 4
Reflux a solution of (2-bromophenyl)[2-(1-pyrrolidinyl)-1-cyclopenten-1-yl]-methanone (14.1 g) (from Preparative Example 1) in benzene (100 ml) containing aniline (4.5 ml) and p-toluenesulfonic acid monohydrate (8.8 g) for 19 hrs. Remove water continuously with a Dean-Stark trap. Wash the cooled solution with water, 1M NaHCO 3 solution, and with water. Dry the benzene solution, filter it, and evaporate the solvent. Crystallize to obtain (2-bromophenyl)[2-(phenylamino)-1-cyclopenten-1-yl]-methanone, m.p. 106-5°-108.5° from CH 3 CN.
Reflux a mixture of (2-bromophenyl)[2-(phenylamino)-1-cyclopenten-1-yl]-methanone (5.8 mmol), potassium tert.-butoxide (0.71 g), and tert.-butanol (25 ml) under nitrogen for 1 hr. Monitor the ensuing reaction by thin-layer chromatography, and cool the mixture when reaction is complete. Evaporate tert.-butanol, add water (25 ml) to the residue, and filter off the product, 1,2,3,4-tetrahydro-4-phenyl-9H-cyclopenta[b]quinolin-9-one, m.p. 265-267, after crystallization from CH 3 CN/CHCl 3 .
PREPARATIVE EXAMPLE 3
Prepare 2-(3-chlorophenylamino)pyridinyl-3-carbonyl chloride as follows. Add excess thionyl chloride (0.6 ml per mmol of acid) to 2-(3-chlorophenylamino)pyridinyl-3-carboxylic acid (0.38 mol), and allow the resulting mixture to stand or stir at 25° C. for 2 hours. To catalyze the reaction, add N,N-dimethyl formamide (0.008 ml per mmol of acid) as needed. When acid chloride formation is complete, evaporate excess thionyl chloride. Remove any traces of the reagent by adding benzene and evaporating it. To ensure that solid products are relatively dense and therefore easily manipulated, carry out evaporation at an elevated temperature; a temperature not exceeding 50° C. is suitable. Wash the resulting solid with benzene and petroleum ether to give 2-(3-chlorophenylamino)pyridinyl-3-carbonylchloride, m.p. 110°-114° C.
By employing the 2-arylaminopyridinyl-3-carboxylic acid listed below in Table 5, basically the same process may be used to prepare the corresponding carbonyl chlorides thereof. The 2-arylaminopyridinyl-3-carboxylic acids that are needed to apply this method may be prepared according to U.S. Pat. No. 3,689,653.
TABLE 5______________________________________2-Arylamino-pyridyl-3-carboxylic acid ##STR146##V Ar______________________________________ ##STR147##H ##STR148##H ##STR149##H ##STR150##H ##STR151##CH.sub.3 ##STR152##______________________________________
EXAMPLE 5
Add equimolar amounts of the enamine, 1-acetyl-4-(1-pyrrolidino)-1,2,5,6-tetrahydropyridine (40 mmol) and triethylamine (43 mmol), both dissolved in dichloromethane (27 ml per mmol of the enamine), to a stirred, cooled solution of an equimolar amount of 2-(3-chlorophenylamino)pyridinyl-3-carbonyl chloride in dichloromethane (175 ml). When addition is complete, allow the reaction mixture to stir for 1 hour at 0° C. and for 20 hours at 25° C. Wash the organic solution with water, dilute aqueous sodium bicarbonate solution and with water. Dry the organic solution over a suitable dessicant, filter, and evaporate dichloromethane and any excess triethylamine. Crystallize the residue, 7-acetyl-10-(3-chlorophenyl)-6,8,9,10-tetrahydropyrido[2,3-b][1,6]naphthyridin-5(7H)-one, m.p. 238°-242° C. after recrystallization from CH 3 CN. Alternatively, the residue may be triturated with ether, and the solid collected on a filter and then crystallized.
By employing the 2-arylaminopyridinyl-3-carboxyl chloride and enamine listed in Columns 1 and 2 of Table 6 below, the compounds listed in Column 3 thereof are prepared by basically the same procedure. If the enamine bears a methylthio group on the same carbon attached to the enamine nitrogen atom, pass nitrogen gas through the resulting solution to remove liberated methane thiol.
TABLE 6__________________________________________________________________________ Col. 3 ##STR153## EnamineCol. 2 ##STR154## crystallization)(solvent ofProduct m.p. °C.Col.__________________________________________________________________________ 4 ##STR155## H ##STR156## ##STR157## 165-167 (CH.sub.3 CN) ##STR158## H ##STR159## ##STR160## 170-173 (CH.sub.3 CNCHCl.sub.3) ##STR161## H " " 207-209 (CH.sub.3 CNCHCl.sub.3) ##STR162## H ##STR163## ##STR164## 289-292 (CH.sub.3 CN) ##STR165## H ##STR166## ##STR167## 173-175 (CH.sub.3 CN) ##STR168## H ##STR169## ##STR170## 201.5-202.5 (C.sub.2 H.sub.5 OH) ##STR171## H " " 211.0-212.0 (CH.sub.3 COOHH.sub.2 O) ##STR172## H ##STR173## ##STR174## 232-234.5 (CH.sub.3 CNCHCl.sub.3) ##STR175## H ##STR176## ##STR177## 289-293 (CHCl.sub.3C.sub. 2 H.sub.5OOCCH.sub.3) ##STR178## H ##STR179## ##STR180## 278-279 (d) (C.sub.2 H.sub.5 OH) ##STR181## H " " 228-229.5 (d) (CH.sub.3 CN) ##STR182## H ##STR183## ##STR184## 195-198 (CH.sub.3 CN) ##STR185## H ##STR186## ##STR187## 262-263 (CH.sub.3 COCH.sub.3) ##STR188## H " " 276-277 (CH.sub.3 CN) ##STR189## H " " 228-229 (CH.sub.3 CN) ##STR190## H ##STR191## ##STR192## 219-223 (CH.sub.3 CN) ##STR193## H ##STR194## ##STR195## 201-203 (CH.sub.3 CN) ##STR196## H ##STR197## ##STR198## 304-307 (d) (CHCl.sub.3C.sub.2 H.sub.5 OH) ##STR199## H ##STR200## ##STR201## 203- 206 (CHCl.sub.3CH.su b.3 CO.sub.2 C.sub.2 H.sub.5) ##STR202## H ##STR203## ##STR204## 198-200 (CH.sub.3 CN) ##STR205## H ##STR206## ##STR207## 257-260 (CHCl.sub.3 -hexane) ##STR208## CH.sub.3 ##STR209## ##STR210## 212-216 (CH.sub.3__________________________________________________________________________ CN) .sup.6 Ar and V same as in column 1.
By employing the 2-arylaminopyridinyl-3-carboxylic chlorides and enamines listed in Columns 1 and 2 of Table 7 below, the products listed in Column 3 thereof may be prepared.
TABLE 7__________________________________________________________________________ Col. 3 ##STR211## EnamineCol. 2 ##STR212##__________________________________________________________________________ ##STR213## ##STR214## ##STR215## ##STR216## ##STR217## ##STR218## ##STR219## ##STR220## ##STR221## ##STR222## ##STR223## ##STR224## ##STR225## ##STR226## ##STR227## ##STR228## ##STR229## ##STR230##__________________________________________________________________________ .sup.7 Ar same as in column 1. .sup.8 May be prepared from the corresponding ketone described in J. Het. Chem. 21 1569 (1984). .sup.9 May be prepared from the corresponding ketone described in Heterocycles 22 2313 (1984). .sup.10 May be prepared from the corresponding ketone described in Chem. Abstr. 87 68119 (1977). .sup.11 May be prepared from corresponding ketone available from Aldrich Chemical Co.
EXAMPLE 6
With some compounds, the process of Example 5 may result in incomplete cyclization, i.e., intermediates of formula Ib or mixtures of such intermediates with the desired cyclized product may be produced. In such instances, the intramolecular cyclization of the intermediate to the desired product may be carried out by the following process.
The procedure of Example 4 above is repeated, except that the 2-(3-chlorophenylamino)-pyridinyl-3-carboxylic chloride and 2-(1-pyrrolidino)-indene are employed as the 2-arylaminopyridinyl-3-carbonyl chloride and enamine respectively. The intermediate product of the reaction, i.e., [2-(3-chlorophenylamino)-pyridinyl] [2-(1-pyrrolidino)-1-indenyl]methanone, (or mixture with the corresponding cyclized product) is treated with paratoluenesulfonic acid basically as described in Example 1 above (but substituting the intermediate (or mixture) for the primary amine and the enaminoketone) to produce 11-(3-chlorophenyl)-10,11-dihydro-5H-indeno[2,1-b] [1,8]naphthyridin-5-one, m.p. 304°-307° C. (d) after crystallization from C 2 H 5 OH.
EXAMPLE 7
Dissolve ethyl chloroformate (0.01 mole) in CH 2 Cl 2 (40 ml). Add the resulting solution over 30 min. to a 3° C.-solution of 2-anilinonicotinic acid (0.01 mole) and triethylamine (0.01 mole) dissolved in CH 2 Cl 2 (400 ml). Keep the resulting solution at 3° C. for 2 hrs. to provide a solution containing 2-anilino-3-ethoxycarbonyloxycarbonyl-pyridine. Add a solution of the enamine 3,3-dimethyl-9-(1-pyrrolidinyl)-1,5-dioxaspiro [5.5]undec-8-ene (0.01 mole) dissolved in CH 2 Cl 2 (60 ml) over 15 min. When the last addition is complete, keep the reaction mixture at 3° C. for another 2 hrs and at 25° C. for 24 hrs. Wash the CH 2 Cl 2 solution with aqueous NaHCO 3 solution, with water, with four portions of dilute aqueous HCl solution, and finally with water. After drying the CH 2 Cl 2 solution, evaporate solvent to obtain the naphthyridinone, 6,8,9,10-tetrahydro-5',5'-dimethyl-10-phenyl-spiro[benzo-[b][1,8]naphthyridin-7-(5H), 2,[1,3]dioxan]-5-one, which is chromatographed as needed and is finally crystallized from ethyl acetate/methanol, m.p. 235.5°-238.5° C.
1-acetyl-4-(1-pyrrolidinyl)-1,2,3,6-tetrahydropyridine can be employed as the enamine to produce 7-acetyl-6,8,9,10-tetrahydro-10-phenylpyrido[2,3-b][1,6]naphthyridin-5(7H)-one, m.p. 209.5°-212.5°, after crystallization from CH 3 CN.
U.S. Re. Pat. No. 26,655 describes the commercially available (Aldrich Chemical Co.) 2-anilinonicotinic acid. The pyrrolidine enamine of 1,4-cyclohexanedione mono-2,2-dimethyltrimethylene ketal is known (Synth. Comm. 7, 417 (1977)), and the pyrrolidine enamine of 4-acetyl-1-piperidone is made according to J. Am. Chem. Soc. 76, 2029 (1954).
EXAMPLE 8
Dilute a 1M solution (73 ml) of lithium bistrimethylsilylamide in hexane with dry THF (75 ml), and add a solution of cyclopentanone (0.070 m) in THF. After brief stirring at 25° C., add a solution of methyl 2-phenylaminonicotinate (0.073 mol) in THF (48 ml). Reflux the solution for 22 hours, monitoring progress of the condensation by thin-layer chromatography.
When condensation is complete, cool the reaction mixture, evaporate solvent, and dissolve the residue in CHCl 3 . Wash the CHCl 3 solution with water and with saturated aqueous NaCl solution. After drying the CHCl 3 solution, evaporate the solvent to obtain the crude naphthyridinone. Purify the crude product by chromatography on silica gel with CHCl 3 , and crystallization from CH 3 CN to provide 6,7,8,9-tetrahydro-9-phenyl-5H-cyclopenta[b][1,8]-naphthyridin-5-one.
By employing the ketones and arylaminonicotinates indicated in Columns 1 and 2 of Table 8 below in basically the same process, the compounds listed in Column 3 are prepared. In these reactions THF or toluene are employed as solvents and lithum bistrimethylsilylamide, sodium hydride or freshly prepared sodium amide are employed as the base.
TABLE 8__________________________________________________________________________ Col. 3 KetoneCol. 1 ##STR231## ##STR232## crystallization)(solvent ofProduct m.p. °C.Col.__________________________________________________________________________ 4 ##STR233## C.sub.2 H.sub.5 N CH ##STR234## ##STR235## 195-198 (CH.sub.3 CN)" " " " ##STR236## " 268-272 (C.sub.2 H.sub.5 OH)" CH.sub.3 " " ##STR237## " 256.6-260 (CH.sub.3 CN)" C.sub.2 H.sub.5 " " ##STR238## " 200-206 (CH.sub.3 CN) ##STR239## CH.sub.3 " " ##STR240## ##STR241## 220-224 (CH.sub.3 OH) ##STR242## " " " ##STR243## ##STR244## 248-251 (C.sub.2 H.sub.5 OH) ##STR245## " " " ##STR246## ##STR247## 301-304.5 (C.sub.2 H.sub.5 OH)" * " 273-277 (DMF)__________________________________________________________________________ .sup.12 Ar, M and X same as in column 2. *Made using Nphenyl isatoic anhydride, i.e., Ar in the formula of column is phenyl, and M and X are both CH.
EXAMPLE 9
With some compounds, the process of Example 8 results in incomplete cyclization to the desired naphthyridinone, i.e., a 1,3-diketone (or a mixture thereof with the desired cyclized product) results (see formula Ia above). In such instances, the intramolecular cyclization to the naphythyridinone may be accomplished by subjecting the 1,3-diketone (or mixture) which results from the process of Example 8 to the following procedure.
For example, with 3,4-dihydro-6-methoxy-1-napthalenone as the ketone and methyl 2-phenylaminonicotinate as the arylaminonicotinate, the 1,3-diketone, 3,4-dihydro-6-methoxy-2-[[2-(phenylamino)-3-pyridinyl]carbonyl]-1(2H)-napthalenone, results from the process of Example 8. To cyclize, reflux 9 g of the diketone in 400 ml of toluene containing a catalytic amount of p-toluenesulfonic acid. Collect the evolved water in a Dean-Stark trap. Remove the heat after 21/2 hours and allow the mixture to stand overnight. Distill the toluene under vacuum on a steam bath and crystallize the residue from acetonitrile, to provide the product 5,6-dihydro-3-methoxy-12-phenylnaphtho[1,2-b][1,8]naphthyridin-7(12H)-one, m.p. 234°-237.5° C., after crystallization from CH 3 CN.
By employing basically the same procedure and employing the ketones and arylaminonicotinates listed in Columns 1 and 2 of Table 9 below, the compounds listed in Column 3 are prepared.
TABLE 9__________________________________________________________________________ Col. 3 Product KetoneCol. 1 ##STR248## ##STR249## crsytallization)(solvent ofProduct m.p. °C.Col.__________________________________________________________________________ 4 ##STR250## CH.sub.3 ##STR251## ##STR252## 197.5-201 (CH.sub.3 CN) ##STR253## " " ##STR254## 288-291 (CH.sub.3 CN) ##STR255## " " ##STR256## 207.5-211.5 (CH.sub.3 CN) ##STR257## " " ##STR258## 261-266 (DMF) ##STR259## " " ##STR260## 234-238 (CH.sub.3 CN)__________________________________________________________________________
EXAMPLE 10
The compound 3,4-dihydro-6-methoxy-2-[[2-(phenylamino)-3-pyridinyl]carbonyl]-1(2H)-naphthalenone, may be cyclized and dealkylated by heating 10 g of the diketone in 160 ml 48% hydrobromic acid on a steam bath with stirring for 48 hours. Remove the steam bath and stir for an additional 48 hours at ambient temperature. Pour the reaction mixture into ice water and basify with 50% sodium hydroxide solution while stirring. Collect the yellow precipitate by filtration and wash with ether. Stir the solid product in 200 ml of water and acidify the solution with glacial acetic acid. Collect the precipitated solid by filtration and wash with dilute acetic acid and then with water. Recrystallize the product 5,6-dihydro-3-hydroxy-12-phenylnaphtho[1,2-b][1,8]naphthyridin-7(12H)-one from DMF, m.p. >340° C.
Basically the same procedure is used with 3,4-dihydro-7-methoxy-2-[[2-(phenylamino)-3-pyridinyl] carbonyl]-1-(2H)-naphthalenone to make 5,6-dihydro-4-hydroxy-12-phenyl-naphtho[1,2-b][1,8]naphthyridin-7(12H)-one, m.p. >330°, after crystallization from C 2 H 5 OH.
EXAMPLE 11
Oxidize 10-(3-chlorophenyl)-6,7,8,9-tetrahydropyrido[2,3-b][1,6]naphthyridin-5(10H)-one with sodium tungstate and hydrogen peroxide, following the procedure of Chem. Commun. 874-875 (1984), to provide a mixture of a nitrone and a pyridine N-oxide which are separated by column chromatography on silica gel, each compound being eluted from the column by dichloromethane containing 2% methanol. The two compounds are 10-(3-chlorophenyl)-8,9-dihydro-pyrido[2,3-b][1,6]naphthyridin-5(10H)-one-7-oxide, hemihydrate (m.p. 208°-209° C. after crystallization from CH 3 CN) and 10-(3-chlorophenyl)pyrido[2,3-b][1,6]-naphthyridin-5(10H)-one-7-oxide m.p. 262°-265° C. after crystallization from CHCl 3 /CH 3 COOC 2 H 5 .
EXAMPLE 12
Reflux 10-(3-chlorophenyl)-8,9-dihydropyrido[2,3-b][1,6]naphthyridin-5(10H)-one-7-oxide (7.3 mmol), N-phenylmaleimide (7.4 mmol) in a solvent of ethylacetate (100 ml) and benzene (50 ml) for 15 hrs. Evaporate the solvents after filtration, and elute the residue from silca gel with chloroform. Crystallize the product, 8-(3-chlorophenyl)-6,7,13b,13c-tetrahydro-2-phenylpyrrolo[3",4":4',5']isoxazolo[2',3':1,2]pyrido[4,3-b][1,8]naphthyridin-1,3,13(2H,3aH,8H)-trione, from diisopropylether/CH 3 CN, m.p. 255°-258° C.
By employing the same nitrone and the compounds listed in Column 1 of Table 10 in place of N-phenylmaleimide in basically the same procedure, the compounds as listed in Column 2 of Table 10 are prepared.
TABLE 10__________________________________________________________________________ Col. 2 Product Col. 1 ##STR261## crystallization)(solvent ofProduct m.p. °C.Col. 3__________________________________________________________________________ ##STR262## ##STR263## 197-202 (CH.sub.3 CN-Pet. ether) ##STR264## ##STR265## 169-172 (CH.sub.3 CN-Pet.__________________________________________________________________________ ether)
By basically the same procedure as described above employing the same nitrone and the compound listed in Column 1 of Table 11 below in place of phenylmaleimide, the compounds listed in Column 2 of Table 11 may be prepared, except that the last listed compound may be prepared by the procedure described in J. Org. Chem. 46, 3502 (1981).
TABLE 11______________________________________ Col. 2 Product Col. 1 ##STR266##______________________________________ ##STR267## ##STR268## ##STR269## ##STR270## ##STR271## ##STR272## ##STR273## ##STR274##______________________________________
EXAMPLE 13
Charge a Paar bottle with 5,6-dihydro-3-hydroxy-12-phenyl-naphtho[1,2-b] [1,8]naphthyridin-7(12H)-one, an equal weight of 5% Pd on carbon, and ethanol. Pressurize the bottle with hydrogen to about 50 psi, and shake the contents in a Paar apparatus at 25° C. Monitor the progress of hydrogenation by pressure changes or by thin-layer chromatography. When hydrogen uptake ceases, remove catalyst by filtration and ethanol by evaporation. Crystallize the residue to obtain 5,6,8,9,10,11-hexahydro-3-hydroxy-12-phenyl-naphtho[1,2-b] [1,8]naphthyridin-7(12H)-one, m.p. >330° C. after crystallization from C 2 H 5 OH.
By starting with the compounds listed in Column 1 of Table 12, the compounds listed in Column 2 thereof are prepared by basically the same procedure:
TABLE 12__________________________________________________________________________ ##STR275## ##STR276## (solvent of crystallization) Product of m.p. °C.Col. 3__________________________________________________________________________ ##STR277## ##STR278## 265-270 (C.sub.2 H.sub.5 OH) ##STR279## ##STR280## 248.5-253 (C.sub.2 H.sub.5 OH) ##STR281## ##STR282## 265-267 (CH.sub.3 COOC.sub.2 H.sub.5CH.sub .3 OH)__________________________________________________________________________
EXAMPLE 14
Oxidize 6,7,8,9-tetrahydro-9-(3-methylthiophenyl)-5H-cyclopenta[b] [1,8]naphthyridin-5-one with 3-chloroperbenzoic acid dissolved in CH 2 Cl 2 . Use one equivalent of peracid oxidant at 0°-5° C. for 5 hrs to make the corresponding sulfoxide, 6,7,8,9-tetrahydro-9-(3-methylsulfinylphenyl)-5H-cyclopenta[b] [1,8]naphthyridin-5-one. Wash the reaction mixture with aqueous NaHCO 3 solution and with water. After drying the CH 2 Cl 2 solution, evaporate the solvent, and chromatograph the residue on silica gel. Elute the sulfoxide with CHCl 3 containing increasing amounts of CH 3 OH and crystallize the product from CH 3 CN, m.p. 257°-259° C.
By basically the same reaction but employing two equivalents of the peracid oxidant at 25° C. for 50 hrs., the corresponding sulfone, 6,7,8,9-tetrahydro-9-(3-methylsulfonylphenyl)-5H-cyclopenta[b] [1,8]naphthyridin-5-one is prepared, m.p. 271°-273°, after crystallization from CH 3 CN. Similarly, starting with 10-(3-chlorophenyl)-6,8,9,10-tetrahydro-5H-thiopyrano[4,3-b] [1,8]naphthyridin-5-one or 4-(3-chlorophenyl)-2,3,4,9-tetrahydrothieno[3,2-b] [1,8]naphthyridin-9-one and one equivalent of the peracid oxidant, the sulfoxides, 10-(3-chlorophenyl)-6,8,9,10-tetrahydro-5H-thiopyrano[4,3-b] [1,8]naphthyridin-5-one-7-oxide (m.p. 211°-212° C. after crystallization from CH 3 CN/CH 3 COOC 2 H 5 ) or 4-(3-chlorophenyl)-2,3,4,9-tetrahydrothieno[3,2-b] [1,8]naphthyridin-9-one-1-oxide (m.p. 266°-267° C. after crystallization form CH 3 CN), respectively, are prepared. By employing two equivalents of the peracid oxidant, the corresponding dioxides are prepared; i.e., 10-(3-chlorophenyl)-6,8,9,10-tetrahydro-5H-thiopyrano[4,3-b] [1,8]naphthyridin-5-one-7,7-dioxide (m.p. 249°-250° C. after crystallization from CH 3 CN/pet. ether) and 4-(3-chlorophenyl)-2,3,4,9-tetrahydrothieno[3,2-b] [1,8]naphthyridin-9-one-1,1-dioxide (m.p. 277°-278° C. after crystallization from CHCl 3 --CH 3 CN).
EXAMPLE 15
Reflux 6,8,9,10-tetrahydro-5',5'-dimethyl-10-phenyl-spiro[benzo[b] [1,8]naphthyridin-7-(5H),2'-[1,3]dioxan]-5-one (32 mmoles) with water (6 ml) and p-toluenesulfonic acid monohydrate (3.2 g) dissolved in 2-butanone (319 ml) for 3 days. Monitor the progress of hydrolysis by thin-layer chromatography. When hydrolysis is complete, cool the solution and evaporate the 2-butanone. Wash a CH 2 Cl 2 solution of the residue with aqueous NaHCO 3 solution and with water. Evaporate the CH 2 Cl 2 after drying the organic solution, and crystallize the residue from C 2 H 5 OH--CHCl 3 to obtain 6,8,9,10-tetrahydro-10-phenyl-benzo[b] [1,8]naphthyridin-5,7-dione, m.p. 244°-247° C. (d).
EXAMPLE 16
Treat 5,6,8,9,10,11-hexahydro-3-methoxy-12-phenyl-naphtho[1,2-b] [1,8]naphthyridin-7(12H)-one (10 mmoles) with equimolar amounts of acetyl chloride and triethylamine dissolved in CH 2 Cl 2 (10 ml) at 0°-25° C. for 3 days. Wash the resulting solution with aqueous NaHCO 3 solution and with water, and dry the organic solution. Evaporate the CH 2 Cl 2 , and chromatograph the residue on silica gel. Elute the N-acetylated product with 2% MeOH in CHCl 3 , and crystallize it from isopropyl acetate/disopropyl ether to provide 11-acetyl-5,6,8,9,10,11-hexahydro-12-phenyl-naphtho[1,2-b] [1,8]naphthyridin-7(12H)-one, m.p. 178.5°-182° C.
EXAMPLE 17
Reflux 7-acetyl-6,8,9,10-tetrahydro-10-phenylpyrido[2,3-b] [1,6]naphthyridin-5(7H)-one (10.9 grams) with hot, dilute (10%) aqueous hydrochloric acid (240 ml) in 95% ethanol (129 ml) for 8 hrs. Cool the resulting solution and collect the hydrochloride salt by filtration. If desired, the corresponding free base can be prepared by treating the hydrochloride salt with 50% aqueous sodium hydroxide solution. Crystallize the product, 6,8,9,10-tetrahydro-10-phenylpyrido[2,3-b] [1,6]naphthyridin-5(7H)-one, monohydrate hydrochloride, from CH 3 OH/C 2 H 5 OOCCH 3 , m.p. 277°-279.5° C.
By employing 7-acetyl-10-(3-chlorophenyl)-6,8,9,10-tetrahydropyrido[2,3-b] [1,6]naphthyridin-5(7H)-one as the acetamide (30 g) in a similar procedure, (using N HCl (445 ml) and 95% ethanol (225 ml) for 15 hours), the product, 6,8,9,10-tetrahydro-10-(3-chlorophenyl)pyrido[2,3-b] [1,8]naphthyridin-5(7H)-one may be prepared, m.p. 212°-215° C. after crystallization from CH 2 Cl 2 /CH 3 COCH 3 .
EXAMPLE 18
Charge a stainless-steel bomb with 9-(3-dimethylaminophenyl)-6,7,8,9-tetrahydro-5H-cyclopenta[b] [1,8]naphthyridin-5-one (2 g), and with methyl iodide (80 ml). Close the bomb and heat it in a 140° C. oil bath for 20 hrs. Cool the bomb and contents, filter the latter, and wash the collected solid with ether to provide the product, 9-(3-trimethylammonium)-6,7,8,9-tetrahydro-cyclopenta[b] [1,8]naphthyridin-5-(5H)-one iodide salt, m.p. 235°-239° C., after crystallization from H 2 O.
By a similar method 10-(3-chlorophenyl)-6,7,8,9-tetrahydropyrido[2,3-b] [1,6]naphthyridin-5(10H)-one may be quaternized, using methyl iodide or ethyl iodide, respectively, to yield the products, 10-(3-chlorophenyl)-6,7,8,9-tetrahydro-7,7-dimethyl-pyrido[2,3-b] [1,6]-naphthyridinium-5(10H)-one, iodide (m.p. 305°-308° C. after crystallization from CH 3 OH) or 10(3-chlorophenyl)-6,7,8,9-tetrahydro-7,7-diethylpyrido[4,3-b] [1,8]naphthyridinium-(5(10H)-one iodide 1/4 hydrate (m.p. 256°-258° C. after crystallization from CH 3 OH-CHCl 3 ), respectively.
EXAMPLE 19
React 10-(3-chlorophenyl)-6,7,8,9-tetrahydropyrido[2,3-b] [1,6]naphthyridin-5(10H)-one (5 mmol) with benzylbromide (5.8 mmol) in acetone (40 ml) at 25° C. for 3 hours. Evaporate the acetone solvent, and elute the product from silica gel with chloroform to provide the product, 10-(3-chlorophenyl)-6,7,8,9-tetrahydro-7-N-benzyl-pyrido[2,3-b] [1,6]naphthyridin-5(10H)-one, m.p. 157°-161° C. after crystallization from CH 3 CN.
EXAMPLE 20
Oxidize 10-(3-chlorophenyl)-6,7,8,9-tetrahydropyrido[2,3-b] [1,6]naphthyridin-5(10H)-one (1.6 mmol) in a refluxing solution of xylene (15 ml), using air as the oxidant and 5% Pd on C (15 mg) as the catalyst. Follow the procedure of Tetrahedron Letters26, 1259-1260 (1985); pass air through the hot solution for 15 hours. Evaporate the xylene and elute the residue from silica gel with chloroform to provide 10-(3-chlorophenyl)pyrido[2,3-b] [1,6]naphthyridin-5(10H)-one, m.p. 222°-224° C. after crystallization from CH 3 Cl/pet. ether.
EXAMPLE 21
Saponify 7-ethoxycarbonyl-10-(3-chlorophenyl)-6,7,8,9-tetrahydrobenzo[b] [1,8]naphthyridin-5(10H)-one (7.1 g) with potassium hydroxide (1.10 g) in a solvent of ethanol and water (142 ml, 9:1 by volume). After 21 hours at 25° C., add water (200 ml), cool the resulting solution in ice, and acidify (pH 2) the solution with concentrated hydrochloric acid. Collect the resulting precipitate on a filter, and crystallize it from ethanol to provide 7-carboxy-10-(3-chlorophenyl)-6,7,8,9-tetrahydrobenzo[b] [1,8]naphthyridin-5(10H)-one, m.p. 279°-280.5° C.
EXAMPLE 22
Reduce 6,8,9,10-tetrahydro-10-phenylbenzo[b] [1,8]naphthyridin-5,7-dione (2 mmol) with sodium borohydride (50 mg) in a solvent of ethanol (30 ml) and water (0.25 ml). After 15 minutes, pour the reaction mixture over ice and collect the resulting precipitate on a filter. Reserve the precipitate, and extract the aqueous filtrate with chloroform. Dry the extracts, evaporate the chloroform, and combine the residue with the reserved precipitate to give the product, 10-phenyl-7-hydroxy-6,7,8,9-tetrahydro-benzo[b] [1,8]naphthyridin-5(10H)-one, m.p. 283°-286° C. after crystallization from ethanol.
EXAMPLE 23
Reduce the nitro group of 6,7,8,9-tetrahydro-9-(3-nitrophenyl)-5H-cyclopenta[b] [1,8]naphthyridin-5-one with stannous chloride in hydrochloric acid following the procedure of Org. Syn. (Coll. Vol. III, 1955, p. 453), precipitating the product, 9-(3-aminophenyl)-6,7,8,9-tetrahydrocyclopenta[b] [1,8]naphthyridin-5(5H)-one from H 2 O, m.p. 284.5°-285.5° C.
EXAMPLE 24
Reflux a mixture of 4-(3-chlorophenyl)-2,3-dihydrothieno[3,2-b] [1,8]naphthyridin-9(9H)-one (0.11 g), ethanol (100 ml), and commercial aged Raney nickel (from 5 ml of an aqueous suspension) for 10 hours under nitrogen. Filter the resulting mixture, evaporate the solvent, and chromatograph the residue over silica gel. Elute with CHCl 3 to give 4-(3-chlorophenyl)-thieno[3,2-b] [1,8]naphthyridin-9(4H)-one, m.p. 264°-267° C. from CHCl 3 hexane.
EXAMPLE 25
Add a solution containing a mixture of 1-acetyl-3-(1-pyrrolidinyl)-3- and 2-pyrrolines (3.55 g) and triethylamine (2.17 g) in dichloromethane (20 ml) to a cooled, stirred suspension of 2-(3-chlorophenylamino)pyridinyl-3-carbonyl chloride (5.26 g) in an atmosphere of N 2 . Use an ice bath for cooling. When addition is complete (30 minutes), remove the ice bath and allow stirring to continue at ambient temperature for 20 hours. Wash the resulting solution with 1M NaHCO 3 solution, with H 2 O, with 1M HCl and with H 2 O. Dry the CH 2 Cl 2 solution, filter it, and evaporate the CH 2 Cl 2 . Crystallize the residue to give 7-acetyl-9-(3-chlorophenyl)-6,7,8,9-tetrahydro-5H-pyrrolo[3,4-b] [1,8]naphthyridin-5-one, m.p. 289°-293° C. from CHCl 3 --C 2 H 5 OOCCH 3 . Chromatograph the mother liquor over silica gel, and elute the column with 2% CH 3 OH in CH 2 Cl 2 to obtain 1-acetyl-2-[2-[(3-chlorophenyl)amino]-3-pyridinylcarbonyl]-3-(1-pyrrolidinyl)-1H-pyrrole, m.p. 170°-173° C. from CH 3 CN.
Reflux a mixture of 1-acetyl-2-[2-[(3-chlorophenyl)amino]-3-pyridinylcarbonyl]-3-(1-pyrrolidinyl)-1H-pyrrole (0.45 g), p-toluenesulfonic acid monohydrate (0.21 g) in a solvent of benzene (20 ml), and tert-butanol for 12 hours. Evaporate solvent and partition the residue between CHCl 3 and 1M NaHCO 3 . Wash the CHCl 3 solution with water, dry and filter the solution. Evaporate the solvent, and triturate the residue with CHCl 3 to give 4-(3-chlorophenyl)-1,4-dihydro-9H-pyrrolo[3,2-b] [1,8]-naphthyridin-9-one, m.p. 300°-301° C.
The following formulations exemplify some of the dosage forms of the compositions of this invention. In each, the term "active compound" designates 9-phenyl-6,7,8,9-tetrahydro-5H-cyclopenta[b] [1,8]naphthyridin-5-one. It is contemplated, however, that this compound may be replaced by equally effective amounts of other compounds of formula I.
PHARMACEUTICAL DOSAGE FORM EXAMPLES
EXAMPLE A
Tablets
______________________________________No. Ingredient mg/tablet mg/tablet______________________________________1. Active compound 100 5002. Lactose USP 122 1133. Corn Starch, Food Grade, 30 40as a 10% paste inPurified Water4. Corn Starch, Food Grade 45 405. Magnesium Stearate 3 7Total 300 700______________________________________
Method of Manufacture
Mix Item Nos. 1 and 2 in a suitable mixer for 10-15 minutes. Granulate the mixture with Item No. 3. Mill the damp granules through a coarse screen (e.g., 1/4") if needed. Dry the damp granules. Screen the dried granules if needed and mix with Item No. 4 and mix for 10-15 minutes. Add Item No. 5 and mix for 1-3 minutes. Compress the mixture to appropriate size and weight on a suitable tablet machine.
EXAMPLE B
Capsules
______________________________________No. Ingredient mg/tablet mg/tablet______________________________________1. Active compound 100 5002. Lactose USP 106 1233. Corn Starch, Food Grade 40 704. Magnesium Stearate NF 4 7Total 250 700______________________________________
Method of Manufacture
Mix Item Nos. 1, 2 and 3 in a suitable blender for 10-15 minutes. Add Item No. 4 and mix for 1-3 minutes. Fill the mixture into suitable two-piece hard gelatin capsules on a suitable encapsulating machine.
EXAMPLE C
Parenteral
______________________________________Ingredient mg/vial mg/vial______________________________________Active Compound Sterile Powder 100 500______________________________________
Add sterile water for injection or bacteriostatic water for injection, for reconstitution.
EXAMPLE D
Injectable
______________________________________Ingredient mg/vial______________________________________Active Compound 100Methyl p-hydroxybenzoate 1.8Propyl p-hydroxybenzoate 0.2Sodium Bisulfite 3.2Disodium Edetate 0.1Sodium Sulfate 2.6Water for Injection q.s. ad 1.0 ml______________________________________
Method of Manufacture (for 1000 vials)
1. Dissolve p-hydroxybenzoate compounds in a portion (85% of the final volume) of the water for injection at 65°-70° C.
2. Cool to 25°-35° C. Charge and dissolve the sodium bisulfite, disodium edetate and sodium sulfate.
3. Charge and dissolve active compound.
4. Bring the solution to final volume by added water for injection.
5. Filter the solution through 0.22 membrane and fill into appropriate containers.
6. Finally sterilize the units by autoclaving.
EXAMPLE E
Nasal Spray
______________________________________ mg/ml______________________________________Active Compound 10.0Phenyl Mercuric Acetate 0.02Aminoacetic Acid USP 3.7Sorbitol Solution, USP 57.0Benzalkonium Chloride Solution 0.2Sodium Hydroxide 1N Solution to --adjust pHWater Purified USP to make 1.0 ml______________________________________
The following formulations F and G exemplify some of topical dosage forms in which "Active Compound" refers to 9-(3-nitrophenyl)-6,7,8,9-tetrahydro-5H-cyclopenta [b][1,8]naphthyridin-5-one, but again other compounds of formula I may be substituted therefor.
EXAMPLE F
Ointment
______________________________________Formula mg/g______________________________________Active Compound 1.0-20.0Benzyl Alcohol, NF 20.0Mineral Oil, USP 50.0White Petrolatum, USP to make 1.0 g______________________________________
Method of Manufacture
Disperse active compound in a portion of the mineral oil. Mix and heat to 65° C., a weighed quantity of white petrolatum, the remaining mineral oil and benzyl alcohol, and cool to 50°-55° C. with stirring. Add the dispersed active compound to the above mixture with stirring. Cool to room temperature.
EXAMPLE G
Cream
______________________________________Formula mg/g______________________________________Active Compound 1.0-20.0Stearic Acid, USP 60.0Glyceryl Monostearate 100.0Propylene Glycol, USP 50.0Polyethylene Sorbitan Monopalmitate 50.0Sorbitol Solution, USP 30.0Benzyl Alcohol, NF 10.0Purified Water, USP to make 1.0 g______________________________________
Method of Manufacture
Heat the stearic acid, glyceryl monostearate and polyethylene sorbitan monopalmitate to 70° C. In a separate vessel, dissolve sorbital solution, benzyl alcohol, water, and half quantity of propylene glycol and heat to 70° C. Add the aqueous phase to oil phase with high speed stirring. Dissolve the active compound in remaining quantity of propylene glycol and add to the above emulsion when the temperature of emulsion is 37°-40° C. Mix uniformly with stirring and cool to room temperature.
While the present invention has been described in conjunction with the specific embodiments set forth above, many alternatives, modifications and variations thereof will be apparent to those of ordinary skill in the art. All such alternatives, modifications and variations are intended to fall within the spirit and scope of the present invention.
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Novel polycyclic quinoline, naphthyridine and pyrazinopyridine derivatives are disclosed which are useful for treatment allergic reactions, inflammation, peptic ulcers, hypertension, and hyperproliferative skin diseases and for suppressing the immune response in mammals. Methods for preparing said compounds are also disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the tracking of objects in video sequences. More particularly, the present invention relates to storage of coordinates used to track object trajectories.
[0003] 2. Description of the Related Art
[0004] In the prior art, when objects are tracked in a video sequence, trajectory coordinates are typically generated for each frame of video. Considering that, for example, that under the NTSC standard, which generates 30 frames per second, a new location or coordinate for each object in a video sequence must be generated and stored for each frame.
[0005] This process is extremely inefficient and requires tremendous amounts of storage. For example, if five objects in a video sequence were tracked, over two megabytes of storage would be needed just to store the trajectory data for a single hour. Thus, storage of all of the trajectories is expensive, if not impractical.
[0006] There have been attempts to overcome the inefficiency of the prior art. For example, in order to save space, the coordinates for every video frame have been compressed. One drawback is that the compression of the trajectories introduces delay into the process. Regardless of the compression, there is still a generation of coordinates for each frame. In addition, there has been an attempt to circumvent the generation of trajectories by devices that store the location of motion in video for every frame, based on a grid-based breakup of the video frame. These devices still store data for each frame, and the accuracy of the location of motion is not comparable to the generation of trajectories.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is an object of the present invention to provide a method and system that addresses the shortcomings of the prior art.
[0008] In a first aspect of the present invention, the coordinates are stored only when objects move more than a predetermined amount, rather than storing their movement after every frame.
[0009] This feature permits a tremendous savings in memory or disk usage over conventional methods. In addition, the need to generate coordinates can be greatly reduced to fractions of the generation per frame that is conventionally processed.
[0010] A video content analysis module automatically identifies objects in a video frame, and determines the (x i ,y i ) coordinates of each object i. The reference coordinates for each for object i, (xref i ,yref i ) are set to (x i ,y i ) when the object is first identified. For subsequent frames, if the new coordinates (xnew i ,ynew i ) are less than a given distance from the reference coordinates, that is if ∥(xnew i ,ynew i )−(xref i ,yref i )∥ 2 <ε, then the current coordinates are ignored. However, if the object moves more than the distance e, the current coordinates (xnew i ,ynew i ) are stored in the object's trajectory list, and we set the reference coordinates (xref i ,yref i ) to the object's current position. This process is repeated for all subsequent video frames. The resulting compact trajectory lists can then be written to memory or disk while they are being generated, or when they are complete.
[0011] The present invention can be used in many areas, including video surveillance security system that tracks movement in a particular area, such as a shopping mall, etc. The amount of storage conventionally required for standard video cameras that scan/videotape an area, such a VCR, often creates a huge unwanted library of tapes. In addition, there is a tendency to reuse the tapes quickly so as not to set aside tape storage areas, or pay for their shipment elsewhere. The compact storage of the present invention makes the permanent storage of secure areas much more practical, and provides a record to investigators to see whether a particular place was “cased” (e.g. observed by a wrongdoer prior to committing an unlawful act) by a wrongdoer prior to a subsequent unlawful action being performed.
[0012] Also, in a commercial setting, the present invention could be applied to track people in, for example, a retail store to see how long they waited on the checkout line.
[0013] Accordingly, a method for storing a trajectory of tracked objects in a video, comprising the steps of:
[0014] (a) identifying objects in a first video frame;
[0015] (b) determining first reference coordinates (xref i ,yref i ) for each of said objects identified in step (a) in the first video frame;
[0016] (c) storing the first reference coordinates (xref i ,yref i );
[0017] (d) identifying said objects in a second video frame;
[0018] (e) determining current reference coordinates (xnew i ynew i ) of said objects in said second video frame; and
[0019] (f) storing the current reference coordinates of a particular object in an object trajectory list and replacing the first reference coordinates (xref i ,yref i ) with the current reference coordinates (xnew i ,ynew i ) if the following condition for the particular object is satisfied:
∥( xnew i ,ynew i )−( xref i ,yref i )∥ 2 ≧ε,
[0020] wherein ε is a predetermined threshold amount, and
[0021] retaining the first reference coordinates (xref i ,yref i ) for comparison with subsequent video frames when said condition in step (f) is not satisfied.
[0022] The method according may further comprise (g) repeating steps (e) and (f) for all video frames subsequent to said second video frame in a video sequence so as to update the storage area with additional coordinates and to update the current reference coordinates with new values each time said condition in step (f) is satisfied.
[0023] Optionally, the method may include a step of storing the last coordinates of the object (i.e., the coordinates just before the object disappears and the trajectory ends), even if the last coordinate does not satisfy condition (f).
[0024] The object trajectory list for the particular object stored in step (f) may comprise a temporary memory of a processor, and
[0025] the method may optionally include the following step:
[0026] (h) writing the object trajectory list to permanent storage from all the coordinates stored in the temporary memory after all the frames of the video sequence have been processed by steps (a) to (g).
[0027] The permanent storage referred to in step (h) may comprise at least one of a magnetic disk, optical disk, and magneto-optical disk, or even tape. Alternatively, the permanent storage can be arranged in a network server.
[0028] The determination of the current reference coordinates (x 1new y inew ) in step (e) can include size tracking of the objects moving one of (i) substantially directly toward, and (ii) substantially directly away from a camera by using a box bounding technique. The box bounding technique may comprise:
[0029] (i) determining a reference bounding box (wref i ,href i ) of the particular object i, wherein w represents a width, and h represents a height of the particular object;
[0030] (ii) storing a current bounding box (w i ,h i ) if either of the following conditions in substeps (ii) (a) and (ii) (b) are satisfied:
| w i −wref i |>δ w ; (ii) (a)
| h i −href i |>δ h , (ii) (b)
[0031] where δ w and δ h are predetermined thresholds.
[0032] Alternatively, the box bounding technique may comprise:
[0033] (i) determining an area aref i =wref i *href i of a reference bounding box (wref i ,href i ) of the particular object, wherein w represents a width, and h represents a height of the particular object; and
[0034] (ii) storing coordinates of a current bounding box (w i ,h i ) if a change in area δ a =|aref I −w i *h i | of the current bounding box is greater than a predetermined amount.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIGS. 1 A- 1 C illustrate a first aspect of the present invention wherein the motion in FIG. 1B relative to FIG. 1A fails to satisfy the expression in FIG. 1C.
[0036] FIGS. 2 A- 2 C illustrate a second aspect of the present invention wherein the motion in FIG. 2B relative to FIG. 2A satisfies the expression in FIG. 1C.
[0037] FIGS. 3 A- 3 C illustrate another aspect of the present invention pertaining to a box bounding technique.
[0038] [0038]FIG. 4 illustrates a schematic of a system used according to the present invention.
[0039] [0039]FIGS. 5A and 5B are a flow chart; illustrating an aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] FIGS. 1 A- 1 C illustrate a first aspect of the present invention. As shown in FIG. 1A a frame 105 contains an object 100 (in this case a stick figure representing a person). To aid in understanding, numerical scales in both the X direction and Y direction have been added to the frame. It is noted that the x,y coordinates can be obtained, for example, by using the center of the mass of the object pixels, or in the case of a bounding box technique (which is disclosed, infra) by using the center of the object bounding box.
[0041] It should be understood by persons of ordinary skill in the art that the scales are merely for illustrative purposes, and the spaces there between, and/or the number values do not limit the claimed invention to the scale. The object 100 is identified at a position (xref i ,yref i ) which are now used as the x and y reference point for this particular object.
[0042] It should be noted that the objects identified do not have to be, for example, persons, and could include inanimate objects in the room, such as tables, chairs, and desks. As known in the art, these objects could be identified by, for example, their color, shape, size, etc. Preferably, a background subtraction technique is used to separate moving objects from the background. One way this technique is used is by learning the appearance of the background scene and then identifying image pixels that differ from the learned background. Such pixels typically correspond to foreground objects. Applicants hereby incorporate by reference as background material the articles by A. Elgammal, D. Harwood, and L. Davis, “Non-parametric Model for Background Subtraction”, Proc. European Conf. on Computer vision , pp. II: 751-767, 2000, and C. Stauffer, W. E. L. Grimson, “Adaptive Background Mixture Models for Real-time Tracking”, Proc. Computer Vision and Pattern Recognition , pp. 246-252, 1999 as providing reference material for some of the methods that an artisan can provide object identification. In the Stauffer reference, simple tracking links objects in successive frames based on distance, by marking each object in the new frame by the same number as the closest object in the previous frame. Additionally, the objects can be identified by grouping the foreground pixels, for example, by a conected-components algorithm, as described by T. Cormen, C. Leiserson, R. Rivest, “Introduction to Algorithms”, MIT Press, 1990, chapter 22.1, which is hereby incorporated by reference as background material. Finally, the objects can be tracked such as disclosed in U.S. patent application Ser. No. ______ entitled “Computer Vision Method and System for Blob-Based Analysis Using a Probabilistic Network, U.S. Ser. No. 09/988,946 filed Nov. 19, 2001, the contents of which are hereby incorporated by reference.
[0043] Alternatively, the objects could be identified manually. As shown in FIG. 1B, object 100 has moved to a new position captured in the second frame 110 having coordinates of (xnew i ,ynew i ) which is a distance away from the (xref i ,yref i ) of the first frame 105 .
[0044] It is appreciated by an artisan that while there are many ways that objects can be identified and tracked, the present invention is applicable regardless of the specific type of identification and tracking of the objects. The amount of savings in storage is significant irrespective of the type of identification and tracking.
[0045] According to an aspect of the present invention, rather than storing new coordinates for every object and every frame, an algorithm determines whether or not the movement by object 100 in the second frame is greater than a certain predetermined amount. In the case where the movement is less than the predetermined amount, coordinates for FIG. 1B are not stored. The reference coordinates identified in the first frame 105 continue to be used against a subsequent frame.
[0046] [0046]FIG. 2A again illustrates, (for convenience of the reader), frame 105 , whose coordinates will be used to track motion in a third frame 210 . The amount of movement by the object 100 in the third frame, as opposed to its position in the first frame 105 , is greater than the predetermined threshold. Accordingly, the coordinates of the object 100 in FIG. 2B now become the new reference coordinates (as identified in the drawing as new (xref i ,yref i ), versus the old (xref i ,yref i ). Accordingly, the trajectory of the object 100 includes the coordinates in frames 1 and 3 , without the need to save the coordinates in frame 2 . It should be understood that, for example, as standards such as NTSC generate 30 frames per second, the predetermined amount of movement could be set so that significant amounts of coordinates would not require storage. This process can permit an efficiency in compression heretofore unknown.
[0047] The amount of movement used as a predetermined threshold could be tailored for specific applications, and includes that the threshold can be dynamically computed, or modified during the analysis process. The dynamic computation can be based on factors such as average object velocity, general size of the object, importance of the object, or other statistics of the video.
[0048] For example, in a security film, very small amounts of motion could be used when items being tracked are extremely valuable, as opposed to larger threshold amounts permit more efficient storage, which can be an important consideration based on storage capacity and/or cost. In addition, the threshold amount can be application specific so that the trajectory of coordinates is as close to the actual movement as desired. In other words, if a threshold amount is too large, it could be movement in different directions that is not stored. Accordingly, the trajectory of the motion would be that between only the saved coordinates, which, of course, may not necessarily comprise the exact path that would be determined in the conventional tracking and storage for each individual frame. It should be noted that with many forms of compression, there normally is some degree of paring of the representation of the objects.
[0049] [0049]FIGS. 3A to 3 C illustrate another aspect of the present invention pertaining to a box bounding technique. It is understood by persons of ordinary skill in the art that while a camera is depicted, the video image could be from a video server, DVD, videotape, etc. When objects move directly toward or away from a camera, their coordinates may not change enough to generate new trajectory coordinates for storage. A box bounding technique is one way that the problem can be overcome. For example, in the case of an object moving directly toward or away from the camera, the size of the object will appear to become larger or smaller depending on the relative direction.
[0050] [0050]FIGS. 3A to 3 C illustrate a box bounding technique using size tracking. As shown in FIG. 3A, a bounding box 305 represents the width and height of an object 307 the first frame 310 .
[0051] As shown in the second frame 312 in FIG. 3B, the bounding box in 310 of object 307 has changed (as these drawings are for explanatory purposes, they are not necessarily to scale).
[0052] As shown in FIG. 3C, the box bounding technique would store the coordinate of the object in the second frame 312 if the width of a bounding box in a subsequent frame is different from the width of the reference box of the previous frame, or the height of the bounding box in a particular frame is different from the height of the bounding box of a reference frame; in each case the difference is more than a predetermined threshold value. Alternatively, the area of the bounding box (width x height) could be used as well, so if the area of the bounding box 310 is different than the area of the reference bounding box 305 by a predetermined amount, the coordinates of the second frame would be stored.
[0053] [0053]FIG. 4 illustrates one embodiment of a system according to the present invention. It should be understood that the connections between all of the elements could be any combination of wired, wireless, fiber optic, etc. In addition, some of the items could be connected via a network, including but not limited to the Internet. As shown in FIG. 4, a camera 405 captures images of a particular area and relays the information to a processor 410 . The processor 410 includes a video content analysis module 415 which identifies objects in a video frame and determines the coordinates for each object. The current reference coordinates for each object could be stored, for example, in a RAM 420 , but it should be understood that other types of memory could be used. As a trajectory is a path, the initial reference coordinates of the identified objects would also be stored in a permanent storage area 425 . This permanent storage area could be a magnetic disc, optical disc, magneto optical disc, diskette, tape, etc. or any other type of storage. This storage could be located in the same unit as the processor 410 or it could be stored remotely. The storage could in fact be part of or accessed by a server 430 . Each time the video content module determines that motion for an object in a frame exceeds the value of the reference coordinates by a predetermined threshold, the current reference coordinates in the RAM 420 would be updated as well as permanently stored 425 . As the system contemplates only a storage of motion beyond a certain threshold amount, the need to provide storage or sufficient capacity to record every frame is reduced and in most cases, eliminated. It should also be noted that the storage could be video tape.
[0054] Applicants' FIGS. 5A and 5B illustrate a flow chart that provides an overview of the process of the present of the present invention.
[0055] At step 500 , objects in the first video frame are identified.
[0056] At step 510 , the reference coordinates for each of the objects identified in the first video frame are determined. The determination of these reference coordinates may be known by any known method, e.g., using the center of the object bounding box, or the center of mass of the object pixels.
[0057] At step 520 , the first reference coordinates determined in step 10 are stored. Typically, these coordinates could be stored in a permanent type of memory that would record the trajectory of the object. However, it should be understood that the coordinates need not be stored after each step. In other words, the coordinates could be tracked by the processor in the table, and after all the frames have been processed, the trajectory could be stored at that time.
[0058] At step 530 , the objects in the second video frame are identified.
[0059] At step 540 , there is a determination of the current reference coordinates of the objects in the second video frame. These coordinates may or may not be the same as in the first frame. As shown in FIG. 5B, at step 550 the current reference coordinates of a particular object are stored in an object trajectory list and used to replace the first referenced coordinates of that particular object if the following condition for the particular object is satisfied ∥(xnew i ,ynew i )−(xref i ,yref i )∥ 2 ≧ε, However, when the condition is not satisfied, the first reference coordinates are retained for comparison with subsequent video frames. The process continues until all of the video frames have been exhausted. As previously discussed, the object trajectory list could be a table, and/or a temporary storage area in the processor which is later stored, for example, on a hard drive, writeable CD ROM, tape, non volatile electronic storage, etc. Various modifications may be made on the present invention by a person of ordinary skill in the art that would not depart from the spirit of the invention or the scope of the appended claims. For example, the type of method used to identify the object in the video frames, the threshold values provided by which storage of additional coordinates and subsequent frames is determined, may all be modified by the artisan in the spirit of the claimed invention. In addition, a time interval could be introduced into the process, where for example, after a predetermined amount of time, the coordinates of a particular frame are stored even if a predetermined threshold of motion is not reached. Also, it is within the spirit of the invention and the scope of the appended claims, and understood by an artisan that that coordinates other than x and y could be used, (for example, z) or, the x,y coordinates could be transformed into another space, plane or coordinate system, and the measure would be done in the new space. For example, if the images were put through a perspective transformation prior to measuring. In additio, the distance measured could be other than Euclidian distance, such as a less-compute-intensive measure, such as |xnew−xref|+|ynew−yref|≧ε.
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A process and system for enhanced storage of trajectories reduces storage requirements over conventional methods and systems. A video content analysis module automatically identifies objects in a video frame, and determines the (x i ,y i ) coordinates of each object i. The reference coordinates for each for object i, (xref i ,yref i ) are set to (x i ,y i ) when the object is first identified. For subsequent frames, if the new coordinates (xnew i ,ynew i ) are less than a given distance from the reference coordinates, that is if ∥(xnew i ,ynew i )−(xref 1 ,yref i )∥ 2 <ε, then the current coordinates are ignored. However, if the object moves more than the distance ε, the current coordinates (xnew i ,ynew i ) are stored in the object's trajectory list, and we set the reference coordinates (xref 1 ,yref i ) to the object's current position. This process is repeated for all subsequent video frames. The resulting compact trajectory lists can then be written to memory or disk while they are being generated, or when they are complete.
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Table of Contents
Background of the invention:
3
Reference application U.S. #20070199669 Yang:
4
Reference Application, U.S. # 20070049661:
4
Reference Application, U.S. # 20080032147A1:
4
Reference Pat. No. 6,492,574:
4
Reference Pat. No. 5,705,216:
5
Reference Pat. No. 4,468,428, P&G:
5
Summary of the Invention:
6
Description of the views of the Drawings
10
Detailed Description of the Preferred Embodiments:
10
Example #1:
14
Example #2:
15
Example #3:
15
Table 1
19
FIG. 1
20
FIG. 2
21
FIG. 3
22
FIG. 4
23
Claims:
24
Abstract:
26
BACKGROUND OF THE INVENTION
[0002] The present invention relates to annual crop straw and stalk fibers which have suitable properties for use in paper, paperboard and related products made therefrom, disposable dinner plates, cups, and bowls, molded pulp containers, and food trays and food handling containers, clamshell containers, tissue and toweling, and absorbent products such as diapers, roligoods, and feminine hygiene articles. Other uses include reconstituted cellulose such as rayon and electronic article packaging. Up to this time, farmers have the alternatives of tilling part of the stalk and straw back into the soil and disposal of the excess. Only a portion of the stalks can be reasonably tilled back into the soil each year. Therefore, the farmer is faced with disposal of large quantities of the waste stalk and straw after harvesting the food crop. Straw and stalk have been burned in the past, but this is obviously not an environmentally friendly process due to the air pollution created. The use of straw and stalk fibers in high value products also represents an opportunity to the farmer to recover additional income per acre of crop land without impacting the food crop supply.
[0003] A significant amount of effort has been undertaken to use annual crop waste straw such as wheat, oats, soy, corn, sugar cane, and rice in paper and paperboard products. The opportunity in this area is to use waste materials from agricultural products which decreases need and cost of waste disposal, increases value to the fanner, and provides a viable replacement for wood pulp, thereby saving trees. Also, the use of the waste straw and stalks does not impact the food supply. This approach represents the next level of “Green” or environmentally responsible manufacturing. Also, the annual crop fibers have the potential of providing enhanced properties compared to wood pulp. Wheat straw has been made into pulp fibers, and wet laid into paper products. Much work has been done in Canada and United States as well as China to process Wheat into paper for printing. In Canada, the Alberta Research Center has taken Wheat straw from China and processed it into printable paper called Wheat Sheet and it was used to print a publication of National Geographic in 2008. The Wheat Sheet had 20% wheat fiber and 80% wood pulp fiber. The pulping and recovery systems proved to lack commercial economic viability. Also, chlorine bleaching is an environmentally undesirable process. The present invention relates to processes and applications that do not require chlorine bleaching to be suitable for paper, paperboard, and related products, and absorbent product end uses.
[0004] Reference Application U.S. #20070199669 Yang:
[0005] The reference patent application relates to processing of annual crops for the formation of long, coarse fiber bundles for use in textiles and composites. This reference teaches towards maintenance of high coarseness, long fiber bundles from annual crop straw and teaches away from formation of individual fiber cells, low coarseness and shorter fibers consisting of small multiple cells bonded in the manner of the original straw which are unsuitable for textile use. The fibers and the process of the reference application are intended to be a coarseness of at least one denier and preferably 30 denier and larger. The process creates fibers having a variety of coarseness levels and that have approximately 10-30% of the fibers that are suitable for textiles. The desirable high coarseness fibers must then be extracted from the digested fiber mass for use in textiles.
[0006] Reference Application, U.S. #20070049661:
[0007] The reference relates to the use of soy and other annual crop straw and stalks for use in strandboard. The technology includes the step of de-pithing, cutting to length, drying and applying resin and wax to bind the fibers into the final strandboard product. No digesting or cooking of the fibers is involved. The straw and stalks are simply mechanically processed or steam treated into long bundles of fibers with little or no separation into smaller fiber cells.
[0008] Reference Application, U.S. #20080032147A1:
[0009] This reference relates to the use of annual crop fibers for Medium Density Fiberboard (MDF). The straw and stalks are steam treated to open the fibers enough to create fibers suitable for MDF manufacture. No digestion or bleaching or lignin removal is indicated.
[0010] Reference U.S. Pat. No. 6,492,574:
[0011] General reference to use of wheat straw as a source of cellulose for absorbent articles, but no mention of soy stalk fiber or any specific enabling technology for processing the wheat or fiber specific properties or dimensions.
[0012] Reference U.S. Pat. No. 5,705,216:
[0013] Describes process for steam treatment and extrusion of straw to make hydrophobic fibers suitable for injection molded plastics. The reference patent does not mention use of soy stalk fibers.
[0014] Reference U.S. Pat. No. 4,468,428, P&G:
[0015] This patent discloses use of wheat straw fibers and other micro-fibers having diameter of 0.5 to 10 microns and an absorbent pad density of 0.04 to 0.15 g/cc. for use in absorbent articles such as diapers.
[0016] Although the above indicated technologies have been used to produce fibers from annual crops, to date there have been none that are technologically, commercially and economically viable for use in paper and related products and none that have been suitable for use in absorbent products. Also, none have shown the appearance and color needed for certain paper, tissue and toweling, molded pulp products, paperboard, and absorbent products without chlorine bleaching which is environmentally undesirable and economically unfeasible.
[0017] Furthermore, these references do not disclose mixtures of soy and wheat fibers, which mixtures have surprisingly improved properties and value including but not limited to twice the available fiber (acres of crop) due to required crop rotation and more flexibility in fiber furnish that can be processed at the same operating conditions, requiring little or no process changes or adjustments. In order to maintain soil quality, soy is typically rotated with wheat every year, resulting in a field providing wheat or soy every other year. The mixtures also provide more pleasing color than each fiber alone and the mixtures provide improved processing for the Thermoformed Pulp process including more effective of water spray trimming and elimination of steam bubbles during the drying and molding step of the process associated with the use of 100% wheat straw fiber.
SUMMARY OF THE INVENTION
[0018] The aforementioned opportunities for use of all species of annual crops are realized by the use the fibers of the present invention containing soy stalk fibers, and straw from wheat and other annual crops in paper, paperboard, linerboard, related wet laid paperboard and products made therefrom, tissue and toweling, napkins, Molded Pulp, Transfer Molded Pulp, Slush Molded Pulp, and Thermoformed Pulp applications, reconstituted cellulose such as rayon, food handling service and packaging products such as trays, clamshell boxes, meat trays, serving trays, plates, cups and bowls, packaging for electronics and other items, and in absorbent products including diapers, feminine hygiene products, airlaid rollgoods, and wipes. Fibers of the present invention are produced from soy stalks and wheat straw, and other annual crops which are chopped and digested with caustic or other suitable cooking liquors and various cooking sequences of time, temperature and agitation. The digested fibers are then refined to various degrees of coarseness appropriate to the end use application. A higher level of cooking and higher level of refining creates fibers with lower coarseness and shorter length. Conversely, a lower level of cooking and refining results in a longer apparent fiber length and higher coarseness indicated by larger apparent fiber diameter consisting of multiple fiber cells that remain bonded in the manner of the original straw or stalk. For example, the lower coarseness fibers are suitable for smooth, strong paper and paper board. Higher coarseness fibers are suitable for better wet laid drainage and possible use in wet laid tissue and toweling and in some forms of paperboard or other wet laid products that require good drainage properties. The digesting and refining conditions may be optimized for a suitable balance of paper strength and smoothness and drainage rate. The improved color of the soy and wheat mixtures is attained at all levels of digestion and refining. It has been discovered that the same digesting and refining conditions that are used for wheat straw can be used for soy stalk to provide appropriate fiber for the specific application. Since the soy stalk and wheat fiber can be digested and refined at the same conditions and the mixtures converted to end products at same conditions, there is little to no need to change operating conditions over a broad range of mixtures such as 5% soy/95% wheat to 95% soy/5% wheat by weight. These aforementioned characteristics of the soy and wheat mixtures provide unique benefits and value to the fiber manufacturer and the end product manufacturer.
[0019] Also, a suitable level of digestion and refining makes the fibers desirable for use in absorbent products. The fibers of the present invention are suitable for use in roll pulp for absorbent products which are wet laid, dried and then re-fiberized from wet laid pulp sheet into fluff pulp suitable for absorbent products such as diapers and feminine hygiene pads and airlaid rollgoods. Lab scale tests using hand sheets and Waring Blender de-fiberization indicate that the annual crop fibers of the present invention can be re-fiberized from a wet laid roll pulp similar to that currently used by the diaper industry The wet laid pulp sheet typically used in the diaper industry is a Southern Pine fluff pulp fiber that has been made into a continuous web that is sheeted or rolled and dried for transport to the diaper plant where it is fed into a hammermill or similar fiberization process in the diaper making equipment. Typically, these wet laid pulp sheets have a basis weight of about 750-780 g/sq. meter, but could be made at lower or higher basis weight as required by the diaper making or other fiberization equipment.
[0020] Wheat straw fibers and soy stalk fibers were evaluated in a lab study in which the fibers were dissolved and made into rayon fibers. The molecular weight of the fibers was lower than desired for dissolving pulp. No other issues were identified.
[0021] Each application may require specific levels of digestion and refining to provide the appropriate level of fiber length, coarseness, and apparent fiber diameter for the end use.
[0022] A surprising result is that the soy stalks can be easily digested and refined with normal annual crop straw pulping and refining processes into fibers beneficial for the aforementioned uses. Soy stalk may be digested and refined at the same conditions as wheat and therefore provides value and improved ease of providing mixtures of soy and wheat fibers. Soy fibers and wheat fibers can use the same processing conditions for converting the fibers to products such as molded trays in the Thermoformed Pulp Process which provides the ability to use a broad range of mixtures from about 5% soy/95% wheat to about 95% soy/5% wheat by weight. The fibers and mixtures of the present invention are also suitable for use in Molded Pulp and Transfer Molded Pulp processes and applications. Less cooking and less refining result in longer effective fiber length and apparently larger diameter fibers in the form of multiple fiber cells that remain bonded in the manner of the original straw or stalk. Fibers having multiple fiber cells bonded together in the manner of the original straw structure to form fibers with larger apparent diameter drain faster in wet laid processes. The advantages of the Soy Stalk fibers are their ability to be easily digested and refined, smooth and strong wet laid paper and paper board, molded pulp containers and trays and food processing containers, and tissue and toweling. Fiber coarseness and length may be adjusted to accommodate the needs of the particular end use.
[0023] A most surprising result is that mixtures of soy stalk fibers with wheat straw fibers produces a unique balance of properties not attainable with any single fiber type. When soy fibers are mixed with wheat fibers in ratios of about 5% to 95% of soy stalk fiber and about 95% to 5% wheat straw fiber, the resultant mixtures have more pleasing color for various applications. The mixtures of soy stalk fibers and wheat stalk fibers allow the fiber manufacturer and the end product manufacturer to obtain twice the amount of fiber available from any one fiber source since such as wheat or soy alone. Crops must be rotated annually and the normal practice is to rotate wheat with soy for soil quality retention. Therefore there is a greater supply of the mixtures than each fiber alone. Other fiber types such as wood fiber, synthetic fiber and other annual crop fibers may be added without departing from the scope of this invention when the soy to wheat ratio of about 5% to 95% soy and about 95% to 5% wheat is maintained.
[0024] Another aspect of the present invention is the use of annual crop fiber mixtures of soy stalk fibers and wheat straw fibers in absorbent products. It has been discovered that oat, wheat, soy, and other annual crops straws may be processed into fibers suitable for absorbent products such as baby and adult diapers, feminine hygiene products, and other absorbent products. The mixtures of soy fiber and wheat fiber produce surprising improvements over any single fiber; such improvements include pleasing color as well as increased supply due to crop rotation between soy and wheat.
[0025] The annual crops fibers of the present invention represent a “green” environmentally friendly fiber to replace wood pulp currently used. The annual crop fibers have less impact on the environment due to less chemicals used to digest, no bleaching, and use of waste agricultural crops instead of harvested trees or food products such as soy beans or corn. The fibers of the present invention for absorbent products have an optimum level of digestion and refining to produce fibers which have coarseness, diameter, and length suitable for wet laying and water drainage rate and which can be re-fiberized from a wet laid pulp sheet in a hammermill or other suitable fiberizing equipment. The optimum length and coarseness are suitable for absorbent products and may be used to produce quality fluff pulp comparable to Kraft wood pulp (southern Pine) currently extensively used in diapers and other absorbent products. The present fibers can be fiberized from wet fibers that have been dried in “crumb” form from a screw press, sheets or rolls from a paperboard machine, or other suitable process.
[0026] The fiber mixtures of the present invention have excellent absorbent properties compared to Kraft wood pulp currently used in diapers and other absorbent products. They are very hydrophilic and have high free swell capacity, capacity under load, water retention values, vertical wicking, softness, and high fluid acquisition rate which is equal to or superior to Southern pine fluff pulp. Laboratory tested samples of the soy stalk fibers in absorbent core produced the following results which are comparable to Kraft wood fluff pulp:
[0027] Soy Stalk Fiber:
Free swell, g/g=13.6 Capacity under 1 psi load, g/g=7.8 Vertical wicking capacity, g/g=11.8
[0031] Wheat Straw Fiber:
Free swell, g/g=17.6 Capacity under 1 psi load, g/g=11.1 Vertical wicking capacity, g/g=10.6
[0035] The fibers of the present invention can also be made hydrophobic by lower level of digestion and less removal of waxes and lignin from the fibers. The hydrophobic fibers are more suitable for molded pulp products that require water hold out for food service and other applications.
DESCRIPTION OF THE VIEWS OF THE DRAWINGS
[0036] Table 1 shows the data collected regarding the relationship of the wheat and soy fiber blend with respect to the Canadian Freeness. The Canadian freeness drops as the ratio of soy fibers in the blend are increased and the wheat fiber content is decreased.
[0037] FIG. 1 is a graph giving a visual display of the data in Table 1. The graph shows the Canadian freeness dropping as the ratio of soy to wheat increases.
[0038] FIG. 2 is a graph of the data collected showing the effect of the ratio of wheat fibers to soy fibers in the blend on the inclined wicking rate. As the soy fibers in the ratio are increased the inclined wicking rate decreases.
[0039] FIG. 3 is a graph of the data collected showing the effect of the ratio of wheat fibers and soy fibers on dry tensile strength. The data shows the dry tensile strength is statistically unaffected by the change in the ratio of the blend. The dry tensile strength is maintained regardless of the ratio of wheat fibers to soy fibers.
[0040] FIG. 4 is a graph of the data collected showing the effect of the ratio of wheat fibers to soy fibers in the blend on wet tensile strength. The wet tensile strength decreases as the ratio of soy fibers is increased in the blend.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] The fibrous product mixtures of the present invention are annual crop fibers from wheat straw and soy stalks processed to coarseness levels, diameter, and length suitable to the requirements of the end use. The soy and wheat fiber of the present invention can be digested, refined and converted to end products at the at the same process conditions which provides the unique ability to use a broad range of soy and wheat fiber mixtures of about 5% soy/95% wheat to about 95% soy/5% wheat by weight.
[0042] For absorbent products, the fibers have a high degree of wettability and water retention, a high coarseness and long fiber length achieved by medium level of digestion/cooking and low level of refining. Also, the fibers are re-fiberizable from a wet laid paper board or an oven dried particle or crumb. The term re-fiberizable is defined as the ability to be separated into individual fibers cells or fibers containing multiple fiber cells by suitable process equipment such as a hammer mill. These re-fiberized materials will have low knots or knits and will have the characteristics needed to airlay into absorbent pads with suitable capacity, wicking, fluid acquisition, pad integrity, and wettability. The re-fiberizing is performed in a typical diaper process hammermill or similar fiberizing equipment. Long textile fibers are not suitable for airlaying or mixing with SAP for diapers and other absorbent products due to lack of containment of the SAP in the very coarse and long, straight fibers that are not suitable for hammermilling into fluff pulp. These extremely long fibers would tend to tangle and jam hammermills and other fiberizing systems. For paper, paperboard, Molded Pulp, Transfer Molded Pulp, Slush Molded Pulp and Thermoformed Pulp applications and related products, the fiber mixtures have a range of coarseness, diameter, and fiber lengths to provide a unique balance of sheet smoothness and strength along with pleasing color, as well as increased supply availability. The fibers may be made to be hydrophobic for food handling applications through the addition of sizing agents and low levels of digestion. These properties are achieved by various levels of digestion/cooking and various level of refining to produce fibers having individual fiber cells and fibers containing multiple fiber cells bonded in the manner of the original straw or stalk and by the appropriate mixture of soy stalk fiber and wheat straw fiber.
[0043] Mixtures with enhanced properties contain about 5-95% soy stalk fibers and about 95-5% wheat straw fibers. Most preferable, the mixtures of about 70% wheat/30% soy to about 30% wheat/70% soy offer more enhanced benefits including but not limited to pleasing color and optimum coordination of use with available crop production and crop rotation.
[0044] Another embodiment of the present invention is paper, paperboard, tissue and toweling, and other related products comprising these fibers. Paper product may include writing paper, copy paper, magazine stock, newsprint, liner board, corrugated medium, compression molded paper dinner plates, paperboard, coated and uncoated freesheet, wet laid tissue and toweling and napkins. The annual crop fibers from wheat straw, and soy stalk may be present in these products in a ratio from about 5% to 95% soy stalk fiber and 95% to 5% wheat straw fiber by weight. Other fibers such as wood fiber, recycled paper, or synthetic fibers may be blended with the soy and wheat while maintaining the stated ratios of soy and wheat fibers without being outside the scope of this invention; however, other fiber additions may produce less optimum properties in the final product.
[0045] Another embodiment of the present invention is its use in the Thermoformed Pulp process and products including but not limited to food trays, clam shells, plates, cups, and bowls. Surprisingly, it has been discovered that the soy stalk and wheat straw fiber mixtures of the present invention provide significant benefits in the Thermoformed Pulp processes including, but not limited to, significant reduction or elimination of ragged or fuzzy molded part edges and significant reduction or elimination of steam bubbles in the molded part. It has been discovered that wheat straw fibers lose water rapidly during the heated drying of the molded part in the Thermoformed Pulp process; this causes gas bubbles to form in the final product which results in rejected parts. Mixing of soy stalk fibers with the wheat straw fibers even at about 5% level and up to about 95% level practically eliminates the gas bubble problem. It has also been discovered that the wheat fiber alone does not provide a smoothly trimmed (water spray trimming) part, but tends to have fuzzy or ragged edges which are unacceptable and have an unpleasant appearance. Surprisingly, the addition of soy fiber to the wheat even at about 5% level and up to about 95% level significantly improves the trimming and thereby provides smooth edges to the molded parts. The parts molded from mixtures of soy and wheat fibers have a more pleasing color than parts made from either fiber alone. The wheat fiber has a yellow color which is unpleasant in food applications and the soy fiber has a brown, unpleasant color as well. The mixtures of soy fiber and wheat fiber even at about 5% soy fiber and up to about 95% soy fiber by weight provide a pleasant tan color more suitable to food use applications. Also, the molded parts made from the mixtures feel smoother and have a more pleasant texture to them than parts made with either fiber alone. Another significant benefit of the soy fiber/wheat fiber mixtures is the slower water wicking rate provided by the soy fibers which is critical to food service applications for the molded products. The aforementioned benefits are apparent at mixtures containing from about 5% soy stalk fiber/95% wheat straw fiber to 95% soy stalk fiber/5% wheat straw fiber. More preferably the mixtures of this invention contain from about 10% soy stalk fiber/90% wheat straw fiber to about 90% soy stalk fiber/10% wheat straw fiber. Most preferably, the mixtures of the present invention contain from about 30% soy stalk fiber/70% wheat straw fiber to about 70% soy stalk fibers/30% wheat straw fibers. These benefits provided by the fibers and mixtures of the present invention also apply to Molded Pulp, Slush Molded Pulp, and Transfer Molded Pulp processes and products.
[0046] Molded Pulp or Molded Fiber are general terms known in the industry and refer to processes that convert a variety of fibers into a variety of shaped articles. The processes included in the Molded Pulp technology include Transfer Molded Pulp, Slush Molded Pulp, and Thermoformed Pulp. Fibers used in these processes include but are not limited to recycled paper, paper bags, paperboard, newsprint, annual crop fibers, and virgin and recycled cellulose wood fibers. Shaped articles include but are not limited to food service applications such as plates, bowls, clamshells, cups, trays and other beverage and food carriers; also, shaped articles may include urinal trays, egg cartons, and support packaging. Some articles are manufactured by compression molding paperboard sheets into plates, and bowls using matched male and female molds. Transfer Molded parts are mostly thin ( 1/16″ to 3/16″). The Transfer Molding Process uses fine wire mesh mold which is mated with a vacuum chamber that draws water through the mesh chamber with the mesh mold suspended above a liquid return pool. The fibrous slurry is sprayed from below onto the mold and then vacuum draws the slurry tightly against the mesh filling all gaps and spaces. When air through the mesh has been sufficiently blocked, then the excess slurry falls into the return pool for recycling and the mold advances to the drying process where the article is separated from the mold and dried in an oven. Thermoformed Pulp is the newest form of Molded Pulp and is the highest quality thin walled product. The process uses the “Cure-In-The-Mold” technology which makes a well-defined smooth surface. In this process, the article is formed by vacuum on a wire mesh mold which is submerged in a slurry of fiber. The formed article is then transferred to a heated forming mold which presses, densifies and dries the molded product. When the article is dry, it is then ejected from the heated mold as a finished product. Slush molding is used for thicker parts ( 3/16″ to ½″) such as support packaging.
[0047] Yet another embodiment of the present invention is the absorbent core for baby diapers, feminine hygiene products, adult incontinent products, training pants, and sanitary napkins, and also wipes, airlaid rollgoods or webs for use in diapers, wipes, toweling, diaper absorbent cores, and feminine hygiene products such as sanitary napkins. The yellow color of wheat straw fibers and the dark brown color of soy stalk fibers are undesirable in absorbent products and therefore, the mixture of soy stalk fibers and wheat straw fibers are desirable due to the pleasing tan color obtained with the mixture.
[0048] The fibrous product of the present invention is the mixture of soy stalk fibers and wheat straw fibers in the ratio of about 5% to 95% soy stalk fibers and about 95% to 5% wheat straw fibers by weight. Mixtures with enhanced properties contain about 5-95% soy stalk fibers and about 95-5% wheat straw fibers by weight. Most preferable, the mixtures of 70% wheat/30% soy to 30% wheat/70% soy offer more enhanced benefits including but not limited to pleasing color and optimum coordination of use with available crop production and crop rotation.
[0049] The fibrous product may also include other fibers such as wood pulp, recycled paper and paperboard and corrugated medium and liner board and the like as well as synthetic fibers such as rayon, nylon, polypropylene, polyethylene, and polyester, and annual crop fibers such as sugar cane, oats, corn, bagasse, cotton, and jute providing that the ratio of soy fiber to wheat fiber is in the ratio of about 5% to 95% soy fiber and about 95% to 5% wheat fiber.
[0050] The following examples further illustrate the present invention and its benefits as well as its unique features.
EXAMPLE #1
[0051] Harvested wheat straw was obtained in bale form and processed through a Hay Grinder with a 3 inch minus screen to provide chopped fiber. Fifty kilograms of chopped straw was placed in a digester at 10% consistency and 10% NaOH caustic by dry fiber weight. The mixture was then cooked at 190 degrees Fahrenheit for one hour. The digested fiber slurry was then refined using a 12″ Sprout Waldron double disc refiner set at minimum plate clearance. The refined fiber was then dewatered to about 25% solids using a screw press. The dewatered fiber was then diluted with water to 4% consistency. The product was then pumped through a pressure screen using a 0.20″ slotted screen; the accepts that passed though the screen were saved for use in making product and testing fiber and product properties reported in this application.
EXAMPLE #2
[0052] Harvested soy stalk was obtained in bale form and processed through a Hay Grinder with a 3 inch minus screen to provide chopped stalk. Fifty kilograms of chopped stalk was placed in a digester at 10% consistency and 10% NaOH caustic by dry fiber weight. The mixture was then cooked at 190 degrees Fahrenheit for one hour. The digested fiber slurry was then refined using a 12″ Sprout Waldron double disc refiner set at minimum plate clearance. The refined fiber was then dewatered to about 25% solids using a screw press. The dewatered fiber was then diluted with water to 4% consistency. The product was then pumped through a pressure screen using a 0.20″ slotted screen; the accepts that passed though the screen were saved for use in making product and testing fiber and product properties reported in this application
EXAMPLE #3
[0053] Laboratory hand sheets were prepared from the finished fibers of Examples #1 and #2 as follows: the wet slurries of wheat straw fiber, soy stalk fiber and mixtures of both fibers were weighed in a beaker and transferred to a disintegrator and processed for 500 revolutions. The slurry was then transferred to a hand sheet mold and wet laid into an 8″×8″ sheet at 140 grams per square meter basis weight. The sheets were then dried at 300 degrees Fahrenheit, and then pressed for one minute between polished steel plates. The following hand sheet compositions were prepared:
1. 100% wheat straw fiber 2. 100% soy stalk fiber 3. 95%wheat fiber/5% soy fiber 4. 75% wheat fiber/25% soy fiber 5. 50% wheat fiber/50% soy fiber 6. 25% wheat fiber/75% soy fiber 7. 35% wheat fiber/65% soy fiber.
[0061] The fiber slurries of Example #3 containing 100% wheat straw fiber, 100% soy stalk fiber, 75% wheat straw fiber/25% soy stalk fiber, and 50% wheat straw fiber/50% soy stalk fiber were tested for Canadian Freeness and the results are reported in FIG. 1 and Table 1.
[0062] The hand sheets from example #3 were then tested as follows:
1. Inclined wicking rate and capacity: 1″×4″ specimens were cut from the handsheets. The specimens were placed on a metal screen positioned at a 30 degree angle with the horizontal. Water was introduced to the bottom ¼″ of the specimen. The time for the water to wick to a height of 2″ on the specimen was recorded as the inclined wicking rate in seconds. These results are shown in FIG. 2 . 2. Dry tensile strength: specimens were cut from the hand sheets to ¼″ wide by 4″ long. The specimens were then clamped into holding fixtures with a 2″ span between the fixtures. One fixture was attached to a digital scale. The other fixture was manually pulled until the specimen failed and the load at failure was recorded as grams per inch of specimen width. The results are shown in FIG. 3 . 3. Wet tensile strength: specimens were cut from the hand sheets to ½″ wide by 4″ long. The specimens were then clamped into holding fixtures with a 2″ span between the fixtures. One fixture was attached to a digital scale. Three drops of water were applied with an eye dropper to wet the specimen at the center of the span. The other fixture was manually pulled until the specimen failed and the load at failure was recorded as grams per inch of specimen width. The results are shown in FIG. 4 . 4. Color: the 8″ by 8″ hand sheets were visually evaluated for,color. Color differences and color appeal were noted and subjectively evaluated.
[0067] The Canadian Freeness results are shown in Table 1 and FIG. 1 . These results show that the wheat straw fiber alone has a good freeness value of 480 and the soy stalk fiber alone has a low freeness value of 200 which may represent a limiting manufacturing rate in some wet laid applications. As the soy stalk fiber content increases, the freeness of the mixture is lowered. Above 50% by weight of soy stalk fiber there may be manufacturing limitations in high basis weight wet laid sheets. There may be no issue with low basis weight products such as tissue and toweling or wipes for instance. Experience with the Thermoformed Pulp Process indicates no effect of the low Canadian Freeness on the cycle time or product quality and it was found that the soy stalk fiber improves the water spray trimming function so that the products have clean edges. It was discovered that wheat straw fiber alone does not trim cleanly and the product edges are fuzzy and ragged.
[0068] The inclined wicking rate results are show in FIG. 2 . The wicking rate of the 100% wheat straw fiber is the highest and the rate decreases rapidly as soy stalk fiber is added. Although the decreased wicking may be an issue in absorbent products; it is a significant advantage in Thermoformed Pulp products for food service since these products require excellent water hold out. The decreased water wicking creates an opportunity for decreased use of water hold-out additives and decreased cost. The decreased wicking may also be advantageous in printing paper for ink hold-out, milk and juice carton, and coffee cups and other liquid holding containers produced from paperboard.
[0069] The dry tensile strength results are shown in FIG. 3 . These results indicate little or no difference in dry tensile strength between 100% wheat straw fiber, 100% soy stalk fiber and all combinations of wheat and straw fiber mixtures. This result confirms the ability to gain the benefits (crop supply coordination and color enhancement) of the soy stalk fiber and wheat straw fiber mixtures without sacrificing strength required in paperboard, related products fabricated from paperboard, and Thermoformed Pulp Products.
[0070] The wet tensile strength results are shown in FIG. 4 . The 100% soy stalk fiber has about 33% lower wet strength than 100% wheat straw fiber. However, the results indicate that at least 30% soy stalk fibers may be added without affecting the wet strength; above 40% soy stalk fiber by weight the wet strength decreases gradually as the level approaches 100% soy stalk fiber. The low wicking rate of the soy stalk fibers may help to alleviate any decrease in wet strength of the products since they are likely to absorb less water or at least absorb slower.
[0071] The color of the hand sheets of Example #3 were subjectively evaluated for color and shade appeal and pleasantness. The 100% wheat straw fiber sheets were yellow and were not appealing for use in absorbent products or food service items. The 100% soy stalk fiber sheets were dark brown and also did not have high appeal for absorbent products or food service items. However, the sheets containing mixtures of wheat straw fiber and soy stalk fiber were tan in color and had more appeal for absorbent products and food service items.
[0000]
TABLE 1
Canadian Freeness
Fiber
% Wheat
% Soy
Freeness
100
0
480
75
25
390
50
50
320
0
100
200
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This invention relates to annual crop straw and stalk fibers having properties suitable for use in paper, paperboard, and related products disposable paper plates, cups, and bowls, molded and thermoformed pulp products, disposable food handling containers, tissue and toweling, and absorbent products such as airlaid roll goods, wipes, diapers and feminine hygiene articles. Annual crop straw or stalk is the waste product from the harvesting of the food including soy, wheat, corn, rice, and oats. The food chain is not impacted by use of these stalks and straw. Currently, most of the straw or stalk is burned, tilled under for soil amendment, or otherwise disposed of. Use of this stalk or straw for paper, paperboard and related products, and absorbent products manufacture including any product made from cellulose fibers represents an opportunity to provide additional income to farmers and a green alternative to wood pulp and therefore conserve trees.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a recording apparatus, and more particularly to a recording apparatus capable of recording a video signal and an audio signal, and a regenerating apparatus capable of regenerating a video signal and an audio signal.
2. Related Background Art
For recording a video signal and an audio signal, there are already known cassette tape recorders and video tape recorders.
Also there has recently been developed a still video system capable of recording a still video signal and an audio signal on a magnetic sheet called a video floppy disk. In such still video system each of concentric tracks formed on the magnetic sheet can record a video signal of a field, or an audio signal of several tens of seconds compressed in time.
In such recording apparatus for recording a video signal and an audio signal, it is necessary, for the user, to be able to know in advance the time available for recording the audio signal, and, also in the course of use, preferable for the user to be able to confirm the remaining recording time. For this purpose the assignee of the present invention has already disclosed, in Japanese Patent Application No. 209311/1985, a technology for displaying the available recording time. Also in recording the video signal, it is desirable to provide a display related to the recording operation, such as the track position utilized for recording the video signal on the magnetic sheet. However, simultaneous display of these two data may not only increase the space required for display, thus leading to an increased cost, but may also cause confusion to the user.
Such drawbacks are also present in the regenerating apparatus.
SUMMARY OF THE INVENTION
A prime object of the present invention is to provide a recording apparatus which is free from the foregoing drawbacks and allows the user to know the time available for audio recording, with a simple structure.
Another object of the present invention is to provide a recording apparatus capable of displaying the time available for audio recording in a readily understandable manner, without the fear of confusion with other displays.
The above-mentioned objects can be achieved, according to a preferred embodiment of the present invention, by a recording apparatus for recording a video signal and an audio signal in the blocks of a recording medium, provided with display means for providing a display related to the recording operation in case of video signal recording, and a display of the elapsed recording time from the start of recording in case of audio signal recording.
In such embodiment, said display means provides a display concerning the recording operation in the case of video signal recording, and a display on the elapsed recording time in the case of audio signal recording.
Still another object of the present invention is to provide a regenerating apparatus allowing the user to know the available time for audio regeneration, with a simple structure.
Still another object of the present invention is to provide a regenerating apparatus capable of displaying the available audio regenerating time in a readily understandable manner, without the fear of confusion with other displays.
The above-mentioned objects can be achieved, according to a preferred embodiment of the present invention, by a regenerating apparatus capable of signal regeneration from a recording medium on which a video signal and an audio signal are recorded in the blocks thereof, provided with display means for providing a display concerning the regenerating operation in the case of video signal regeneration, and a display on the elapsed regenerating time from the start of regeneration in the case of audio signal regeneration.
In such regenerating apparatus, the display means provides a display on the regenerating operation in the case of video signal regeneration, and a display on the elapsed regenerating time in the case of audio signal regeneration.
Still another object of the present invention is to provide an apparatus equiped with display means capable, in recording or reproducing an information signal such as an audio signal in a compressed state with a predetermined compression rate, of displaying the state of such compression in an easily understandable manner.
Still another object of the present invention is to provide a process and means for displaying the audio recording or regenerating time, adapted for use in an audio record/regenerating apparatus meeting the still video standards.
The foregoing and still other objects, features and advantages of the present invention will become fully apparent from the following description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an embodiment of the present invention;
FIG. 2 is an external perspective view of the embodiment shown in FIG. 1;
FIGS. 3A (consisting of FIGS. 3A-1, 3A-2, 3A-3 and 3A-4) and 3B are flow charts showing the function of a main controller 20 shown in FIG. 1;
FIG. 4 is a plan view, showing a first display example of a display unit 24 shown in FIG. 1;
FIG. 5 is a plan view, showing a second display example of the display unit 24;
FIG. 6 is a plan view, showing a third display example of the display unit 24;
FIG. 7 is a flow chart illustrating another embodiment of the present invention;
FIGS. 8 and 9 are plan views showing other display examples of the display unit 24 in the execution of the sequence shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now the present invention will be clarified in detail by embodiments shown in the appended drawings.
In the following description there will be disclosed a record/regenerating apparatus capable of recording and regenerating, according to the still video format, a still video signal or audio signal of several tens of seconds compressed in time axis, on or from one of concentric tracks of a magnetic sheet as explained before, but the present invention is naturally applicable also to other record/regenerating apparatus for recording and regenerating an ordinary video signal or non-compressed audio signal, for example on or from an optical recording medium. Furthermore the present invention is applicable also to an apparatus designed exclusively for recording, or an apparatus designed exclusively for regeneration. FIG. 1 is a block diagram of an embodiment of the present invention, and FIG. 2 is an external perspective view thereof.
In FIGS. 1 and 2 there are shown a camera lens 1; a diaphragm 2 thereof; a shutter 3; a solid-state image sensor 4 for photoelectrically converting the light entering from an object through said lens 1, diaphragm 2 and shutter 3; a signal processing circuit 5 for effecting a clamp process, color separation process etc. on the signal from the image sensor 4; an FM modulation circuit 6 for FM modulating the signal processed by said signal processing circuit 5; a switching circuit 7 for selectively supplying a head 33 with the output of said FM modulating circuit 6 or of an FM modulating circuit 15 to be explained later, according to a signal from a main controller 20; a microphone 11 for audio input; a converter 12 for A/D conversion of said audio input; and a RAM 13 for time axis compression of which writing and reading operations are controlled by the main controller 20. The time-axis compression can be achieved by selecting mutually different writing and reading speeds for said RAM 13. Also the level of said compression can be regulated, in the present embodiment, by varying the sampling rate of the A/D converter 12. There are further shown a D/A converter 14 for D/A conversion of the read-out audio data; an FM modulating circuit 15; a switching circuit 7 for the video and audio signals, controlled by the main controller 20; a main controller 20 for controlling the diaphragm 2, the shutter 3, the RAM 13, switching circuits 7, 38, 40, a track position control circuit 21, a display controller 23, a motor 30 and other circuits, according to flow charts to be explained later; and a track position control circuit 21 for controlling the access position of the head 33 by controlling the rotation of a motor 31 according to the instruction from the main controller 20.
There is further shown a display controller 23 which drives a display unit 24, according to a signal from the main controller 20, in such a manner as to provide a display as shown in FIG. 4(i) in the case of video signal recording, or a display as shown in FIG. 4(ii) in the case of audio signal recording.
The display unit 24 is positioned on an upper face of the recording apparatus formed as a camera.
There are further shown a motor 30 for rotating a magnetic sheet 34; a motor 31 driven by the track position control circuit 21; a rack 32 engaging with a gear of the motor 31; a head 33 mounted on said rack 32, for recording the signal entered from the switching circuits 7, 38 on the magnetic sheet 34; a track 35 formed on the magnetic sheet 34; a differential phase shift keying (DPSK) circuit 36 for multiplex recording, with the video or audio signal to be recorded, of an ID signal which is released by the main controller 20 and which indicates the video or audio signal recording and the level of time-axis compression in case of audio signal recording; a recording amplifier 37 for amplifying the FM modulated signal for supply to the head 33; a switching circuit 38 for connecting either the recording amplifier 37 or a regenerating amplifier 39 to the head 33; a regenerating amplifier 39 for amplifying the signal regenerated by the head 33; a selector switch 40 for supplying the output of said regenerating amplifier 39 either to an A/D converter 48 in case of audio signal regeneration, or to an FM demodulating circuit 43 in case of video signal regeneration; an adder 41 for adding the signal to be recorded and the output of the DPSK circuit 36; an FM demodulating circuit 43 for FM demodulation of the signal regenerated by the regenerating amplifier 39; a regeneration process circuit 44 for effecting a clamping process etc. on the FM demodulated signal; an encoder 45 for converting the signal after regeneration process into a complex television signal such as NTSC signal; a monitor 46 for displaying the signal from the encoder 45; an FM demodulating circuit for FM demodulation of the output of the regenerating amplifier 47; a converter 48 for A/D conversion of the FM demodulated signal; a RAM 49 for storing the A/D converted signal; and a converter 50 for D/A conversion of the signal read from the RAM 49 by the main controller 20, with a time-axis expansion achieved by mutually different writing and reading speeds.
There are further shown a loudspeaker 51 for acoustic regeneration of the signal converted by the D/A converter 50; a filter 53 filtering the signal modulated by the DPSK circuit 36 and overlapped with the signal regenerated by the regenerating amplifier 39; a demodulating circuit 54 for DPSK demodulation of the output of said filter 53; a magnetic sheet detecting circuit 56 for detecting the presence of a magnetic sheet from the output of a photocoupler 56A, 56B; an envelope detecting circuit 57 for discriminating whether the track of the magnetic sheet 34 is already recorded so that the head 33 provides a regeneration output; and a cover openable for inserting the magnetic sheet 34.
There are further shown an external terminal 69 for example for releasing the signal regenerated from the magnetic sheet 34; a record/regeneration mode selector switch 101 for selecting the recording mode in the closed state or the regenerating mode in the open state; an audio/video mode selector switch 102 for example for selecting an audio signal recording mode in the closed state or a video signal recording mode in the open state; and an audio compression rate switch 103 for cyclically select the audio compression rate or the sampling rate of the A/D converter 12. An actuation of said switch 13 in the audio recording mode changes the display of the display unit 24 from the indication of a track number shown in FIG. 4(i) to a display of the available audio recording time shown in FIG. 4(ii), and successive actuations of said switch 103 cyclically change the display in the order of (ii), (iii), (iv) and (ii) shown in FIG. 4.
A release switch 104 has two strokes, and, when depressed to the second stroke, serves as a trigger switch in the recording mode, and as a switch for starting and stopping the regeneration in the regenerating mode.
An UP switch 105 moves the head 33 by a track toward the inside of the magnetic sheet, while a DOWN switch 106 moves said head 33 by a track toward the outside of the magnetic sheet.
Now reference is made to FIGS. 3A and 3B which are flow charts of the control sequence of the main controller 20 shown in FIG. 1, in order to explain the function of the above-explained embodiment of the present invention.
In the following is explained each step in said flow charts:
#1: When the release switch 104, shown in FIG. 2, is depressed to the first stroke, the output of the magnetic sheet detecting circuit 56 is discriminated, and the program proceeds to a step #2 if the magnetic sheet is absent, or to a step #3 if said sheet is present, with the activation of the motor 30.
#2: Initialize reset flag (IRQF) is reset to zero.
#3: The state of the switch 101 is checked to identify the recording mode or the regenerating mode, and the program proceeds to a step #4 or #51 respectively.
#4: There is made discrimination whether the flag IRQF is set, and the program proceeds to a step #26 or #5 respectively if said flag is set or not.
#5: The output of the magnetic sheet detecting circuit 56 is checked, and the program proceeds to a step #1 or #34 respectively when the magnetic sheet 34 is absent or present.
#6: The motor 31 is driven through the track position control circuit 21 in such a manner that the head 33 makes access to the 0-th track (a position outside of the 1st track by one track pitch).
#7: Discrimination is made whether the head 33 is at the 50th track or not, and the program proceeds to a step #12 or #8.
#8: This step is executed when the step #7 identifies that the head 33 is not positioned at the 50th track, and the head 33 is displaced inwards by a track.
#9: Discrimination is made whether the track on which the head 33 is positioned is already recorded, by switching the switching circuit 38 to the regenerating amplifier 39, effecting the regenerating operation for a short period and detecting the output of the envelope detecting circuit 57.
#10: If the step #9 identifies that said track is not yet recorded, a bit of a track memory corresponding to the number of the track where the head 33 is positioned is shifted to "0". For example, if the head 33 is positioned at the 10th track, a 10th bit of the track memory provided in the main controller 20 is shifted to "0".
#11: If the step #9 identifies that said track is already recorded, a bit of the track memory corresponding to the track number where the head 33 is positioned is shifted to "1".
#12: If the step #7 identifies that the head 33 is positioned at the 50th track, the recorded or non-recorded state of all the tracks on the magnetic sheet 34 is recorded in the track memory. Thus the flag IRQF is set and the program proceeds to a step #26. Said identification is made by the track position control circuit 21.
#26: If all the bits of the track memory are "1", indicating the absence of empty track, the flow proceeds to a step #27. On the other hand, if an empty track is available, the flow proceeds to a step #13.
#27: A mark, for example "PP" flashes on the display unit 24 through the display controller 23, thus indicating that the recording operation is not possible.
#13: The head 33 is moved to the outermost empty track on the magnetic sheet 34.
#14: The display unit 24 is controlled through the display controller 23 so as to display the number of the track where the head 33 is positioned.
#15: The state of the switch 102 is detected to identify the audio recording mode or the video recording mode, and the flow proceeds to a step #16 or #28 respectively.
#16: In case of the audio recording mode, the display unit 24 displays for example the available audio recording time as shown in FIG. 4(ii), instead of the track number. In this state the display controller 23 is so driven as the display on the display unit 24 to flash intermittently, indicating that the audio compression rate is regulable.
#17: Discrimination is made as to whether the audio compression rate setting switch 103 is turned on or not, and the flow proceeds respectively to a step #18 or #20.
#18: Discrimination is made as to whether the switch 103, identified as turned on in the step #17, is turned off, namely whether the operating finger has left said switch 103, and, if affirmative, the flow proceeds to a step #19.
#19: The count of the audio compression rate counter is increased by one.
The count of the audio compression rate counter is related with the display of the display unit 24 in the following manner.
Said counter is composed of a ring counter, of which count is stepwise increased and returns from "2" to "0" in response to each actuation of the audio compression rate setting switch 103. A count "0", "1" or "2" respectively provides a display as shown in FIG. 4(ii), (iii) or (iv).
The state shown in FIG. 4(ii) indicates that the audio time-compression rate is 1280 times and that the available audio recording time is 20 seconds, while the state in FIG. 4(iii) indicates that the audio time-compression rate is 640 times with the available audio recording time of 10 seconds, and the state in FIG. 4(iv) indicates that the audio time-compression rate is 320 times, with the available audio recording time of 5 seconds. A signal indicating said time-compression rate is recorded on the track in the form of the aforementioned ID signal, and the writing and reading speeds of the RAM's 13, 49 are controlled according to said time-compression rate.
#20: Discrimination is made as to whether the release switch 104 is depressed to the second stroke or not, and the flow proceeds respectively to a step #21 or #15.
#21: A count corresponding to the compression rate selected in the steps #16 to #20 is preset in the audio recording time counter. Said preset value is same as that displayed on the display unit 24.
#22: It is discriminated whether one second has elapsed. This step is repeated until the lapse of one second, after which the flow proceeds to a step #23.
#23: The count of the audio recording time counter is stepwise decreased. The display controller 23 controls the display unit 24 so as to display the count of the audio recording time counter. Thus, in response to the depression of the release switch over the second stroke, the display unit 24 indicates the available remaining time for audio recording. The display on the display unit 24 flashes in the selection of the audio compression rate in the steps #16-#19, but it is continuously lighted when the release switch 104 is turned on, thus indicating that the audio recording is proceeding.
#24: It is discriminated whether the count of the audio recording time counter is "0" or not, and the flow respectively proceeds to a step #25 or returns to the step #22.
#25: The switch 7 is connected to the FM modulating circuit 15 while the switch 38 is connected to the head 33. The audio signal stored in the RAM 13 is read at a high speed in such a manner that the audio signal stored in said RAM 13 can be recorded in one track, or that all the signal in the RAM 13 is read during one rotation of the magnetic sheet, and the time-compressed audio signal is recorded on the magnetic sheet 34.
In this step, a bit of the track memory corresponding to the track subjected to recording operation is shifted to "1".
The foregoing is the procedure when the audio recording mode is selected by the switch 102. In the following there will be explained the procedure when the video recording mode is selected by the switch 102.
#28: The audio compression rate counter is reset.
#29: In response to the detection that the release switch 104 has been depressed to the second stroke, the flow proceeds to a step #30, and, in absence of said detection the flow returns to the step #14.
#30: The diaphragm 2 is closed to a predetermined stop value according to the output of an unrepresented light measuring circuit.
#31: The shutter 3 is opened for a predetermined period to expose the image sensor 4 to the incoming light.
#32: There is discriminated whether an exposure time, determined from the output of said unrepresented light measuring circuit and the stop value of the diaphragm set in the step #30, and, after the lapse of said exposure time, the flow proceeds to a step #33.
#33: The shutter 3 is closed.
#34: The switch 7 is connected to the FM modulating circuit 6 while the switch 38 is connected to the head 33, and the image sensor 4 is activated to obtain photoelectrically converted signal, whereby the signal processed in the processing circuit 5, and FM modulated in the FM modulating circuit 6 is recorded by the head 33 on the magnetic sheet 34. In this step there is set a bit of the track memory corresponding to the track subjected to the recording operation.
In the above-explained recording modes, the display unit 24 indicates the available audio recording time when the audio recording mode is selected by the switches 101, 102, and the display on said display unit 24 flashes when the audio compression rate is regulable with the switch 103. Once the audio recording operation is started, the display unit 24 indicates the remaining available time for audio recording according to the time elapsed.
In the video recording mode, the display unit 24 indicates the number of the track on which the head 33 is positioned.
In the present embodiment, a single display unit is utilized for indicating the number of the track where the head 33 is positioned, the available audio recording time, and the data corresponding to the audio compression rate. However, it is also possible to construct the display unit 24 as shown in FIG. 5, so that the available audio recording time and the number of track where the head 33 is positioned are indicated by a single display unit while the data corresponding to the audio compression rate is displayed by another display unit.
The foregoing explains the procedure executed when the recording mode is selected by the record/regeneration mode selector switch 101. In the following there will be explained a procedure, branching from the step #3 and starting from a step #51, when the regenerating mode is selected by said switch 101.
#51: When the regenerating mode is set, there is discriminated whether the UP switch 105 is turned on or not, and the flow proceeds respectively to a step #52 or #53.
#52: The head 33 is shifted inwards by a track.
#53: There is discriminated whether the DOWN switch 106 is turned on or not, and the flow proceeds respectively to a step #54 or #56.
#54: The head 33 is shifted by a track outwards.
#55-1: The display unit 24 is so controlled as to display the track number.
#55-2: There is discriminated whether a regeneration flag is set or not, and the flow proceeds respectively to a step #57 or #56.
#56: There is discriminated whether the release switch 104 has been depressed to the second stroke. The flow returns to the start if said second stroke depression has not been made. If said depression has been made, a step #59 detects that said depression has been released, and the flow then proceeds to a step #57.
#57: The selector switch 38 is connected to the regenerating amplifier 39, and the demodulated ID signal is read by the filter 53 and the DPSK demodulating circuit 54. Also there is set a regeneration flag which is to be discriminated in a step #55-2.
#58: From the ID signal read in the step #57, there is discriminated whether audio signal recording has been made or not, and the flow proceeds respectively to a step #60 or #70.
#60: The display unit 24 is so controlled as to display the regenerating time according to the audio compression rate regenerated from said ID signal. There will be given a display, for example, as shown in FIG. 4(ii), (iii) or (iv) respectively for a compression rate of 1280 times, 640 times or 320 times.
#61: The switch 40 is connected to the FM demodulating circuit 47 to provide the signal regenerated by the head 33 to said circuit 47 and to store the regenerated audio signal in the RAM 13. The time required for said storage corresponds to the one cycle time of the magnetic sheet 34 and is very short in fact.
#62: The reading of the signal, stored in the RAM 13 in the step #61, is started with a speed corresponding to the audio compression rate, thereby regenerating the audio signal by the loudspeaker 51 or the monitor 46 through the D/A converter 50.
#63: The reading of the signal, stored in the RAM 13, is continued, and the lapse of one second is discriminated, and the flow proceeds to a step #64 after the lapse of one second.
#64: The display on the display unit 24 is decreased stepwise, thus indicating the remaining regenerating time of the audio signal.
#65: There is discriminated whether the signal reading from the RAM 13 has been completed or not, and the flow proceeds respectively to a step #71 or returns to the step #63. Then, if the step #71 identifies that the second stroke depression of the release switch 104 has not been made, the flow returns to the step #51. The reading and writing operations of the RAM 49 are controlled by the main controller 20, and the completion of signal reading is identified by the state of a read-out control counter provided in the main controller 20.
If the step #58 does not identify the audio recording operation, there is executed a flow starting from a following step #70:
#70: The selector switch 40 is shifted to the FM demodulating circuit 43. The signal regenerated by the head 33 is demodulated in said FM demodulating circuit 43, then processed in the regeneration process circuit 44, converted into a complex television signal by the encoder 45, and supplied to the monitor 46 connected to the external monitor terminals 69, for regeneration of the image.
#71: There is discriminated whether the release switch 104 has been turned on again, and, if not, the flow returns to the step #51 to repeat the above-explained procedure. Once the regenerating operation is started, the steps #56 and #59 are not executed, since the regeneration flag is set in the step #57. Thus, after said setting of the regeneration flag, the access position of the head 33 can be arbitrarily changed by the UP switch 105 or DOWN switch 106.
#72: If the release switch 104 is depressed to the second stroke, the regeneration flag is reset to interrupt the regenerating operation, and the flow returns to the start.
In the above-explained embodiment, the regenerating operation is started by the depression of the release switch 104 to the second stroke after the selection of the regenerating mode by the switch 101. The ID signal detected from the output of the head 33, of which access position is controlled by the UP switch 105 and the DOWN switch 106, is used for discriminating whether the track where the head 33 is positioned record video signal or audio signal, and the display unit 24 provides different displays according to the result of said discrimination. If audio signal is recorded, a display corresponding to the compression rate of said signal is given on the display unit 24.
Also in the regeneration of audio signal, the remaining regenerating time is automatically displayed with the progress of the audio regeneration.
Furthermore, in said embodiment, the lapse of audio recording time in the recording mode and the lapse of audio regenerating time in the regenerating mode are both displayed by the remaining time on a same display unit, but it is naturally possible also to represent the elapsed time of recording or regeneration. In essence, any mode of display capable of indicating the lapse of time is acceptable.
Also in said embodiment the display unit 24 is composed of seven-segment display elements of two digits, but it is also possible, as shown in FIG. 6, to construct the display unit 24 from scales 71, 73, display elements 74 such as light-emitting diodes, and display elements 70, 72 for indicating either of said scales. In this structure, in case of the audio recording or regenerating mode, the display element 72 is turned on, and the display elements 74 are turned on in succession from a position corresponding to an index "1" on the scale 73, or are all turned on at the beginning and are turned off in succession from a position "1" to a position "20", with the progress of the audio recording or regeneration. In the video recording or regeneration, the display element 70 is turned on, and a display element 74 is turned on, corresponding to an index 71 of a track number where the head 33 is positioned.
Also in said embodiment the elapsed time of audio recording or regeneration, the track number of video recording or regeneration, and the disabled recording state are indicated by the display unit 24, but it is also possible to provide a switch 107, connected to the main controller 20, for displaying the number of empty tracks and to execute a sequence shown in FIG. 7 when said switch is turned on.
In the following there will be explained a flow shown in FIG. 7, which is to be inserted between the steps #3 and #4 shown in FIG. 3A and is to be executed only when the recording mode is selected by the switch 101. In order to display the number of empty tracks also in the regenerating mode, the flow shown in FIG. 7 may be inserted between the steps #2 and #3 shown in FIG. 3A:
#80: Determine whether or not the empty track display switch 107 is turned on. In case of that it is determined that the switch is turned on, then go to the step #81. In case of not, then go to step #4.
#81: When the empty track display switch 107 is turned on, there is counted the number of unrecorded tracks, represented by the "0" bits in the track memory of the controller 20.
#82: The number of empty tracks counted in the step #81 is displayed on the display unit 24. Respectively corresponding to the display format shown in FIG. 4 or FIG. 5, there will be provided a display shown in FIG. 8 or FIG. 9, together with a message "unrecorded", signifying that the displayed number indicates the number of empty tracks.
#83: The flow waits for 2 seconds, in order to continue the display executed in the step #82.
#84: There is discriminated whether the empty track display switch 107 is turned on or not, and this step is repeated if said switch is turned on. If said switch is turned off, the flow proceeds to a step #85.
#85: The display on the display unit 24 is shifted to the display state in the step #3.
The embodiment of the flow shown in FIG. 7 allows one further to simplify the structure of the display unit 24, since the display of the number of empty tracks and the display of the elapsed recording or regenerating time are both made on the display unit 24.
In the foregoing embodiments the display unit 24 is used for multiple purposes, and there are employed additional messages such as "TR", "SEC", "UN-RECORDED" shown in FIGS. 4, 5, 8 and 9 or additional scales 71, 73 shown in FIG. 6 for indicating the nature of displayed information, but it is also possible to modify the format of display for this purpose, for example by employing different colors or modifying the positions of displayed data.
Also in the foregoing embodiments of FIGS. 4 and 5, the display is flashing in the setting of the audio compression rate but is continuous in the audio recording operation in order to distinguish these two states, but such distinguishing can be achieved also through a modification in the display format.
As explained in the foregoing, the embodiment of the present invention provides a recording apparatus allowing the user to know the lapse of time in audio recording with display of a simple structure without the fear of confusion.
Also the embodiment of the present invention provides a recording apparatus allowing the user to know the lapse of time in audio regeneration with display of a simple structure, without the fear of confusion.
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There is disclosed a recording or reproducing apparatus for recording video or audio signal on a recording medium with plural recording blocks or reproducing video or audio signal from such recording medium, equipped with a display unit for providing a display related to the recording or reproducing operation in the case of video signal recording or reproduction, or the elapsed recording or reproducing time from the start of recording or reproducing operation in the case of audio signal recording or reproduction.
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TECHNICAL FIELD
The present invention relates generally to telephone voice messaging systems. More particularly, the present invention relates to a system for detecting the presence of a message stored in a remote site and alerting a user to the presence of the stored message.
BACKGROUND OF THE INVENTION
Over the years, many types of telephone voice messaging systems have been developed. There are two general types of telephone voice messaging systems: local and remote. Both systems record and store voice messages from incoming telephone calls after a specified number of rings go unanswered. Typically, a local telephone voice messaging system is physically cabled to a local telephone set and stores telephone messages on a device near the local telephone set. A user commonly is alerted to the presence of stored messages by an indicator, such as a light, on the storage device itself. An example of a local telephone messaging system is a personal or home telephone answering machine.
In contrast, a remote telephone voice messaging system stores telephone messages at a site remote from the user. A remote telephone voice messaging system typically includes a central switchboard for intercepting telephone calls and storing messages. An example of an automated remote telephone voice messaging system is the system offered by a number of Regional Bell Operating Companies.
In a Regional Bell Operating Companies (RBOC) telephone voice messaging system, the telephone company automatically intercepts any telephone calls intended for a local telephone number which are not answered after a predetermined number of rings. Additionally, the RBOC system will intercept and store messages intended for a local telephone number that is busy. The telephone voice messaging system then records and stores any message at the telephone company office. The telephone voice messaging system alerts a user to the presence of stored messages by changing the dial tone of the user's telephone set to a unique tone. The user recognizes the tone by picking up the receiver of the telephone set and listening. The user then accesses the messages stored by the telephone company according to the prescribed procedures for that telephone voice messaging system.
The problem with current automated telephone voice messaging systems is that the procedure of checking the dial tone must be performed many times a day in order to ensure that the user is receiving their messages in a timely manner. Although relatively simple to implement for the telephone companies, the use of a special tone to alert users to stored messages is a time and labor intensive process for the system user. For system users who are physically challenged or handicapped, for example, frequent and consistent manual manipulation of the telephone set to check for stored messages may be very difficult.
At the heart of the problem with current automated telephone voice messaging systems is the lack of an external indicator to alert a user to the presence of stored messages. Users may not receive their messages in a timely manner unless they consistently remember to lift the telephone receiver and listen for the special tone. Users typically do not lift the telephone receiver and listen on a consistent basis without being prompted by a audible ring or visual reminder. For example, if a user has not been near their telephone set for an extended period of time, the user may not have a reason to lift the receiver and thus, would not receive their messages in a timely manner. As another example, when a message is left while the user is using the telephone set, the user would not know of the message unless the user remembered to lift the receiver a few moments after hanging up the receiver. Lifting the receiver just after completing a telephone call is awkward and not intuitive.
One solution to the lack of an external indicator is installing an external indicator, such as a light, directly on a telephone set. However, installation of a light directly on a telephone set requires significant technical expertise in dismantling and reconfiguring a telephone set. Uniform installation procedures for an external indicator are not possible because of the great variety of styles of telephone sets available. Depending upon the style of telephone set, the addition of an external indicator may not be aesthetically pleasing. Installation of a light on the telephone is not really a solution since there is no signal supplied by the telephone system that could turn it on.
For these reasons, an invention that could automatically check a remote telephone voice messaging system for stored messages in a consistent and timely manner, announce the presence of stored messages through an external indicator and, optionally, automatically connect the user to a stored message center upon entry of a predetermined command would minimize the time and manual effort required of the user of such a remote telephone voice messaging system. It would be advantageous if such an invention could be easily installed by a person without technical expertise and could be adaptable to any type of telephone set. It would also be desirable for such an invention to improve the performance of device which announces the messages stored by a remote telephone voice messaging system, while minimizing the number and complexity of required components and circuitry.
SUMMARY OF THE INVENTION
The present invention provides an automated local system for detecting a unique tone sent to a user's telephone set or telephone number by a remote telephone voice messaging system to indicate the presence of stored messages, alerting the user to the presence of any messages stored by the telephone voice messaging system as indicated by the tone without the need for any manual intervention by the user and, optionally, connecting the user to a remote message storage in response to the entry of a simple command by the user.
It is a primary objective of the present invention to provide a local system for detecting the presence of a unique tone indicating the presence of stored messages in a remote telephone voice messaging system occurs in a consistent, reliable and timely manner without the manual intervention of a user.
It is also an objective of the present invention to provide an easy-to-use, convenient system to notify a user of stored messages in a remote telephone voice messaging system.
It is a further objective of the present invention to provide a telephone message announcing system in a remote telephone voice messaging system that can detect the presence of stored messages without significantly interfering with the operation of the local telephone set.
It is also an objective of this invention to provide a telephone message announcing system in accordance with the present invention that minimizes the number and complexity of the components and circuitry of the device thereby enhancing performance and reducing costs.
These and other objectives of the present invention will become apparent with reference to the drawings, the detailed description of the preferred embodiment and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified schematic diagram depicting a telephone message announcing device, local telephone set and remote telephone voice messaging system in accordance with the present invention.
FIG. 2 is a block diagram of a telephone message announcing device in accordance with the present invention.
FIG. 3 is a flowchart depicting the message detection and announcement process of the present invention.
FIG. 4 is a flowchart depicting the optional message retrieval process of the present invention.
FIG. 5 is a timing diagram depicting the changing states of the telephone set, device, remote telephone voice messaging system and message indicator when the local telephone set initiates a telephone call and the system receives a telephone call while the local telephone set is in use.
FIG. 6 is a timing diagram depicting the changing states of the telephone set, device, remote telephone voice messaging system and message indicator after an unanswered telephone call has been answered by the telephone voice messaging system.
FIG. 7 is a timing diagram depicting the changing states of the telephone set, device, remote telephone voice messaging system and message indicator after a telephone call is answered by the user and the system receives a telephone call while the local telephone set is in use.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures, the preferred embodiment of the system of the present invention will be described. For purposes of this description, it is assumed that the reader is familiar with the basic telephony concepts and terminology.
Referring to FIG. 1, a telephone message announcing device 10 in accordance with the present invention (labeled as a call notifier) is operably connected to a local telephone set 12 and to a remote telephone voice messaging system 14 through a telephone line 15. The local telephone set 12 typically includes a cradle 16, numeric keypad 17 and receiver 18.
Referring to FIG. 2, the device 10 includes a hook relay circuit 20, logic circuitry 22, one or more tone detection circuits 24, 26, a code detection circuit 27, a current detection circuit 28, a code generation circuit 29, a power source 30 such as, for example, a battery or an AC adapter, an external message indicator interface 32 and an external message indicator 34. As described in greater detail hereinafter, the logic circuitry 22 includes various timing elements which synchronize the actions and processing of the logic circuitry 22. In the preferred embodiment, the logic circuitry 22, the tone detection circuits (referenced in the drawings as "stutter tone detect" and "ring detect" respectively) 24, 26, code detection circuit 27, current detection circuit (referenced in the drawings as "loop current detect") 28 and code generation circuit 29 are integrated in a customized monolithic microchip which minimizes the circuitry of the device 10. It will be understood by those skilled in the art that the various circuits 24, 26, 27, 28, 29 could also be implemented using discrete elements operably coupled to a microprocessor, for example, rather than to the logic circuitry 22.
Operation of the device 10 is best understood with reference to FIGS. 3-7. Referring to FIG. 5, the timing diagram illustrates the changes in the state of the local telephone receiver 18, the device 10, the remote telephone voice messaging system 14 and the external message indicator 34 for various sequences of events. Changes in state are indicated by the changes in the position of the horizontal lines for each component 18, 10, 14, 34 while concurrent time intervals 44-74 are indicated by the vertical dashed lines. The change in the state of the telephone voice messaging system 14 indicates the presence and absence of a message waiting tone. Referring to FIGS. 6 and 7, the timing diagrams are similar to the timing diagram of FIG. 5 with the additional illustration of the changes in the state of incoming telephone line 15. The change in the position of the horizontal line for the telephone line 15 indicates the presence or absence of a ring tone.
Referring again to FIG. 1, in operation, the device 10 is operably connected to telephone set 12 via standard telephone line 15 with a standard connector (not shown) at each terminal. One terminal connector is inserted in a corresponding receptor (not shown) on the telephone set 12 and the second terminal connector is inserted in a corresponding receptor (not shown) on the device 10 such that the device can detect whether the telephone set is in use or not.
The device is also operably coupled to the telephone voice messaging system 14 via a standard telephone line 15 with a standard connector (not shown) at the line terminal. The line terminal connector is inserted in a corresponding receptor (not shown) on the device 10 whereby the device 10 can detect the readiness of the telephone line 15 to accepting and sending calls and can detect any tones sent along the telephone line 15.
Use of the standard, uniform telephone line connectors ensure easy installation of the device. Because the device 10 as a freestanding unit, physically separate from the telephone set 12, installation of the device 10 does not interfere with the aesthetic appeal of any telephone set 12 and can be adapted for use with any telephone set 12 regardless of its style or form. In addition, the device 10 can be selectively positioned by the user in the local environment such that the indicator 34 is easily visible to the user.
Referring again to FIG. 2, in the preferred embodiment, the device 10 is powered by a battery or AC adapter 30 and controlled by the logic circuitry 22 so as not to interfere with the telephone line power. Alternatively, if permitted by local telephone company regulations, the device 10 could be configured to draw its power from the telephone line 15. The logic circuitry 22 analyzes the data obtained from the stutter tone detection circuit 24, the ring detection circuit 26, the code detection circuit 27 and the loop current detection circuit 28 and controls the operation of the device 10 based on the data obtained. With the exception of the stutter tone detection circuit 24 and the logic circuitry 22, all of the other circuitry 26, 27, 28, 29 operates in a conventional manner and is known to one skilled in the telephony art.
During operation, the loop current detect 28 indicates whether the telephone set 12 is on or off the hook. The device 10 uses the hook relay 20 to simulate the telephone set 12 being off hook when the device 10 tests the telephone line 15 for a message waiting tone or accesses the remote telephone voice messaging system 14. The loop current detection circuit 28 continually checks that the telephone line 15 is being used by the local telephone 12 and provides that information to the logic circuitry 22.
The preferred embodiment of the invention includes a ring tone detection circuit 26 for detecting when an incoming telephone call is ringing the telephone set 12, a stutter tone detection circuit 24 for detecting when the message waiting tone is detected, and a loop current detect circuit 28 for determining when the local telephone 12 is in use. Also, in the optional version, the preferred embodiment includes a code detection circuit 27 for detecting when the user enters a code to retrieve stored messages and a code generation circuit 29 for accessing the remote telephone voice messaging system 14 when the user wishes to retrieve stored messages. The code detection circuit 27 and code generation circuit 29 use standard DTMF codes in the preferred embodiment. The logic circuitry periodically actuates the hook relay 20, simulating the telephone off hook, and checks the stutter tone detection circuit 24 for the presence of the message waiting tone on the telephone line 15. It will be understood that the tone used to indicate a message stored at a remote telephone voice messaging system 14 may be any distinct tone that the telephone company has chosen to indicate messages have been stored for that user. In this embodiment, the message waiting tone is a stutter tone, as shown, for example, in FIGS. 5-7.
In the preferred embodiment, the code detection circuit 27 monitors the telephone line 15 in response to an off hook condition to test for the presence of a predetermined DTMF numeric code sequence transmitted from the local telephone numeric keypad 17. In response to the predetermined DTMF numeric code sequence, the logic circuitry 22 initiates the calling of the remote telephone voice messaging system 14 and entry of a preselected user password code via the code generation circuit 29.
The external message indicator 34 may be a light or a bell or a recorded beep or any combination thereof such that the indicator 34 preferably has at least two modes of operation. One indicator mode alerts the user to the presence of messages stored by the remote telephone voice messaging system. The second mode indicates the absence of messages stored by the remote telephone voice messaging system. The external message indicator interface 32, here labeled LED blinker, maintains the message indicator 34 in whichever mode is currently appropriate.
As is described in greater detail hereinafter, in the preferred embodiment of the present invention, the device 10 operates in two modes: a call detection mode and a continuous testing mode. The call detection mode is first initiated in response to the device 10 detecting that the user is utilizing the telephone set 12 or that the telephone set 12 is ringing with an incoming call. After the first initiation of the call detection mode, the call detection mode is set when the external message indicator 34 is turned on or the telephone set 12 is off hook.
While operating in the call detection mode, the device 10 performs at least two tests of the telephone line 15 for the presence of the message waiting tone. The first test is performed, for example, a few seconds after the event or series of events triggering the call detection mode have terminated in order to alert the user to messages that may have been stored while the user was on the line or to a message that were stored from an unanswered incoming telephone call. The second test is performed, for example, a few minutes after the first test to detect a message waiting tone that would not have been detected during the first test. A message waiting tone may not have been detected during the first test when, for example, the message being stored is very long and is in the process of being stored when the first test occurs or when, for example, an incoming telephone call is received while the device 10 is off hook during the first test. It will be understood that the chance of an incoming telephone call being received while the device 10 is off hook testing the telephone line 15 is greatly reduced because of the small amount of time, for example, less than ten seconds, that the device 10 is off hook.
In the preferred embodiment, the continuous testing mode is enabled when the device 10 has not detected a message waiting signal after completing the call detection mode tests and is disabled when the external message indicator 34 is turned on or the telephone set 12 is off hook. In an alternate embodiment, the continuous testing mode is disabled only when the telephone set 12 is off hook. If, for example, a remote telephone voice messaging system 14 permits retrieval of stored messages from remote telephone sets other than the local telephone set 12 and/or forwarding of calls to the remote telephone voice messaging system 14 without ringing the telephone set 12, then, in an alternate embodiment of the present invention, the device 10 would continue to test for the presence and absence of the message waiting tone and turn the external message indicator 34 off and on accordingly while operating in the continuous testing mode. The continuous testing mode would be disabled when the user utilized the local telephone set or an incoming telephone call was ringing the local telephone set.
As those skilled in the art will appreciate, the choice of the timing intervals between tests for presence of the message waiting tone may vary depending upon the event or series of events that triggers the need to check. For example, if an incoming telephone call was received while the user was taking a call and thus the receiver 18 was off hook, it is likely that the remote telephone voice messaging system 14 took a message and so a relatively short waiting period between the time the user hangs up the telephone receiver 18 and the device 10 tests for the message waiting tone may be preferable. On the other hand, a longer waiting period between tests as occurs when the device 10 operates in the continuous testing mode may be desirable when both incoming and outgoing telephone calls are infrequent.
Referring to FIG. 3, in the preferred embodiment, the device 10 begins (step 200) by testing whether the telephone set 12 is in use (step 202). If the telephone set 12 is in use, the device 10 checks whether the external message indicator 34 is on, indicating there is a message stored. In the preferred embodiment, shown, for example, in FIG. 3, the device 10 automatically turns the external message indicator 34 off when the local telephone set 12 goes off hook without ringing first (step 204). In the preferred embodiment, when the local telephone set 12 goes off hook without ringing first, it is assumed the user has picked up the local telephone set 12 and will hear the special dial tone. Once the user hangs up, the device 10 automatically checks the line 15. In an alternative embodiment of the present invention, the device 10 turns the external message indicator 34 off only in response to the user's entry of a predetermined indicator code.
If the telephone set 12 is not in use, the device 10 tests whether the telephone set 12 is ringing as indicated by the ring detection circuit 26 (step 206). If the telephone set 12 is ringing (step 206), then the device 10 waits for the telephone set 12 to stop ringing (step 208). If the telephone set 12 is not in use and is not ringing (steps 202, 206), no call has been received and so the device 10 continues testing in the manner described hereinafter until a call is received.
Once a call has been received, the device 10 waits for the call to end and tests the status of the telephone set 12 until the hook relay 20 indicates the telephone set 12 has been hung up (step 210). The device 10 waits for a first waiting period (step 212) and then tests whether the user has picked up the telephone receiver 18 to place a call during the first waiting period (step 214). In the preferred embodiment, the first waiting period is a few seconds though it is understood that the first waiting period may be of any length that would allow the telephone line 15 to clear and would provide the user with timely notice of their messages, particularly messages that may have been received while the user was taking a telephone call. If the local telephone receiver 18 has been picked up for placement of a call during the first waiting period, the device 10 repeats steps 202-212 until the user is no longer placing any calls.
Once the telephone set 12 is on hook, the device 10 tests the telephone line 15 for the message waiting tone (step 216) as indicated by the stutter tone detection circuit 24. If the message waiting tone is detected, the device 10 turns the message indicator 34 on to indicate stored messages (step 218).
If the message waiting tone is not detected, the device 10 waits for a predetermined second waiting period (step 220) before testing the telephone line 15 for the message waiting tone (step 222). In the preferred embodiment, the second waiting period is a few minutes in length though it is understood that the second waiting period may be of any length longer than the first waiting period that would provide the user with timely notice of their messages without significantly interfering with the operation of the telephone set 12. If the local telephone receiver 18 has been picked up for placement of a call during the second waiting period, the device repeats steps 202-220 until the telephone set is no longer off hook (step 224).
If the telephone set 12 does not become off hook during the second waiting period, the device 10 tests the telephone line 15 for the message waiting tone (step 222). If the message waiting tone is detected by the stutter tone detection circuit 24, the microprocessor activates the message indicator 34 via the message indicator interface 32 to indicate that there are stored messages at the telephone company office (step 226). The device 10 then enters the continuous testing mode in order to continually check the telephone line 15 for the message waiting tone indicating messages stored at the telephone company office (steps 202-224).
If no message waiting tone is detected by the stutter tone detection circuit 24, then the device 10 then initiates the continuous testing mode (step 228). Once the continuous testing mode is enabled, the device 10 waits for a predetermined third waiting period (step 230) before testing the telephone line 15 for the message waiting tone (step 232). In the preferred embodiment, the third waiting period is one hour though it is understood that the third waiting period may be of any length longer than the second waiting period that still would provide the user with timely notice of their messages. If the telephone set 12 is off hook during the third waiting period (step 234), the device 10 repeats steps. 202-230 until the telephone set 12 remains on hook during the third waiting period. In the preferred embodiment, the third waiting period is established on the assumption that the user is absent from the premises with the local telephone set 12 during the third waiting period and so monitoring need not occur as frequently thereby conserving the battery supply of the device 10 and decreasing the interference with the operation of the local telephone set 12.
If the telephone set 12 does not become off hook during the third waiting period, the device 10 continues to test the telephone line 15 for the message waiting tone until the message waiting tone is detected (steps 230, 232). In the preferred embodiment, once the message waiting tone is detected, the message indicator is set to indicate the presence of stored messages and the continuous testing mode is disabled (step 236). Next, the device begins the process anew (steps 202-236).
FIG. 4 depicts an alternative embodiment of step 210 of FIG. 3 featuring the optional message retrieval process of the present invention.
Referring to FIG. 4, the device 10 begins (step 238) the procedure to connect the user to the remote telephone voice messaging system 14 to retrieve the stored messages by detecting the user's entry of a predetermined numeric retrieval code on the keypad 17 of the telephone set 12 (step 242) during an off hook condition.
The device 10 tests for an off hook condition (step 240). If an off hook condition is detected, the device 10 then tests for the receipt of the numeric retrieval code by the logic circuitry 22 (step 242). If the device 10 receives the numeric retrieval code, the device 10 calls the telephone voice messaging system 14 using a prestored telephone number and sends a preselected user password to the telephone voice messaging system 14 (step 246). The entry of the user password initiates the user's access to the messages stored by the telephone voice messaging system 14. Once the user is linked to the telephone voice messaging system 14, the device 10 tests until the user hangs up the telephone set 12 (step 240), indicating the user has retrieved all the stored messages and then returns (step 244) to the next step as indicated in FIG 3. (step 212). In the preferred embodiment, the prestored telephone number and user password are stored in non-volatile EPROM such that the telephone number and user password can be modified, if, for example, the user should change telephone numbers due to a move or the like.
FIG. 5 shows a situation where the user places a call, alterating a busy signal on the telephone line 15. During this time the remote telephone voice messaging system 14 may take a message from an incoming call. Referring to FIG. 5, the initial state of each component is as follows: the receiver 18 is on hook, the device 10 is on hook, the telephone voice messaging system 14 has not generated any special tone on the telephone line 15 and the external indicator 34 is off. The first time period 44 begins when the user picks up the receiver 18 to make an outgoing telephone call so the receiver is off hook, the device 10 remains on hook, the telephone voice messaging system 14 generates a dial tone until dialing begins. The time period 44 ends when the user hangs up the receiver 18 so the receiver is now on hook.
In this sequence, the first waiting period is initiated when the user hangs up the receiver 18 and is terminated when the device 10 goes off hook in order to test the dial tone for the special message waiting tone (time interval 46). The telephone voice messaging system 14 will send either a regular dial tone (indicating no message waiting) or will send the special message waiting tone (time interval 48). If the special message waiting tone is not received, the device 10 will test again later as shown in FIG. 3. Once the device 10 is on hook and has detected a message waiting tone, the device 10 turns the external indicator 34 on and the external indicator 34 remains on (time interval 50) until the receiver 18 is again off hook (time interval 52).
FIG. 6 shows a situation where the local telephone 12 rings and there is no answer. After a pre-set number of rings with no answer, the remote telephone voice messaging system 15 may take a message. Referring to FIG. 6, the initial state (time interval 54) of each component is as follows: the telephone line 15 is ringing, the receiver 18 is on the hook, the device 10 is on hook, the telephone voice messaging system 14 has not generated the message waiting tone and the external indicator 34 is off. After the telephone line 15 stops ringing, the device 10 waits, for example, for the first waiting period to allow the telephone voice messaging system 14 to take a message and set the message waiting tone (time interval 56). After the first waiting period, the device 10 is off hook while checking for the message waiting tone (time interval 58). If the special message waiting tone is not received, the device 10 will test again later as shown in FIG. 3. Once the device 10 is on hook after detecting the message waiting tone, the device 10 turns the external indicator 34 on and the external indicator 34 remains on (time interval 60) until the receiver 18 is again off hook (time interval 62).
FIG. 7 shows a situation where the local telephone 12 rings and the user answers, generating a busy signal on the telephone line 15 so the telephone voice messaging system 14 may take a message while the telephone line 15 is busy. Referring to FIG. 7, the initial state (time interval 64) of each component is as follows: the telephone line 15 is ringing, the receiver 18 has just gone from on hook to off hook, the device 10 is on hook, the telephone voice messaging system 14 has not generated the message waiting tone and the external indicator 34 is off. Time internal 66 indicates the time the user is using the local telephone set 12 after taking the call. Time internal 68 indicates the time the device 10 waits before testing the telephone line 15 for the special message waiting tone. If a message is stored by the telephone voice messaging system 14, the telephone voice messaging system 14 generates the message waiting tone (time interval 68).
Once the user hangs up the receiver 18 and the receiver 18 is on hook, the device 10 waits, for example, for the first waiting period to allow the telephone voice messaging system 14 to take a message and set the message waiting tone (time interval 68). After the first waiting period, the device 10 is off hook while checking for the message waiting tone (time interval 70). Once the device 10 is on hook after detecting the message waiting tone, the device 10 turns the external indicator 34 on and the external indicator 34 remains on (time interval 72) until the receiver 18 is again off hook (time interval 74).
Although the description of the preferred embodiment has been presented, it is contemplated that various changes could be made without deviating from the spirit of the present invention. Accordingly, it is intended that the scope of the present invention be dictated by the appended claims, rather than by the description of the preferred embodiment.
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The local telephone message announcing device automatically checks a remote telephone voice messaging system for stored messages in a consistent and timely manner, announces the presence of stored messages through an external indicator and automatically connects the user to the stored messages upon entry of a predetermined command by the user. The device checks for the stored messages by detecting a unique tone sent to a user's telephone set or telephone number by the remote telephone voice messaging system to indicate the presence of stored messages. The detection occurs at predetermined time intervals whereby interference with the operation of the local telephone set is minimized. In addition, the device is easily installed by a person without technical expertise and can be adapted to any type of telephone set.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 10/177,683, filed Jun. 21, 2002, now pending, which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to hydroxamate derivatives of non-steroidal anti-inflammatory drugs (NSAIDs). Invention compounds have multiple uses, for example, as prodrugs of NSAIDs, dual inhibitors of cyclooxygenase (COX) and 5-lipoxygenase (5-LO), as anticancer agents (through promoting apoptosis and/or inhibiting matrix metalloproteinase enzymes (MMP)), and the like. In another aspect, the present invention relates to formulations containing invention compounds and methods for use thereof.
BACKGROUND OF THE INVENTION
[0003] A. NSAIDs
[0004] Despite the advent of modern pharmaceutical technology, many drugs still possess untoward toxicities which often limit the therapeutic potential thereof. For example, although n on- s teroid a nti- i nflammatory d rugs (NSAIDs) are a class of compounds which are widely used for the treatment of inflammation, pain and fever, NSAIDs (e.g., naproxen, aspirin, ibuprofen and ketoprofen) can cause gastrointestinal ulcers, a side-effect that remains the major limitation to the use of NSAIDs (see, for example, J. L. Wallace, in Gastroenterol. 112:1000-1016 (1997); A. H. Soll et al., in Ann Intern Med. 114:307-319 (1991); and J. Bjarnason et al., in Gastroenterol. 104:1832-1847 (1993)).
[0005] There are two major ulcerogenic effects of NSAIDs: (1) irritant effects on the epithelium of the gastrointestinal tract and (2) suppression of gastrointestinal prostaglandin synthesis. In recent years, numerous strategies have been attempted to design and develop new NSAIDs that reduce the damage to the gastrointestinal tract. These efforts, however, have largely been unsuccessful. For example, enteric coating or slow-release formulations designed to reduce the topical irritant properties of NSAIDs have been shown to be ineffective in terms of reducing the incidence of clinically significant side effects, including perforation and bleeding (see, for example, D. Y. Graham et al., in Clin. Pharmacol. Ther. 38:65-70 (1985); and J. L. Carson, et al., in Arch. Intern. Med., 147:1054-1059 (1987)).
[0006] It is well recognized that aspirin and other NSAIDs exert their pharmacological effects through the non-selective inhibition of cyclooxygenase (COX) enzymes, thereby blocking prostaglandin synthesis (see, for example, J. R. Van in Nature, 231:232-235 (1971)). There are two types of COX enzymes, namely COX-1 and COX-2. COX-1 is expressed constitutively in many tissues, including the stomach, kidney, and platelets, whereas COX-2 is expressed only at the site of inflammation (see, for example, S. Kargan et al. in Gastroenterol., 111:445-454 (1996)). The prostaglandins whose production is mediated by COX-1 are responsible for many of their physiological effects, including maintenance of gastric mucosal integrity.
[0007] Many attempts have been made to develop NSAIDs that only inhibit COX-2, without impacting the activity of COX-1 (see, for example, J. A. Mitchell et al., in Proc. Natl. Acad. Sci. USA 90:11693-11697 (1993); and E. A. Meade et al., in J. Biol. Chem., 268:6610-6614 (1993)). There are several NSAIDs presently on the market (e.g., rofecoxib and celecoxib) that show marked selectivity for COX-2 (see, for example, E. A. Meade, supra.; K. Glaser et al., in Eur. J. Pharmacol. 281:107-1 11 (1995) and Kaplan-Machlis, B., and Klostermeyer, B S in Ann Pharmacother. 33:979-88, (1999)). These drugs appear to have reduced gastrointestinal toxicity relative to other NSAIDs on the market.
[0008] On the basis of encouraging clinical as well as experimental data, the development of highly selective COX-2 inhibitors appears to be a sound strategy to develop a new generation of anti-inflammatory drugs. However, the physiological functions of COX-1 and COX-2 are not always well defined. Thus, there is a possibility that prostagladins produced as a result of COX-1 expression may also contribute to inflammation, pain and fever. On the other hand, prostagladins produced as a result of COX-2 expression have been shown to play important physiological functions, including the initiation and maintenance of labor and in the regulation of bone resorption (see, for example, D. M. Slater et al., in Am. J. Obstet. Gynecol., 172:77-82 (1995); and Y. Onoe et al., in J. Immunol. 156:758-764 (1996)), thus inhibition of this pathway may not always be beneficial. Considering these points, highly selective COX-2 inhibitors may produce additional side effects above and beyond those observed with standard NSAIDs, therefore such inhibitors may not be highly desirable.
[0009] Indeed, recent studies with first generation COX-2 inhibitors reveal that arthritic patients treated with rofecoxib had a five-fold higher risk of heart attack, compared to patients treated with naproxen (Wall St. Jrnl, 5/1/10). Thus, like aspirin, naproxen appears to exert cardioprotective effects, while selective COX-2 inhibitors do not. The reason why selective COX-2 inhibitors appear to cause elevated risk of heart attack has been studied (see Y. Cheng et al., in Science 296(19): 539-541 (2002)). Because of this potentially serious side effect of selective COX-2 inhibitors, there is still a need in the art for new NSAIDs (or derivatives thereof) with reduced gastrointestinal (GI) side effects.
[0010] B. Dual Inhibitors of Cyclooxygenase (COX) and 5-Lipoxygenase (5-LO)
[0011] The enzyme 5-LO is an iron-containing dioxygenase (see M. Gibian et al., in Bio-Org. Chem. 1: 117 (1977)) that catalyzes the first step of the biochemical pathway to convert arachidonic acid to leukotrienes. Leukotrienes are important mediators in inflammatory diseases including asthma, arthritis, psoriasis and allergy (see P, Sirois in Adv. Lipid Res. 21:79 (1995)). Inhibition of 5-LO is an important avenue for therapeutic treatment of these diseases.
[0012] Hydroxamates are well known to form strong complexes with transition metal ions including iron (see H. Kiehl in The Chemistry And Biochemistry Of Hydroxyamic Acids, Karger, Basel (1982)). Some hydroxamates have shown good inhibitory activity against 5-LO (See, for example, J. B. Summers et al., in J. Med. Chem. 33:992-998(1990); A. O. Stewart et al., in J. Med. Chem. 40: 1955-1968 (1997); and T. Kolasa et al., in J. Med. Chem. 40:819-824 (1997)).
[0013] As described above, NSAIDs are relatively non-specific COX inhibitors that commonly cause adverse effects, especially, gastrointestinal ulceration. A compound which provides inhibitory activities against both COX and 5-LO may provide improved anti-inflammatory activity with reduced NSAID-related side effects. Indeed, several research groups have studied dual inhibitors containing an hydroxamic acid group in their molecules (see T. Hidaka et al.,in Jpn. L. Pharmacol, 36: 77-85 (1984); H. Ikuta et al., in J. Med. Chem. 30:1995-1998 (1987); S. Wong et al., in Agents Actions 37:90-98(1992); P. C. Unangst et al., in J. Med. Chem. 37: 322-328 (1994); R. Richard L. et al., in J. Med. Chem. 39:246-252 (1996); and M. Inagak et al., in J. Med. Chem. 43:2040-2048 (2000)). In those studies, the molecule as an intact entity is designed to provide inhibitory activity against both COX and 5-LO. In general, however, these approaches have not proven to be very effective.
[0014] Accordingly, there remains a need in the art for compounds which are more effective for the treatment of various inflammatory diseases with reduced NSAID-related side effects.
[0015] C. Anticancer Drugs
[0016] From experimental models of carcinogenesis, it has become apparent that NSAIDs have cancer chemopreventive properties, although their application to human cancer and the extent of their benefits in the clinic is presently a matter of intensive investigation (see G. A. Piazza et al., in Cancer Research, 57: 2452-2459 (1997)). While the results have been explained by reference to different mechanisms, many experiments have shown that NSAIDs have the potential to induce apoptosis (see, for example, K. Lundholm et al., in Cancer Research 54:5602-5606(1994); B. M. Bayer et al., in Biochem. Pharma. 28:441-443(1979), and in The J. Pharma. And Experiment. Therapeutics 210:106 (1979); N. N. Mahmoud et al., in Carcinogenesis 19:876-91(1998); V. Hial et al., in The J . Pharma. And Experiment. Therapeutics 202:446-454 (1977); B. Bellosillo et al., in Blood 92: 1406-1414(1998); N. E. Hubbard et al., in Cancer letters 43:111-120(1988); L. Qiao et al., in Biochem. Pharma. 55:53-64(1998); and S. J. Shiff et al., in Experimental Cell Res. 222: 179-188(1996)).
[0017] Matrix metalloproteinases (MMPs), also called matrixines, are a family of structurally related zinc-containing enzymes that mediate the breakdown of connective tissue and are therefore targets for therapeutic inhibitors in many inflammatory, malignant and degenerative diseases (see M. Whittaker et al., in Chem. Rev. 99: 2735-2776 (1999)). Consequently a considerable amount of effort has been invested in designing orally active MMP inhibitors with the expectation that such agents will be able to either halt or slow the progression of diseases such as osteoarthritis, tumor metastasis, and corneal ulceration ( see M. Cheng et al ., 43: 369-380 (2000)). Since hydroxamate can form strong complexes with transition state metal ions including zinc, the vast majority of MMP inhibitors incorporate an hydroxamate group as the zinc binding ligand (see M. Whittaker et al., in Chem. Rev. 99: 2735-2776 (1999); B. Barlaam et al., 42:4890-4908(1999)).
[0018] Accordingly, incorporation of the hydroxamate functionality into pharmacologically active compounds may provide novel compounds with enhanced anti-cancer activity and/or a reduced side effect profile.
SUMMARY OF THE INVENTION
[0019] In accordance with the present invention, there are provided novel chemical entities which have multiple utilities, e.g., as prodrugs of NSAIDs; as dual inhibitors of cyclooxygenase (COX) and 5-lipoxygenase (5-LO); as anticancer agents (through promoting apoptosis and/or inhibiting matrix metalloproteinases (MMPs); as anti-diabetic agents; and the like. Invention compounds comprise a non-steroidal anti-inflammatory agent (NSAID), covalently linked via a suitable linker, to a hydroxamate. Invention compounds are useful alone or in combination with one or more additional pharmacologically active agents, and can be used for a variety of applications, such as, for example, treating inflammation and inflammation-related conditions; enhancing anti-inflammatory activity of NSAIDs; reducing the side effects associated with administration of anti-inflammatory agents; as anticancer agents (through promoting apoptosis and/or inhibiting matrix metalloproteinases (MMPs)); as anti-diabetic agents; and the like.
[0020] Invention compounds are conjugate compounds of NSAIDs and hydroxamates, covalently linked in such a way that they can be broken into two individual molecules in the circulation system to provide their own inhibitory activity against COX and 5-LO, respectively.
[0021] The NSAID component of invention compounds is capable of inducing apoptosis and the hydroxamate component is capable of inhibiting MMP. The two components are simultaneously administered as they are covalently linked, which in due course produces the original two components upon exposure to enzyme(s) in the circulatory system. Upon cleavage, the individual components are capable of contributing their cancer preventive activity with reduced NSAID-related side effects.
BRIEF DESCRIPTION OF THE FIGURES
[0022] [0022]FIG. 1 illustrates the total length of intestinal ulcers measured for rats treated with vehicle, diclofenac or equimolar invention compound 54.
[0023] [0023]FIG. 2 illustrates the total length of gastric lesion measured for rats treated with vehicle, diclofenac or equimolar invention compound 54.
[0024] [0024]FIG. 3 illustrates the inhibition of paw volume increase in the uninjected feet of Lewis rats in which arthritis was induced by injection of adjuvant into the footpad.
DETAILED DESCRIPTION OF THE INVENTION
[0025] In accordance with the present invention, there are provided compounds having the structure:
[0026] wherein:
[0027] X is C(O), C(O)O, S(O), S(O) 2 , C(S), C(O)S, C(S)S, C(S)O, and the like;
[0028] Y is O or S;
[0029] R 1 and R 2 are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl, alkoxy, substituted alkoxy, aryloxy, substituted aryloxy, heterocyclic, or substituted heterocyclic; or R 1 and R 2 together with N and X can form a cyclic moiety; and
[0030] D-C(O)— is derived from a non-steroidal anti-inflammatory drug (NSAID) bearing a free carboxyl group.
[0031] In a presently preferred embodiment of the invention, X is C(O) or S(O) 2 and Y is O.
[0032] In another presently preferred embodiment of the present invention, R 1 and R 2 are each independently alkyl, substituted alkyl, aryl, substituted aryl, alkoxy, or substituted alkoxy. Substituents on R 1 and/or R 2 , when optionally present, include optionally substituted alkyl, optionally substituted cycloalkyl, optionally substituted heterocyclic, optionally substituted aryl, optionally substituted heteroaryl, optionally substituted aryloxy, optionally substituted alkoxy, thioalkyl, hydroxyl, mercapto, alkylthio, alkylthioalkyl, halogen, trihalomethyl, cyano, nitro, nitrone, —C(O)H, carboxyl, alkoxycarbonyl, carbamate, sulfonyl, alkylsulfonyl, alkylsulfonylalkyl, sulfinyl, alkylsulfinyl, alkylsulfinylalkyl, sulfonamide, sulfuryl, amino, alkylamino, arylamino, aminosulfonyl, alkylaminosulfonyl, dialkylaminosulfonyl, amido, acyl, oxyacyl, —SO 3 M wherein M is H + , Li + , Na + , K + , NH 4 +, , and the like, or —PO 3 M wherein M is H + , Li + , Na + , K + , NH 4 + , and the like; or —OC(S)NR 3 , —OC(O)NR 3 , —C(S)NR 3 , —NR 3 C(S)R 3 , —NR 3 C(S)NR 3 , —OC(S)NR 3 , —NR 3 C(S)OR 3 , —C(S)OR 3 , —OC(S)R 3 , —OC(S)OR 3 , and the like, wherein R 3 is independently any of the substituents contemplated for R 1 and R 2 as defined herein.
[0033] NSAIDs contemplated for incorporation into invention compounds include aspirin (i.e., acetylsalicylic acid), diclofenac, naproxen, indomethacine, flubiprofen, sulindac, ibuprofen, benoxaprofen, benzofenac, bucloxic acid, butibufen, carprofen, cicloprofen, cinmetacin, clidenac, clopirac, etodolac, fenbufen, fenclofenac, fenclorac, fenoprofen, fentiazac, flunoxaprofen, furaprofen, furobufen, furafenac, ibufenac, indoprofen, isoxepac, ketoprofen, Ionazolac, metiazinic, mefenamic acid, meclofenmic acid, piromidic acid, salsalate, miroprofen, oxaprozin, oxepinac, pirprofen, pirozolac, protizinic acid, suprofen, tiaprofenic acid, tolmetin, zomepirac, and the like. Presently preferred NSAIDs contemplated for incorporation into invention compounds include acetylsalicylic acid, diclofenac, naproxen, indomethacine, flubiprofen, sulindac, ibuprofen, and the like.
[0034] As employed herein, “hydrocarbyl” comprises any organic radical wherein the backbone thereof comprises carbon and hydrogen only. Thus, hydrocarbyl embraces alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, aryl, alkylaryl, arylalkyl, arylalkenyl, alkenylaryl, arylalkynyl, alkynylaryl, and the like.
[0035] As employed herein, “substituted hydrocarbyl” comprises any of the above-referenced hydrocarbyl groups further bearing one or more substituents selected from hydroxy, alkoxy (of a lower alkyl group), mercapto (of a lower alkyl group), cycloalkyl, substituted cycloalkyl, heterocyclic, substituted heterocyclic, aryl, substituted aryl, heteroaryl, substituted heteroaryl, aryloxy, substituted aryloxy, halogen, trifluoromethyl, cyano, nitro, nitrone, amino, amido, —C(O)H, acyl, oxyacyl, carboxyl, carbamate, dithiocarbamoyl, sulfonyl, sulfonamide, sulfuryl, and the like.
[0036] As employed herein, “alkyl” refers to saturated straight or branched chain hydrocarbon radical having in the range of 1 up to about 20 carbon atoms. “Lower alkyl” refers to alkyl groups having in the range of 1 up to about 5 carbon atoms. “Substituted alkyl” refers to alkyl groups further bearing one or more substituents as set forth above.
[0037] As employed herein, “alkoxy” refers to —O-alkyl groups having in the range of 2 up to 20 carbon atoms and “substituted alkoxy” refers to alkoxy groups further bearing one or more substituents as set forth above.
[0038] As employed herein, “cycloalkyl” refers to a cyclic ring-containing groups containing in the range of about 3 up to about 8 carbon atoms, and “substituted cycloalkyl” refers to cycloalkyl groups further bearing one or more substituents as set forth above.
[0039] As employed herein, “cycloalkylene” refers to divalent ring-containing groups containing in the range of about 3 up to about 8 carbon atoms, and “substituted cycloalkylene” refers to cycloalkylene groups further bearing one or more substituents as set forth above.
[0040] As employed herein, “alkylene” refers to saturated, divalent straight or branched chain hydrocarbyl groups typically having in the range of about 2 up to about 12 carbon atoms, and “substituted alkylene” refers to alkylene groups further bearing one or more substituents as set forth above.
[0041] As employed herein, “oxyalkylene” refers to saturated, divalent straight or branched chain oxygen-containing hydrocarbon radicals typically having in the range of about 2 up to about 12 carbon atoms, and “substituted oxyalkylene” refers to oxyalkylene groups further bearing one or many substituents as set forth above.
[0042] As employed herein, “alkenyl” refers to straight or branched chain hydrocarbyl groups having at least one carbon-carbon double bond, and having in the range of about 2 up to 12 carbon atoms, and “substituted alkenyl” refers to alkenyl groups further bearing one or more substituents as set forth above.
[0043] As employed herein, “cycloalkenyl” refers to cyclic ring-containing groups containing in the range of 3 up to 20 carbon atoms and having at least one carbon-carbon double bond, and “substituted cycloalkenyl” refers to cycloalkenyl groups further bearing one or more substitutents as set forth above.
[0044] As employed herein, “alkenylene” refers to divalent straight or branched chain hydrocarbyl groups having at least one carbon-carbon double bond, and typically having in the range of about 1 up to 12 carbon atoms, and “substituted alkenylene” refers to alkenylene groups further bearing one or more substituents as set forth above.
[0045] As employed herein, “alkenylene” refers to divalent straight or branched chain hydrocarbyl groups having at least one carbon-carbon double bond, and typically having in the range of about 2 up to 12 carbon atoms, and “substituted alkenylene” refers to alkenylene groups further bearing one or more substituents as set forth above.
[0046] As employed herein, “alkynyl” refers to straight or branched chain hydrocarbyl groups having at least one carbon-carbon triple bond, and having in the range of about 2 up to 12 carbon atoms, and “substituted alkynyl” refers to alkynyl groups further bearing one or more substituents as set forth above.
[0047] As employed herein, “aryl” refers to aromatic groups having in the range of 6 up to 14 carbon atoms and “substituted aryl” refers to aryl groups further bearing one or more substituents as set forth above.
[0048] Aryloxy
[0049] As employed herein, “aryloxy” refers to —O-aryl groups having in the range of 6 up to 14 carbon atoms and “substituted aryloxy” refers to aryloxy groups further bearing one or more substituents as set forth above.
[0050] As employed herein, “heteroaryl” refers to aromatic groups having in the range of 4 up to about 13 carbon atoms, and at least one heteroatom selected from O, N, S, or the like; and “substituted heteroaryl” refers to heteroaryl groups further bearing one or more substituents as set forth above.
[0051] As employed herein, “alkylaryl” refers to alkyl-substituted aryl groups and “substituted alkylaryl” refers to alkylaryl groups further bearing one or more substituents as set forth above.
[0052] As employed herein, “arylalkyl” refers to aryl-substituted alkyl groups and “substituted arylalkyl” refers to arylalkyl groups further bearing one or more substituents as set forth above.
[0053] As employed herein, “arylalkenyl” refers to aryl-substituted alkenyl groups and “substituted arylalkenyl” refers to arylalkenyl groups further bearing one or more substituents as set forth above.
[0054] As employed herein, “alkenylaryl” refers to alkenyl-substituted aryl groups and “substituted alkenylaryl” refers to alkenylaryl groups further bearing one or more substituents as set forth above.
[0055] As employed herein, “arylalkynyl” refers to aryl-substituted alkynyl groups and “substituted arylalkynyl” refers to arylalkynyl groups further bearing one or more substituents as set forth above.
[0056] As employed herein, “alkynylaryl” refers to alkynyl-substituted aryl groups and “substituted alkynylaryl” refers to alkynylaryl groups further bearing one or more substituents as set forth above.
[0057] As employed herein, “arylene” refers to divalent aromatic groups typically having in the range of 6 up to 14 carbon atoms and “substituted arylene” refers to arylene groups further bearing one or more substituents as set forth above.
[0058] As employed herein, “aralkylene” refers to aryl-substituted divalent alkyl groups typically having in the range of about 7 up to 16 carbon atoms and “substituted aralkylene” refers to aralkylene groups further bearing one or more substituents as set forth above.
[0059] As employed herein, “aralkylene” refers to aryl-substituted divalent alkyl groups typically having in the range of about 7 up to 16 carbon atoms and “substituted aralkylene” refers to aralkylene groups further bearing one or more substituents as set forth above.
[0060] As employed herein, “aralkenylene” refers to aryl-substituted divalent alkenyl groups typically having in the range of about 8 up to 16 carbon atoms and “substituted aralkenylene” refers to aralkenylene groups further bearing one or more substituents as set forth above.
[0061] As employed herein, “aralkynylene” refers to aryl-substituted divalent alkynyl groups typically having in the range of about 8 up to 16 carbon atoms and “substituted aralkynylene” refers to aralkynylene group further bearing one or more substituents as set forth above.
[0062] As employed herein, “heterocyclic” refers to cyclic (i.e., ring-containing) groups containing one or more heteroatoms (e.g., N, O, S, or the like) as part of the ring structure, and having in the range of 3 up to 14 carbon atoms and “substituted heterocyclic” refers to heterocyclic groups further bearing one or more substituents as set forth above.
[0063] As employed herein, “heterocycloalkylene” refers to divalent cyclic (i.e., ring-containing) groups containing one or more heteroatoms (e.g., N, O, S, or the like) as part of the ring structure, and having in the range of 3 up to 14 carbon atoms and “substituted heterocycloalkylene” refers to heterocycloalkylene groups further bearing one or more substituents as set forth above.
[0064] As employed herein, “aroyl” refers to aryl-carbonyl species such as benzoyl and “substituted aroyl” refers to aroyl groups further bearing one or more substituents as set forth above.
[0065] As employed herein, “acyl” refers to alkyl-carbonyl species.
[0066] As employed herein, “halogen” refers to fluoride, chloride, bromide or iodide atoms.
[0067] As employed herein, reference to “a carbamate group” embraces substituents of the structure —O—C(O)—NR 2 , wherein each R is independently H, alkyl, substituted alkyl, aryl or substituted aryl as set forth above.
[0068] As employed herein, reference to “a dithiocarbamate group” embraces substituents of the structure —S—C(S)—NR 2 , wherein each R is independently H, alkyl, substituted alkyl, aryl or substituted aryl as set forth above.
[0069] As employed herein, reference to “a sulfonamide group” embraces substituents of the structure —S(O) 2 —NH 2 .
[0070] As employed herein, “sulfuryl” refers to substituents of the structure ═S(O) 2 .
[0071] As employed herein, “amino” refers to the substituent —NH 2 .
[0072] As employed herein, “monoalkylamino” refers to a substituent of the structure —NHR, wherein R is alkyl or substituted alkyl as set forth above.
[0073] As employed herein, “dialkylamino” refers to a substituent of the structure —NR 2 , wherein each R is independently alkyl or substituted alkyl as set forth above.
[0074] As employed herein, “alkoxycarbonyl” refers to —C(O)O-alkyl groups having in the range of 2 up to 20 carbon atoms and “substituted alkoxycarbonyl” refers to alkoxycarbonyl groups further bearing one or more substituents as set forth above.
[0075] As employed herein, reference to “an amide group” embraces substituents of the structure —C(O)—NR 2 , wherein each R is independently H, alkyl, substituted alkyl, aryl or substituted aryl as set forth above. When each R is H, the substituent is also referred to as “carbamoyl” (i.e., a substituent having the structure —C(O)—NH 2 ). When only one of the R groups is H, the substituent is also referred to as “monoalkylcarbamoyl” (i.e., a substituent having the structure —C(O)—NHR, wherein R is alkyl or substituted alkyl as set forth above) or “arylcarbamoyl” (i.e., a substituent having the structure —C(O)—NH(aryl), wherein aryl is as defined above, including substituted aryl). When neither of the R groups are H, the substituent is also referred to as “di-alkylcarbamoyl” (i.e., a substituent having the structure —C(O)—NR 2 , wherein each R is independently alkyl or substituted alkyl as set forth above).
[0076] As employed herein, “organosulfinyl” refers to substituents having the structure —S(O)-organo, wherein organo embraces alkyl-, alkoxy- and alkylamino-moieties, as well as substituted alkyl-, alkoxy- or alkylamino-moieties.
[0077] As employed herein, “organosulfonyl” refers to substituents having the structure —S(O) 2 -organo, wherein organo embraces alkyl-, alkoxy- and alkylamino-moieties, as well as substituted alkyl-, alkoxy- or alkylamino-moieties.
[0078] In accordance with another embodiment of the present invention, there are provided synthetic methods for the preparation of invention compounds. For example, invention compounds can be prepared as illustrated in SCHEME 1.
[0079] Thus, an NSAID bearing a free carboxyl group (or a carboxy-substituted NSAID) can be contacted with an appropriately substituted hydroxamic acid in the presence or absence of a catalyst (e.g., dimethylaminopyridine (DMAP)), and a suitable coupling agent (e.g., 1,3-dicyclohexylcarbodiimide (DCC)) under conditions suitable to form invention compounds shown in SCHEME 1.
[0080] Similarly, thiohydroxamate derivatives of NSAIDs can be prepared as illustrated in SCHEME 2.
[0081] Thus an NSAID bearing a free carboxyl group (or a carboxy-substituted NSAID) can be contacted with an appropriately substituted thiohydroxamate in the presence or absence of a catalyst (e.g. DMAP) and a suitable coupling agent (e.g. DCC) under conditions suitable to for invention compounds as shown in SCHEME 2.
[0082] Employing similar synthetic strategies, a variety of heterocycle-containing derivatives of NSAIDs can be prepared, as illustrated, for example, in SCHEMEs 3 and 4.
[0083] In accordance with yet another embodiment of the present invention, there are provided formulations containing invention compounds as described herein, in a pharmaceutically acceptable carrier. Optionally, invention formulations further comprise one or more additional pharmacologically active agents which are also effective for the treatment of the target indication. Exemplary pharmaceutically acceptable carriers include solids, solutions, emulsions, dispersions, micelles, liposomes, and the like. Optionally, the pharmaceutically acceptable carrier employed herein further comprises an enteric coating.
[0084] Pharmaceutically acceptable carriers contemplated for use in the practice of the present invention are those which render invention compounds (and optionally one or more additional pharmacologically active agents which are also effective for the treatment of the target indication) amenable to oral delivery, transdernal delivery, intravenous delivery, intramuscular delivery, topical delivery, nasal delivery, and the like.
[0085] Thus, formulations of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a micelle, a liposome, and the like, wherein the resulting formulation contains one or more of the compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enterable or parenteral applications. The active ingredient(s) may be compounded, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions and any other suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, manitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening, and coloring agents and perfumes may be used. The active compound(s) is (are) included in the formulation in an amount sufficient to produce the desired effect upon the process or disease condition.
[0086] Invention formulations containing the active ingredient(s) may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Formulations intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such formulations may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing the active ingredient(s) in admixture with non-toxic pharmaceutically acceptable excipients used may be, for example (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as maganesium stearate, steric acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed. They may also be coated by such techniques as those described in U.S. Pat. Nos. 4,256,108; 4,160,452; and 4,265,874, to form osmotic therapeutic tablets for controlled release.
[0087] In some cases, formulations contemplated for oral use may be in the form of hard gelatin capsules wherein the active ingredient is mixed with inert solid diluent(s), for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, for example, peanut oil, liquid paraffin, or olive oil.
[0088] Invention formulations may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids, naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
[0089] Invention formulations may also be administered in the form of suppositories for rectal administration of the drug. These formulations may be prepared by mixing the drug with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquefy and/or dissolve in the rectal cavity to release the drug. Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner.
[0090] Amounts effective for the particular therapeutic goal sought will, of course, depend on the severity of the condition being treated, the optional presence of one or more additional pharmacologically active agents which are also effective for the treatment of the target indication, the weight and general state of the subject, and the like. Various general considerations taken into account in determining the “effective amount” are known to those of skill in the art and are described, e.g., in Gilman et al., eds., Goodman And Gilman's: The Pharmacological Bases of Therapeutics, 8th ed., Pergamon Press, 1990; and Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Co., Easton, Pa., 1990, each of which is herein incorporated by reference.
[0091] The term “effective amount” as applied to invention compounds, means the quantity necessary to effect the desired therapeutic result, for example, a level effective to treat, cure, or alleviate the symptoms of a disease state for which the therapeutic compound is being administered, or to establish homeostasis. Since individual subjects may present a wide variation in severity of symptoms and each drug or active agent has its unique therapeutic characteristics, the precise mode of administration, dosage employed and treatment protocol for each subject is left to the discretion of the practitioner.
[0092] In accordance with still another embodiment of the present invention, there are provided methods for treating inflammation and inflammation-related conditions. Such methods comprise administering to a subject in need thereof an effective amount of at least one invention compound as described herein, optionally in conjunction with one or more additional pharmacologically active agents which are also effective for the treatment of the target indication.
[0093] Subjects contemplated for treatment in accordance with the present invention include mammals such as rodents, canines, felines, farm animals, primates, and the like, including humans.
[0094] Inflammation-related conditions contemplated for treatment in accordance with the present invention include arthritis (e.g rheumatoid arthritis, gouty arthritis, osteoarthritis, juvenile arthritis, systemic lupus erythematosus, spondyloarthopathies, and the like), gastrointestinal conditions (e.g., inflammatory bowel disease, Crohn's disease, gastritis, irritable bowel syndrome, ulcerative colitis, and the like), headache (e.g., migraine), asthma, bronchitis, menstrual cramps, tendinitis, bursitis, and the like.
[0095] As readily recognized by those of skill in the art, inflammation-related conditions are associated with a variety of conditions, such as, for example, vascular diseases, periarteritis nodosa, thyroidiris, aplastic anemia, Hodgkin's disease, sclerodoma, rheumatic fever, diabetes (e.g., type I, type II, etc.), myasthenia gravis, colorectal cancer, sarcoidosis, nephrotic syndrome, Behcet's syndrome, potymyositis, gingivitis, hypersensitivity, conjunctivitis, swelling occurring after injury, myocardial ischemia, and the like.
[0096] As readily recognized by those of skill in the art, a large number of pharmacologically active agents have been developed for treatment of the above-described indications. In accordance with the present invention, the effectiveness of many of these agents can be enhanced by administration in conjunction with invention compounds. For example, when invention compounds are employed for the treatment of diabetes, invention compounds can be administered in conjunction with one or more anti-diabetic compounds, such as, for example, insulin, metformin, acarbose, sulfonylureas, thiazolidine diones (e.g., rosiglitazone, piglitazone, and the like), and the like.
[0097] Similarly, invention compounds can be administered in conjunction with one or more anti-arthritic compounds, anti-asthmatic compounds, anti-neoplastic compounds, and the like.
[0098] When invention compounds are employed in conjunction with one or more additional pharmacologically active agents, the relative amounts of each active agent can vary widely, as can readily be determined by one of skill in the art. Typically the ratio of invention compound(s) to additional pharmacologically active agent(s) will fall in the range of about 1:10 up to about 10:1
[0099] In accordance with a further embodiment of the present invention, there are provided methods for reducing side effects associated with anti-inflammatory agents. Such methods comprise employing, for example, an effective amount of an invention compound as described herein.
[0100] In accordance with yet another embodiment of the present invention, there are provided methods for promoting apoptosis in a subject. Such methods comprise administering to the subject an effective amount of an invention compound as described herein, optionally in conjunction with one or more additional pharmacologically active agents which are also effective for the treatment of the target indication.
[0101] In accordance with a further embodiment of the present invention, there are provided methods of inhibiting the proliferation of a hyperproliferative mammalian cell in a subject in need thereof. Such methods comprise administering to the subject an effective amount of an invention compound as described herein, optionally in conjunction with one or more additional pharmacologically active agents which are also effective for the treatment of the target indication.
[0102] In accordance with a still further embodiment of the present invention, there are provided methods for the treatment of cancer and/or tumor diseases through both promoting apoptosis and inhibiting MMP enzymes. Such methods comprise administering to the subject an effective amount of an invention compound as described herein, optionally in conjunction with one or more additional pharmacologically active agents which are also effective for the treatment of the target indication.
[0103] In accordance with a still further embodiment of the present invention, there are provided methods for enhancing anti-inflammatory activity by the dual inhibition of cyclooxygenase and 5-lipoxygenase in a subject in need thereof. Such methods comprise administering to the subject an effective amount of an invention compound as described herein, optionally in conjunction with one or more additional pharmacologically active agents which are also effective for the treatment of the target indication.
[0104] The invention will now be described in greater detail with reference to the following non-limiting examples.
EXAMPLES
[0105] The syntheses described in Examples 1-14 are illustrated in SCHEME 5.
Example 1
[0106] Compound 13 (Scheme 5). A solution of diclofenac (1) (2.96 g, 10 mmol), acetohydroxamic acid ( 2 ) (0.75 g, 10 mmol), 4-dimethylaminopyridine (DMAP) (0.12 g, 1 mmol) and 1,3-dicyclohexylcarbodiimide (DCC, 2.16 g, 10 mmol) was stirred at 0° C. for 3.5 h. The reaction mixture was filtered and the solvent was evaporated. The residue was partially dissolved in ethyl acetate and filtered. The ethyl acetate solution was washed with 0.5 N HCl solution, Na 2 CO 3 solution and water. The organic solution was dried (Na 2 SO 4 ) and the solvent was evaporated. The residue was purified by column chromatography on a silica gel column using CH 2 Cl 2 and then 200:1 CH 2 Cl 2 /hexanes as eluents to give 0.39 g (11%) of compound 13 as a solid compound; 1 H NMR(CDCl 3 ) δ2.04 (s, 3H), 3.99 (s, 2H, 1H ex D 2 O), 6.55-6.57 (m, 2H), 6.97-7.00 (m, 2H), 7.13-7.16 (t, 1H), 7.26 (s, 1H), 7.32-7.34 (d, 2H), 9.35 (br, 1H, ex D 2 O); MS (ESI) m/z 353 (M) + .
Example 2
[0107] Compound 14 (Scheme 5). Compound 14 was synthesized from diclofenac (2.96 g, 10 mmol), compound 3 (1.05 g, 10 mmol), DMAP (0.12 g, 1 mmol) and DCC (2.06 g, 10 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 1.17 g (31%) of compound 14 as a white solid. 1 H NMR (CDCl 3 ) δ1.24 (t, 3H), 3.97 (d, 2H), 4.22 (q, 2H), 6.55-6.58 (m, 2H, 1H, ex D 2 O), 6.98 (t, 2H), 7.15 (t, 1H), 7.27 (d, 1H), 7.33 (d, 2H), 8.13 (s, 1H, ex D 2 O); MS (ESI) m/z 384 (M+H) + .
Example 3
[0108] Compound 15 (Scheme 5). Compound 15 was synthesized from diclofenac (1) (1.48 g, 5 mmol), compound 4 (0.68 g, 5 mmol), DMAP (0.12 g, 1 mmol) and DCC (1.03 g, 5 mmol) employing the procedure described in Example 1. The compound was purified by crystallization from CH 2 Cl 2 /hexanes to give 1.3 g (65%) of compound 15 as a white solid. 1 H NMR (CDCl 3 ) δ4.08 (s, 2H), 6.58-6.59 (m, 2H, 1H, ex D 2 O), 6.97-7.02 (m, 2H), 7.16 (t, 1H), 7.30-7.33 (m , 2H), 7.46 (t, 2H), 7.57 (t, 1H), 7.81 (d, 1H), 9.4 (br, 1H, ex D 2 O); MS (ESI) m/z 437.7 (M+Na) + .
Example 4
[0109] Compound 16 (Scheme 5). Compound 16 was synthesized from diclofenac (1) (1.48 g, 5 mmol), compound 5 (0.84 g, 5 mmol), DMAP (0.12 g, 1 mmol) and DCC (1.03 g, 5 mmol) employing the procedure described in Example 1. The compound was purified by crystallization from CH 2 Cl 2 /hexanes to give 0.93 g (42%) of compound 16 as a white solid. 1 H NMR (CDCl 3 ) δ3.97 (s, 2H), 5.19 (s, 2H), 6.53 (br, 1H, ex D 2 O), 6.57 (d, 1H), 6.96-7.00 (m, 2H), 7.16 (t, IH), 7.24 (d, 1H), 7.32-7.36 (m, 7H), 8.13 (s, 1H); MS (ESI) m/z 445.3 (M) + .
Example 5
[0110] Compound 17 (Scheme 5). Compound 17 was synthesized from diclofenac (1) (1.48 g, 5 mmol), compound 6 (1.04 g, 5 mmol), DMAP (0.12 g, 1 mmol) and DCC (1.03 g, 5 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 1.9 g (77%) of compound 17 as a white solid. 1 H NMR (CDCl 3 ) δ3.95 (s, 2H), 6.38 (br, 1H, ex D 2 O), 6.54 (d, 1H), 6.94-6.99 (m, 2H), 7.13 (t, 1H), 7.18-7.32 (m, 11H), 7.52 (d, 2H); MS (ESI) m/z 491.5 (M) + .
Example 6
[0111] Compound 18 (Scheme 5). Compound 18 was synthesized from diclofenac (1) (1.48 g, 5 mmol), compound 7 (0.58 g, 5 mmol), DMAP (0.12 g, 1 mmol) and DCC (1.03 g, 5 mmol) employing the procedure described in Example 1. The compound was purified by crystallization from CH 2 Cl 2 /hexanes to give 1.04 g (48%) of compound 18 as a white crystal. 1 H NMR (CDCl 3 )δ1.36 (s, 6H), 3.63 (s, 2H), 4.01 (s, 2H), 6.51 (s, 1H, ex D 2 O), 6.57 (d, 1H), 6.98 (t, 2H), 7.16 (t, 1H), 7.26-7.28 (m, 2H), 7.33 (d, 2H), 9.19 (s, 1H, ex D 2 O); MS (ESI) m/z 429 (M) + .
Example 7
[0112] Compound 8 (Scheme 5). To a solution of propionic acid (0.37 g, 0.37 ml, 5 mmol) and DMF (0.2 ml) in CH 2 Cl 2 , was added slowly oxalyl chloride (1.32 g, 0.92 ml, 10.25 mmol) at room temperature. The resulting solution was stirred at room temperature for 30 min. In a separate flask, to a solution of methylhydroxyamine hydrochloride (1.67 g, 20 mmol) in a mixed solvent of THF (10 ml) and H 2 O (1.5 ml) was added triethylamine (TEA) (4.2 ml, 30 mmol) at 0° C. and stirred for 20 min. The propionic acid-oxalyl chloride solution prepared above was slowly dripped into the methylhydroxylamine solution. Stirring of the resulting solution was continued at room temperature for 1 hour. A solution of 2N HCl (100 ml) was added to the reaction mixture. The solution was extracted three times with CH 2 Cl 2 . The CH 2 Cl 2 solution was dried with sodium sulfate (Na 2 SO 4 ) and the solvent was evaporated to give 80 mg (16%) of compound 7 as an oil. 1 H NMR (CDCl 3 ) δ1.19 (t, 3H), 1.62 (br, 1H, ex D 2 O), 2.35 (q, 2H), 3.33 (s, 3H); MS (ESI) m/z 103 (M) + .
[0113] Compound 19 (Scheme 5). Compound 19 was synthesized from diclofenac (1) (0.23 g, 0.8 mmol), compound 8 (0.08 g, 0.8 mmol), DCC (0.16 g, 0.8 mmol) and DMAP (0.06 g, 0.5 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 150 mg (30%) of compound 19 as a solid. 1 H NMR (CDCl 3 ) δ1.03 (t, 3H), 2.19 (q, 2H), 3.29 (s, 3H), 3.94 (s, 2H), 6.54 (br, 1H, ex D 2 O), 6.58 (d, 1H), 6.99-7.02 (m, 2H), 7.17 (t, 1H), 7.27 (s, 1H), 7.35 (d, 2H); MS (ESI) m/z 381.4 (M) + .
Example 8
[0114] Compound 9 (Scheme 5). A mixture of isopropylhydroxylamine hydrochloride and K 2 CO 3 in acetonitrile was stirred at room temperature for 2 h. A solution of isobutyl chloride in a 20 ml of CH 3 CN was dropped into the above mixture at 0° C. and then stirred at room temperature for 4 days. Water was added and the mixture was extracted four times with CH 2 Cl 2 . The organic phase was washed with brine and dried (Na 2 SO 4 ) and the solvent was evaporated to give 0.36 g (50%) of compound 9 as a pale yellow solid. 1 H NMR (CDCl 3 ) δ1.17 (d, 6H), 1.32 (d, 6H), 2,72 (m, 1H), 4.25 (m, 1H), 8.3 (br, 1H, ex D 2 O); MS (ESI) m/z 144.4 (M−1) + .
[0115] Compound 20 (Scheme 5). Compound 20 was synthesized from diclofenac (1) (0.23 g, 0.8 mmol), compound 9 (0.12 g, 0.8 mmol), DCC (0.16 g, 0.8 mmol) and DMAP (0.06 g, 0.5 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.3 g (88%) of compound 20 as a solid. 1 H NMR (CDCl 3 ) δ1.02 (d, 6H), 1.11 (d, 6H), 2.42 (m, 1H), 3.98 (s, 2H), 4.7 (m, 1H), 6.55 (br, 1H, ex D 2 O), 6.58 (d, 1H), 6.97-7.39 (m, 6H); MS (ESI) m/z 423.5 (M) + .
Example 9
[0116] Compound 10 (Scheme 5). Compound 10 was synthesized from propionic acid (0.74 g, 0.74 ml, 10 mmol), isopropylhydroxyamine hydrochloride (2.22 g, 20 mmol) and oxalyl chloride (0.92 ml, 1.32 g, 10.25 mmol) employing the procedure described in the first paragraph of Example 7. The reaction generated 0.3 g (23%) of compound 10 as an oil. 1 H NMR (CDCl 3 ) δ1.20 (m, 3H), 1.31 (m, 6H), 2.37 (q, 2H), 4.17 (m, 1H), 8.21 (br, 1H, ex D 2 O); MS (ESI) m/z 132.2 (M+1) + .
[0117] Compound 21 (Scheme 5). Compound 21 was synthesized from diclofenac (0.67 g, 2.2 mmol), compound 10 (0.3 g, 2.2 mmol), DCC (0.47 g, 2.3 mmol) and DMAP (0.04 g, 0.3 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.7 g (78%) of compound 21 as a pale yellow solid. 1 H NMR (CDCl 3 ) δ1.03 (t, 3H), 1.09 (d, 6H), 2.15 (q, 1H), 3.98 (s, 2H), 4.76 (br, 1H), 6.57 (br, 1H, ex D 2 O), 6.57 (d, 1H), 6.98-7.36 (m, 6H); MS (ESI) m/z 431.9 (M+H) + .
Example 10
[0118] Compound 11 (Scheme 5). Compound 11 was synthesized from (methylthio)acetic acid (1.06 g, 10 mmol), methylhydroxylamine hydrochloride (3.34 g, 40 mmol), and oxalyl chloride (1.84 ml, 20.5 mmol) employing the procedure described in the first paragraph of Example 7. The reaction generated 0.85 g (63%) of compound 11 as an oil. The compound was used to synthesize compound 22 without further purification.
[0119] Compound 22 (Scheme 5). Compound 22 was synthesized from diclofenac (1.84 g, 6.2 mmol), compound 11 (0.85 g, 6.2 mmol), DCC (1.36 g, 6.6 mmol) and DMAP (0.12 g, 1 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 and CH 2 Cl 2 /CH 3 OH (100/1) as eluents to give 0.91 g (36%) of compound 22 as a solid compound. 1 H NMR (CDCl 3 ) δ2.11 (s, 3H), 3.12(s, 2H), 3.35 (s, 3H), 3.96 (s, 2H), 6.47 (br, 1H, ex D 2 O), 6.58 (d, 1H), 6.98-7.35 (m, 6H); MS (ESI) m/z 413.5 (M) + .
Example 11
[0120] Compound 23 (Scheme 5). To a solution of compound 22 (0.98 g, 2.4 mmol) in 30 ml of acetone was added 3-chloroperoxybenzoic acid (m-CPBA) (1.03 g, 6 mmol) at 0° C. The resulting solution was stirred at 0° C. for 2 h. A solution of sodium bisulfite was added and stirred at 0° C. for 5 min. Water was added to the above solution and stirred for 2 hrs. The suspension was filtered and the solid was dissolved in CH 2 Cl 2 and purified by column chromatography on a silica gel column using CH 2 Cl 2 and CH 2 Cl 2 /MeOH (50/1) as eluents to give 0.59 g (55%) of compound 23 as a solid. 1 H NMR (CDCl 3 ) δ3.08 (s, 3H), 3.38 (s, 3H), 3.92 (s, 2H), 3.99 (s, 2H), 6.34 (br, 1H, ex D 2 O), 6.57 (d, 1H), 6.99-7.04 (q, 2H), 7.18 (t, 1H), 7.28 (d, 1H), 7.35 (d, 2H); MS (ESI) m/z 447.9 (M+H) + .
Example 12
[0121] Compound 24 (Scheme 5). To a solution of compound 22 (0.49 g, 1.2 mmol) in 30 ml of acetone was added 3-chloroperoxybenzoic acid (m-CPBA) (0.25 g, 1.42 mmol) at 0° C. The resulting solution was stirred at 0° C. for 2 h. A solution of sodium bisulfite was added and stirred at 0° C. for 5 min. Water was added to the above solution and stirred for 10 min. The mixture was extracted three times with CH 2 Cl 2 . The combined organic solution was washed with brine and dried (Na 2 SO 4 ). The solvent was evaporated and the residue was purified by column chromatography on a silica gel column using CH 2 Cl 2 and CH 2 Cl 2 /MeOH (50/1) as eluents to give 0.42 g (84%) of compound 24 as an oil. 1 H NMR (CDCl 3 ) δ264 (s, 3H), 3.34 (s, 3H), 3.55 (m, 1H), 3.58 (m, 1H), 3.98 (s, 2H), 6.44 (br, 1H, ex D 2 O), 6.57 (d, 1H), 7.01 (m, 2H), 7.18 (t, 1H), 7.28 (d, 1H), 7.33 (d, 2H); MS (ESI) m/z 451.5 (M+Na) + .
Example 13
[0122] Compound 12 (Scheme 5). Compound 12 was synthesized from benzylthioglycolic acid (1.82 g, 10 mmol), methylhydroxylamine hydrochloride (3.34 g, 40 mmol), oxalyl chloride (1.84 ml, 2.64 g, 20.5 mmol), TEA (8.4 ml, 6.06 g, 60 mmol) and DMF (0.4 ml, 10 mmol) employing the procedure described in the first paragraph of Example 7. The reaction generated 2.1 g (99%) of compound 12 as a pale yellow oil; The compound was used to make compound 25 without further characterization.
[0123] Compound 25 (Scheme 5). Compound 25 was synthesized from diclofenac (1) (2.96 g, 10 mmol), compound 12 (2.1 g, 10 mmol), DCC (2.06 g, 10 mmol) and DMAP (0.02 g, 0.2 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 3.6 g (74%) of compound 25 as an oil; 1 H NMR (CDCl 3 ) δ3.05 (s, 2H), 3.34 (s, 3H), 3.74 (s, 2H), 3.91 (s, 2H), 6.48 (br, 1H, ex D 2 O), 6.57-7.50 (m, 12H); MS (ESI) m/z 489.5 (M) + .
Example 14
[0124] Compound 26 (Scheme 5). Compound 26 was synthesized from compound 25 (0.97 g, 2 mmol) and m-CPBA (0.51 g, 2.1 mmol) employing the procedure set forth in Example 11. The compound was purified by crystallization from CH 2 Cl 2 /hexanes to give 0.62 g (60%) of compound 26 as a white crystal; 1 H NMR (CDCl 3 ) δ3.39 (s, 3H), 3.71 (s, 2H), 3.95 (s, 2H), 4.48 (s, 2H), 6.31 (br, 1H, ex D 2 O), 6.56-7.59 (m, 12H); MS (ESI) m/z 522.4 (M+H) + .
[0125] The syntheses described in Examples 15-28 are illustrated in SCHEME 6.
Example 15
[0126] Compound 27 (Scheme 6). A solution of hydroxylamine hydrochloride (1.38 g, 20 mmol) and TEA (4.2 ml, 3.03 g, 30 mmol) in a mixed solvent of 40 ml of THF and 6 ml of H 2 O was stirred at 0° C. for 15 min. A solution of p-toluenesulfonyl chloride (0.95 g, 5 mmol) in 10 ml of THF was dripped into the above solution at 0° C. The resulting solution was stirred at 0° C. for 2.5 h. Water (400 ml) was added and the solution was extracted with ethyl acetate twice. The combined organic solution was washed with H 2 O three times and dried (Na 2 SO 4 ). The solvent was evaporated and the residue was dissolved in CH 2 Cl 2 and cooled down to −10° C. to give white crystalline solid. The compound was dried to give 0.28 g (30%) of compound 27 as a white solid. 1 H NMR (CDCl 3 ) δ2.46 (s, 3H), 6.07 (d, 1H, ex D 2 O), 6.65 (d, 1H, ex D 2 O), 7.36 (d, 2H), 7.84 (d, 2H); MS (ESI) m/z 186.3 (M−H) − .
[0127] Compound 39 (Scheme 6). Compound 39 was synthesized from diclofenac (1) (0.44 g, 1.5 mmol), compound 27 (0.28 g, 1.5 mmol), DCC (0.31 g, 1.5 mmol) and DMAP (0.012 g, 0.1 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.23 g (33%) of compound 39 as an pale yellow solid. 1 H NMR (CDCl 3 ) δ2.21(s, 3H), 3.77 (s, 2H), 6.17 (s, 1H, ex D 2 O), 6.49 (d, 1H), 6.06-7.01 (q, 2H), 7.10-7.18(m, 4H), 7.32 (d, 2H), 7.68 (d, 2H), 8.98 (s, 1H, ex D 2 O); MS (ESI) m/z 451.5 (M+Na) + .
Example 16
[0128] Compound 28 (Scheme 6). Compound 28 was synthesized from p-toluenesulfonyl chloride (0.95 g, 5 mmol) and methylhydroxylamine hydrochloride (0.83 g, 10 mmol) employing the procedure described in the first paragraph of Example 15. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 to give 0.69 g (68%) of compound 28 as a white solid. 1 HNMR (CDCl 3 ) δ2.47 (s, 3H), 2.82 (s, 3H), 6.35 (s, 1H, ex D 2 O), 7.37 (d, 2H), 7.78 (d, 2H).
[0129] Compound 40 (Scheme 6). Compound 40 was synthesized from diclofenac (1) (0.3 g, 1 mmol) and compound 28 (0.2 g, 1 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.42 g (87%) of compound 40 as a white foam; 1 H NMR (CDCl 3 ) δ2.37 (s, 3H), 3.02 (s, 3H), 3.83 (s, 2H), 6.31 (br, 1H, ex D 2 O), 6.56 (d, 1H), 6.96-7.00 (m, 2H), 7.15-7.19 (m, 2H), 7.24 (s, 2H), 7.32 (d, 2H), 7.65 (d, 2H); MS (ESI) m/z 502.2 (M+Na) + .
Example 17
[0130] Compound 29 (Scheme 6). Compound 29 was synthesized from p-toluenesulfonyl chloride (0.95 g, 5 mmol) and isopropylhydroxylamine hydrochloride (1.2 g, 10 mmol) employing the procedure described in the first paragraph of Example 15. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.33 g (29%) of compound 29 as a white solid.
[0131] Compound 41 (Scheme 6). Compound 41 was synthesized from diclofenac (1) (0.42 g, 1.43 mmol), compound 29 (0.33 g, 1.43 mmol), DCC (0.3 g, 1.43 mmol) and DMAP (0.02 g, 0.2 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.39 g (54%) of compound 41 as pale yellow solid. 1 H NMR (CDCl 3 ) δ1.16 (d, 6H), 2.25 (s, 3H), 3.78 (s, 2H), 4.3 (m, 1H), 6.31 (br, 1H, ex D 2 O), 6.52 (d, 1H), 6.96-7.00 (m, 2H), 7.11-7.20 (m, 4H), 7.32 (d, 2H), 7.68 (d, 2H); MS (ESI) m/z 530.0 (M+Na) + .
Example 18
[0132] Compound 30 (Scheme 6). Compound 30 was synthesized from 4-methoxybenzenesulfonyl chloride (1.03 g, 5 mmol) and methylhydroxylamine hydrochloride (0.83 g, 10 mmol) ) employing the procedure described in the first paragraph of Example 15. The compound was purified by simple extraction to give 0.63 g (58%) of compound 30 as a white solid. 1 H NMR (CDCl 3 ) δ2.81 (s, 3H), 3.89 (s, 3H), 3.75 (s, 1H, ex D 2 O), 7.04 (q, 2H), 7.82 (q, 2H).
[0133] Compound 42 (Scheme 6). Compound 42 was synthesized from diclofenac (0.89 g, 3 mmol) and compound 30 (0.65 g, 3 mmol) employing the procedure described in Example 1. The compound was purified by chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.9 g (61 %) of compound 42 as a white solid. 1 H NMR (CDCl 3 ) δ3.02 (s, 3H), 3.81 (s, 3H), 3.84 (s, 2H), 6.31 (br, 1H ex D 2 O), 6.56 (d, 1H), 6.89 (d, 2H), 6.98 (q, 2H), 7.16 (q, 2H), 7.32 (d, 2H), 7.69 (d, 2H); MS (ESI) m/z 530.0 (M+Na) + .
Example 19
[0134] Compound 31 (Scheme 6). Compound 31 was synthesized from methanesulfonyl chloride (0.81 ml, 1.2 g, 10 mmol) and methylhydroxylamine hydrochloride (1.66 g, 20 mmol) employing the procedure described in the first paragraph of Example 15. The reaction generated 0.63 g (50%) of compound 31 as a white solid. 1 H NMR ( CDCl 3 ) δ2.94 (s, 3H), 3.05 (s, 3H), 6.91 (s, 1H, ex D 2 O); MS (ESI) m/z 148.2 (M+Na) + .
[0135] Compound 43 (Scheme 6). Compound 43 was synthesized from diclofenac (1.48 g, 5 mmol) and compound 31 (0.63 g, 5 mmol) employing the procedure described in Example 1. The compound was purified by crystallization using CH 2 Cl 2 /hexanes to give 1.47 g (73%) of compound 43 as a white solid. 1 H NMR (CDCl 3 ) δ2.91 (s, 3H), 3.17 (s, 3H), 3.94 (s, 2H), 6.47 (br, 1H, ex D 2 O), 6.59 (d, 1H), 6.98 (q, 2H), 7.16 (t, 1H), 7.26 (s, 1H), 7.34 (d, 2H); MS (ESI) m/z 403.5 (M) + .
Example 20
[0136] Compound 32 (Scheme 6). Compound 32 was synthesized from 4-nitrobenzenesulfonyl chloride (1.11 g, 5 mmol) and methylhydroxylamine hydrochloride (0.83 g, 10 mmol) employing the procedure described in the first paragraph of Example 15. Purification by extraction gave 0.6 g (52%) of compound 32 as an yellow solid.
[0137] Compound 44 (Scheme 6). Compound 44 was synthesized from diclofenac (0.76 g, 2.6 mmol), compound 32 (0.6 g, 2.6 mmol), DCC (0.62 g, 3 mmol) and DMAP (0.02 g, 0.2 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.97 g (73%) of compound 44 as a pale yellow solid. 1 H NMR (CDCl 3 ) δ3.11 (s, 3H), 3.83 (s, 2H), 6.15 (br, 1H, ex D 2 O), 6.54 (d, 1H), 6.98-7.04 (m, 2H), 7.16-7.26 (m, 2H), 7.32 (d, 2H), 7.84 (q, 2H), 8.19 (q 2H); MS (ESI) m/z 511 (M+H) + .
Example 21
[0138] Compound 33 (Scheme 6). Compound 33 was synthesized from ethanesulfonyl chloride (1.28 g, 10 mmol) and methylhydroxylamine hydrochloride (0.83 g, 10 mmol) employing the procedure described in the first paragraph of Example 15. The compound was purified by simple extraction to give 0.97 g (70%) of compound 33 as a white oil. 1 H NMR (CDCl 3 ) δ1.46 (t, 3H), 3.08 (s, 3H), 3.18 (q, 2H), 6.49 (s, 1H, ex D 2 O).
[0139] Compound 45 (Scheme 6). Compound 45 was synthesized from diclofenac (1.95 g, 6.6 mmol), compound 33 (0.92 g, 6.6 mmol), DCC (1.36 g, 6.6 mmol) and DMAP (0.12 g, 1 mmol) employing the procedure described in Example 1. The compound was purified by crystallization from CH 2 Cl 2 /hexanes to give 2.1 g (76%) of compound 45 as a white solid. 1 H NMR (CDCl 3 ) δ1.36 (t, 3H), 3.02 (q, 2H), 3.17 (s, 3H), 3.92 (s, 2H), 6.5 (br, 1H ex D 2 O), 6.58 (d, 1H), 7.00 (t, 2H), 7.16 (t, 1H), 7.26 (q, 1H), 7.34 (d, 2H); MS (ESI) m/z 417.4 (M) + .
Example 22
[0140] Compound 34 (Scheme 6). Compound 34 was synthesized from 3-(trifluoromethyl)benzenesulfonyl chloride (1.22 g, 5 mmol), methylhydroxyamine hydrochloride (0.83 g, 10 mmol) employing the procedure described in the first paragraph of Example 15. The compound was purified simply by extraction to give 0.65 g (51%) of compound 34 as a solid.
[0141] Compound 46 (Scheme 6). Compound 46 was synthesized from diclofenac (0.74 g, 2.5 mmol), compound 34 (0.65 g, 2.5 mmol), DCC (0.51 g, 2.5 mmol) and DMAP (0.02 g, 0.2 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.46 g (35%) of compound 46 as a white solid; 1 H NMR (CDCl 3 ) δ3.05 (s, 3H), 3.85 (s, 2H), 6.27 (br, 1H, ex D 2 O), 6.57 (d, 1H), 6.97-7.01 (q, 2H), 7.17-7.18 (m, 2H), 7.32 (d, 2H), 7.60 (t, 1H), 7.88 (d, 2H), 8.14 (s, 1H); MS (ESI) m/z 533.7 (M) + .
Example 23
[0142] Compound 35 (Scheme 6). Compound 35 was synthesized from butylsulfonyl chloride (1.56 g, 10 mmol) and methylhydroxylamine hydrochloride (0.83 g, 10 mmol) employing the procedure described in the first paragraph of Example 15. The compound was purified by simple extraction to give 1.46 g (87%) of compound 35 as a white solid. 1 H NMR ( CDCl 3 ) δ0.97 (t, 3H), 1.50 (m, 2H), 1.88 (m, 2H), 3.06 (s, 2H), 3.13 (t, 2H), 6.80 (br, 1H, ex D 2 O).
[0143] Compound 47 (Scheme 6). Compound 47 was synthesized from diclofenac (2.58 g, 8.7 mmol), compound 35 (1.46 g, 8.7 mmol), DCC (1.79 g, 8.7 mmol) and DMAP (0.1 2 g, 1 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 /Hexanes as an eluent to give 2.1 g (54%) of compound 47 as a pale yellow solid. 1 H NMR (CDCl 3 ) δ0.85 (t, 3H), 1.32 (m, 2H), 1.77 (m, 2H), 2.95 (t, 2H), 3.16 (s, 3H), 3.92 (s, 2H), 6.54 (br, 1H, ex D 2 O), 6.58 (d, 1H), 7.00 (m, 2H), 7.16 (t, 1H), 7.26 (d, 1H), 7.36 (d, 2H); MS (ESI) m/z 478.4 (M+Na) + .
Example 24
[0144] Compound 36 (Scheme 6). Compound 36 was synthesized from 2-mesitylenesulfonyl chloride (2.18 g, 10 mmol) and methylhydroxylamine hydrochloride (0.83 g, 10 mmol) employing the procedure described in the first paragraph of Example 15. The compound was purified by simple extraction to give 1.5 g (66%) of compound 36 as a white solid. 1 H NMR ( CDCl 3 ) δ2.31 (s, 3H), 2.66 (s, 6H), 3.02 (s, 3H), 6.98(s, 1H); MS (ESI) m/z 252.5 (M+Na) + .
[0145] Compound 48 (Scheme 6). Compound 48 was synthesized from diclofenac (1) (1.93 g, 6.5 mmol), compound 36 (1.5 g, 6.5 mmol), DCC (1.33 g, 6.5 mmol) and DMAP (0.12 g, 1 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 2.84 g (86%) of compound 48 as an pale yellow solid. 1 H NMR (CDCl 3 ) δ1.96 (s, 3H), 2.67 (s, 6H), 3.21 (s, 3H), 3.51 (s, 2H), 6.21 (br, 1H, ex D 2 O), 6.44 (d, 1H), 6.77 (s, 2H), 6.90 (t, 1H), 6.98 (t, 1H), 7.09 (t, 1H), 7.33 (d, 2H); MS (ESI) m/z 507.0 (M) + .
Example 25
[0146] Compound 37 (Scheme 6). Compound 37 was synthesized from propanesulfonyl chloride (1.42 g, 10 mmol) and methylhydroxylamine hydrochloride (0.83 g, 10 mmol) employing the procedure described in the first paragraph of Example 15. The compound was purified by simple extraction to give 1.35 g (88%) of compound 37 as a white oil. 1 H NMR ( CDCl 3 ) δ1.09 (t, 3H), 1.94 (m, 2H), 3.09 (s, 3H), 3.11 (t, 2H); MS (ESI) m/z 176.2 (M+Na) + .
[0147] Compound 49 (Scheme 6). Compound 49 was synthesized from diclofenac (1) (2.53 g, 8.55 mmol), compound 37 (1.31 g, 8.55 mmol), DCC (1.79 g, 8.7 mmol) and DMAP (0.12 g, 1 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 2.0 g (88%) of compound 49 as a pale yellow solid. 1 H NMR (CDCl 3 ) δ0.95 (t, 3H), 1.83 (m, 2H), 2.92 (t, 2H), 3.16 (s, 3H), 3.92 (s, 2H), 6.53 (br, 1H, ex D 2 O), 6.57 (d, 1IH), 7.01 (t, 2H), 7.16 (t, 11H), 7.26 (d, 11H), 7.35 (d, 2H); MS (ESI) m/z 431.8 (M+H) + .
Example 26
[0148] Compound 38 (Scheme 6). Compound 38 was prepared from 2-mesitylenesulfonyl chloride (2.18 g, 10 mmol), hydroxyamine hydrochloride (1.38 g, 20 mmol) employing the procedure described in the first paragraph of Example 15. The compound was purified by column chromatography on a silica gel column to give 1.07 g (50%) of the compound 38 as a white solid. 1 H NMR (CDCl 3 ) δ2.26 (s, 3H), 3.32 (s, 6H), 9.24 (d, 1H, ex D 2 O), 9.41 (d, 1H, ex D 2 O).
[0149] Compound 50 (Scheme 6). Compound 50 was prepared from diclofenac (1) (0.55 g, 1.85 mmol), compound 38 (0.4 g, 1.85 mmol), DCC (0.38 g, 1.85 mmol) and DMAP (0.12 g, 1 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.5 g (55%) of compound 50 as a pale yellow solid. 1 H NMR (CDCl 3 ) δ2.09 (s, 3H), 2.63 (s, 6H), 2.75 (s, 2H), 6.21 (br, 1H, ex D 2 O), 6.48 (d, 1H), 6.84 (s, 2H), 6.95 (t, 1H), 6.99 (t, 1H), 7.13 (t, 1H), 7.33 (d, 2H); MS (ESI) m/z 494.5 (M+H) + .
Example 27
[0150] Compound 51 (Scheme 6). To a stirring solution of compound 39 in dimethylformamide at room temperature under N 2 is added sodium hydride. The resulting mixture was stirred at room temperature for 1 h. Propane sultone was added to the above solution and stirred at room temperature overnight to give the desired compound 51 after purification.
Example 28
[0151] Compound 52 (Scheme 6). Compound 52 is prepared from compound 39 and 1,4-butane sultone employing the procedure described in Example 27. The compound is purified by column chromatography on a silica gel column.
Example 29
[0152] The synthesis described in Example 29 is illustrated in SCHEME 7.
[0153] Compound 54 (Scheme 7). Compound 54 was synthesized from diclofenac (1) (1.48 g, 5 mmol), compound 53 (0.73 g, 5 mmol), DCC (1.03 g, 5 mmol) and DMAP (0.12 g, 1 mmol) employing the procedure described in Example 1. The compound was purified by crystallization from CH 2 Cl 2 /hexanes to give 0.77 g (36%) of compound 54 as a white solid. 1 H NMR (CDCl 3 ) δ2.06 (d, 3H), 4.24 (d, 2H), 6.21 (s, 1H), 6.98-7.03 (m, 2H), 7.19 (t, 1H), 7.33-7.36 (m, 3H); MS (ESI) m/z 451.2 (M+Na) + .
Example 30
[0154] The syntheses described in Example 30 is illustrated in SCHEME 8.
[0155] Compound 56 (Scheme 8). Compound 56 was synthesized from diclofenac (1) (0.89 g, 3 mmol), compound 55 (0.49 g, 3 mmol), DCC (0.62 g, 3 mmol) and DMAP (0.12 g, 1 mmol) employing the procedure described in Example 1. The compound was purified by column chromatography on a silica gel column using CH 2 Cl 2 as an eluent to give 0.4 g (30%) of compound 56 as a pale yellow solid. 1 H NMR (CDCl 3 ) δ4.29 (s, 2H), 6.36 (br, 1H, ex D 2 O), 6.64 (d, 1H), 6.98 (t, 1H), 7.78 (t, 1H), 7.21 (t, 1H), 7.32 (d, 2H), 7.42 (d, 1H), 7.85 (t, 1H), 8.01 (t, 1H), 8.24 (d, 1H), 8.38 (d, 1H); MS (ESI) m/z 431.8 (M+H) + .
Examples 31-44
[0156] The syntheses of compounds 58-71 are described in Examples 31-44, respectively. The synthetic strategies employed are illustrated in SCHEME 9.
[0157] Compounds 58-71 (Scheme 9). Compounds 58-71 are synthesized as described above for the preparation of compounds 13-26, respectively, employing naproxene (57), DCC, DMAP and compounds 2-12 as starting materials. The compounds are purified by either crystallization or column chromatography.
Examples 45-58
[0158] The syntheses of compounds 72-85 are described in Examples 45-58, respectively. The synthetic strategies employed are illustrated in SCHEME 10.
[0159] Compounds 72-85 (Scheme 10). Compounds 72-85 are synthesized as described above for the preparation of compounds 39-52, respectively, employing naproxene (57) and compounds 27-38 as starting materials. The compounds are purified by either column chromatography or crystallization.
Examples 59-72
[0160] The syntheses of compounds 87-100 are described in Examples 59-72, respectively. The synthetic strategies employed are illustrated in SCHEME 11.
[0161] Compounds 87-100 (Scheme 11). Compounds 87-100 are synthesized as described above for the preparation of compounds 13-26, respectively, employing indomethacine (86), DCC, DMAP and compounds 2-12 as starting materials. The compounds are purified by either crystallization or column chromatography.
Examples 73-86
[0162] The syntheses of compounds 101-114 are described in Examples 73-86, respectively. The synthetic strategies employed are illustrated in SCHEME 12.
[0163] Compounds 101-114 (Scheme 12). Compounds 101-114 are synthesized as described above for the preparation of compounds 39-52, respectively, employing indomethacine (86) and compounds 27-38 as starting materials. The compounds are purified by either column chromatography or crystallization.
Example 87
[0164] An invention compound, Compound 54 (a pro-drug of Diclofenac), was evaluated for its safety profile in rat models of gastropathy and enteropathy. Compound 54 exhibited significantly less gastric lesion formation and ulcer formation than equivalent doses of Diclofenac. In adjuvant-induced arthritis model, compound 54 exhibited equivalent efficacy to equimolar doses of Diclofenac.
[0165] Gastropathy: Male Sprague-Dawley rats (150-174 g) were obtained from Harlan (San Diego, Calif.). Animals were allowed to acclimatize to the facility for a minimum of 3 days and provided food and water ad libitum until the day before the study. Rats were fasted for 18 hours prior to the study. Diclofenac sodium salt was formulated in PBS, and dosed at 5 ml/kg, and Compound 54 was formulated in polyethyleneglycol (PEG) (MW. 300; Sigma Chemical Co., St. Louis, Mo.), and dosed at 1 ml/kg. Drugs were administered orally as a single dose in the morning and water removed. Two and one-half hours after dosing, rats were injected with 1 ml of 10 mg/ml Evans Blue solution and sacrificed 30 minutes later. Stomachs were removed, placed in weigh boats containing cold PBS, and re-coded with letters to blind the observer. Stomachs were then opened along the greater curvature, any contents removed and then placed flat with the lumen facing up to score blue-stained lesions for gastric toxicity according to the following criteria: First, the number of small rounded lesions were counted followed by measurement of total length of linear lesions of greater than or equal to 2 mm. The two numbers obtained (round lesion number and linear length) were added together to give a total gastropathy score expressed as Total Gastric Lesions.
[0166] [0166]FIG. 1 illustrates the total length of intestinal ulcers measured for rats treated with vehicle, diclofenac or equimolar invention compound 54. Diclofenac caused substantial ulceration, while compound 54 had no ulcerogenic effect, just like the vehicle PEG.
[0167] Enteropathy: Male Sprague-Dawley rats (150-174 g) were obtained from Harlan. Animals were allowed to acclimatize to the facility for a minimum of 3 days and provided with food and water ad libitium. Diclofenac sodium salt was formulated in PBS, and dosed at 5 ml/kg, and compound 54 was formulated in polyethyleneglycol (MW. 300; Sigma Chemical Co.), dosed at 1 ml/kg. Drugs were administered orally either as a single dose (late morning) or twice daily between 8:00-10:00 and 4:00-5:00 beginning with a morning dose for a total of three days. Groups contained 6-8 animals per treatment. On the fourth day each rat was injected intravenously with 1 ml of a 10 mg/ml solution of Evan's Blue to stain the damaged blood vessels in intestinal erosions and ulcers. Animals were sacrificed 10 to 20 minutes after administration of Evan's Blue. The small intestine was then removed from each rat and placed in a large weigh boat in cold PBS, stored briefly in a refrigerator until boats were re-coded to blind the observer. Each intestinal segment was then opened longitudinally and, using a fiber optic light, scored for erosions and ulceration according to the following criteria:
[0168] Erosions: An erosion is a shallow lesion that does not penetrate past the muscularis mucosa immediately below the epithelium. After Evan's Blue injection, intestinal lesions are seen as shallow lesions that are moderately stained around the edge, but with little to no staining in the middle. The depth of an erosion is sometimes only detectable when the edge of the tissue is lifted to reflect light at a different angle. Erosions are usually small and round or oval, but are sometimes as much as 1-2 mm wide, and as long as 1-2 cm, running along the area of mesenteric attachment. When erosions are elongated, the length is measured in mm and divided by 2; otherwise, the erosions are merely counted individually. Note that some areas of intestinal tissue stain blue, but are not erosions. These tend to be near the mesenteric membrane attachment sites and may represent areas of increased permeability that have not progressed to the extent that cell loss has occurred. When such areas are viewed while lifting the edge of the tissue, there is no clear depression in the center, and often the mesentery below contributes significantly to the observed staining.
[0169] Ulcers: An ulcer is a deep lesion penetrating the muscularis mucosa. It is usually thickened and inflamed. After Evan's Blue injection, ulcers present several different types of appearance. Small ulcers are round and oval, thickened and darkly stained (including the center), often with a small white scab on top. Larger ulcers are usually linear, running along the area where the mesenteric membrane attaches. The resulting trough can either be deep (e.g., ˜1 mm) and empty, or filled with granulation tissue. The surrounding intestine is almost always thickened and inflamed. All ulcers are quantified by measuring their long dimensions in mm.
[0170] [0170]FIG. 2 illustrates the total length of gastric lesion measured for rats treated with vehicle, diclofenac or equimolar invention compound 54. Compound 54 caused 73% less lesion than did an equimolar dose of diclofenac.
[0171] Adjuvant-induced Arthritis: Male Lewis rats (175-199 g) were obtained from Harlan (San Diego, Calif.). Animals were allowed to acclimatize to the facility for a minimum of 3 days and provided food and water ad libitium. Mycobacterium tuberculosis (Difco, Bacto H37 RA 3114-25) was dissolved in mineral oil (5 mg/ml) and arthritis induced by injecting 100 μl of the solution into the left footpad using a 25G needle. Paw volume was measured using a water plethysmometer (UBS Basile, Stoelting Co.). A line was drawn across the right ankle to provide the level for baseline measurement of paw volume and paw volume was measured on days 0, 5, 11, 13 and 15. Data is expressed as percent inhibition paw swelling on day 15 which is calculated as follows: % inhibition=(1−((Vol drug-treated day 15 −Vol drug-treated day 5 )/(Vol vehicle treated day 15 −Vol vehicle-treated day 5 )))×100. Diclofenac sodium salt was formulated in PBS, and dosed at 5 ml/kg, and Compound 54 was formulated in polyethyleneglycol (MW. 300; Sigma Chemical Co., St. Louis, Mo.), and dosed at 1 ml/kg. Diclofenac, compound 54 and vehicle were administered orally, daily, on days 8-15.
[0172] [0172]FIG. 3 illustrates the inhibition of paw volume increase in the uninjected feet of Lewis rats in which arthritis was induced by injection of adjuvant into the footpad. Invention compound 54 displayed anti-inflammatory activity similar to diclofenac in the chronic adjuvant arthritis model.
[0173] It will be apparent to those skilled in the art that various changes may be made in the invention without departing from the spirit and scope thereof, and therefore, the invention encompasses embodiments in addition to those specifically disclosed in the specification, but only as indicated in the appended claims.
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In accordance with the present invention, there are provided novel chemical entities which have multiple utilities, e.g., as prodrugs of NSAIDs; as dual inhibitors of cyclooxygenase (COX) and 5-lipoxygenase (5-LO); as anticancer agents (through promoting apoptosis and/or inhibiting the matrix metalloproteinases (MMPs)); as anti-diabetics; and the like. Invention compounds comprise a non-steroidal anti-inflammatory agent (NSAID), covalently linked to a hydroxamate. Invention compounds are useful alone or in combination with one or more additional pharmacologically active agents, and can be used for a variety of applications, such as, for example, treating inflammation and inflammation-related conditions; reducing the side effects associated with administration of anti-inflammatory agents; promoting apoptosis; inhibiting matrix metalloproteinases; as anti-diabetic agents; and the like.
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FIELD OF THE INVENTION
[0001] The present invention relates to the use of a container of an inorganic additive containing plastic material.
DESCRIPTION OF THE RELATED ART
[0002] Plastic containers are readily used for pharmaceutical preparations. However it is known that, due to their character, there are some limitations. Thus to suppress the reactivity of containers from polyethylene or polypropylene and their copolymers/blends towards certain chemicals several methods are used: plasticizers are avoided which would increase the motility of the chain molecules, polymers of higher density or polyolefin blends (e.g. polypropylene/polyacrylate) are used, the wall thickness is increased or the containers are wrapped (e.g. aluminum foil) or sealed (e.g. fluorination, silicone).
[0003] U.S. Pat. No. 4,123,417 (Finberg, 1978) claims that the toughness of LDPE can be increased by a blend comprising low density polyethylene containing an amorphous ethylene-propylene co-polymer having a certain amount of crystallinity and a specified ethylene content.
[0004] U.S. Pat. No. 4,546,882 (Hsu et al., 1985) claims a multiple layer package for oil-containing products comprising an oil barrier layer from nylon or ethylene vinyl alcohol.
[0005] U.S. Pat. No. 5,500,261 (Takei et al., 1996) claims an oil resistant container comprising a blended resin composition having specified glass-transition temperatures.
[0006] U.S. Pat. No. 6,800,363 (Su et al., 2004) claims a film that does not distort in the presence of food oils using a polyolefin multilayer film having a skin layer from oil-absorbing porous particles (calcium carbonate, silicone dioxide, amorphous silica, sodium aluminosilicate, activated charcoal) and a metalized layer.
[0007] U.S. Pat. No. 6,815,506 (Takashima et al., 2004) claims an oil-resistant thermoplastic elastomer composition comprising a propylene resin, an unsaturated group-containing acrylic rubber and an inorganic filler for rubber compositions, preferred silica.
[0008] Also other additives are usual to improve the properties of plastics. Of high importance are pigments and ultraviolet stabilizers (organic and inorganic pigments, dyes, benzophenone, hindered amines etc.). These cover a broad spectrum of requirements, such as heat stability, fastness to light and weathering, where titanium dioxide (TiO 2 ) is most common in pharmaceuticals. TiO 2 is an inert substance known for its broad spectrum of UV-absorption and non-migration (movement into the drug formulation).
SUMMARY OF THE INVENTION
[0009] It is an object of the invention to provide an alternative use of containers made of an additive containing plastic material, which containers contain an oil, fat and/or wax containing formulation.
[0010] This object is achieved by an use of a container, made of an additive containing plastic material, for reducing physical/chemical interaction between the container and an oil, fat and/or wax containing formulation contained therein.
[0011] Preferably, the physical/chemical interaction is an adsorption of the formulation to the plastic material.
[0012] More preferably, the inorganic additive is at least a pigment.
[0013] Most preferably, the at least one pigment is titanium dioxide (TiO 2 ), surface-treated titanium dioxide, or a mixture thereof.
[0014] In one embodiment, the additive is present in the plastic material in an amount between 0.1 and 10% by weight, more preferably between 0.1 and 5% by weight, and most preferably about 2% by weight, based on the weight of the plastic material.
[0015] The plastic material may comprises polyolefin.
[0016] Preferably, the polyolefin is selected from the group of polyethylene, polypropylene, copolymers of ethylene and propylene, or a mixture thereof.
[0017] More preferably, the plastic material comprises low density polyethylene (LDPE).
[0018] The plastic material may be suitable for extrusion blow molding.
[0019] Preferably, the formulation comprises at least one steroid hormone dissolved or suspended in oil, fat and/or wax.
[0020] More preferred, the steroid hormone is a sexual hormone drug, preferably testosterone, and the formulation further comprises at least one lipophilic or partially lipophilic carrier; and a compound or a mixture of compounds having surface tension decreasing activity, in an amount effective for in situ generation of an emulsion upon contact of the formulation with water.
[0021] Finally, the formulation is preferably for nasal application, preferably to a mammalian.
[0022] A preferred low density polyethylene is for example Lupolen® 1840 H. Further, a preferred formulation may be the one which is disclosed in EP 03025769.5.
[0023] Surprisingly, it was found that a container of an inorganic additive containing plastic material may be advantageously utilized for keeping oil, fat and/wax containing formulations, for example oily formulations of steroid hormones, in that the use of such a container will reduce physical-chemical interactions of the container and the formulation, especially the adsorption of the formulation to the plastic material.
[0024] Surprisingly, the inventor has found that TiO 2 can also be used for a purpose for which it was not intended to be used so far: By adding it to plastic packaging material the physical-chemical interaction of certain oily formulations with the container, restricting its use, can be prevented.
[0025] The approaches actually made dealing with oil-plastic interaction did not use inorganic additive auxiliary agents nor a possibility was described for protecting a corresponding steroid hormone containing formulation from adsorption to plastic.
DETAILED DESCRIPTION OF THE INVENTION
[0026] In nasal application forms the suitability of the device for administration is of major importance. This applies to improving patient's compliance by convenient administration. But this also applies to pharmaceutical necessities such as the uniformity of emitted dose and the compatibility of the formulation with the primary packaging material. In pharmaceutical applications it is essential to use inert material for primary packaging; the galenical formulation, the active ingredient and the excipients, should not adversely be influenced by any interaction.
[0027] In principle there are two materials and two types for packaging of nasal formulations: glass vs. plastic and multiple-dose vs. unit-dose containers. The main advantages of plastic materials are their flexibility allowing for a wide range of designs, low weight, shatter resistance, and easy handling. Especially suitable for nasal application are unit-dose containers from plastic because of their small size, because no pump mechanism is necessary nor the addition of preservatives to the product formulation.
[0028] As starting material for such plastic containers polyethylene or polypropylene and their co-polymers are used. Possible drawbacks in respect of their use are the oxygen permeability, poor UV resistance and, due to the nonpolar character, degree of crystallinity and molar mass, the poor resistance to some chemicals.
[0029] Thus polyethylene and polypropylene are not generally resistant to aliphatic and aromatic hydrocarbons and their halogen derivatives as well as to low-volatility substances such as fats, oils and waxes. Incompatibilities which can be seen are adsorption of the chemicals to the plastic, diffusion and swelling by the chemicals, or even dissolution in the chemicals.
[0030] On the other hand hydrocarbon derivatives such as steroid hormones are readily formulated using oil as carrier to increase their solubility and time of action. To avoid stability problems caused by the primary packaging these oily formulations—mostly injectables—usually are filled into glass devices. This kind of packaging however is not suitable for all application forms, e.g. not for oily formulations for nasal application. In concern of multi-dose devices the reason is that, although the bottle might be from glass, there are always parts of the device, such as the pump, which are from plastic material. In concern of unit-dose devices the reason is that these, at least in the case of viscous formulations which have to be squeezed, cannot be made from glass but moulded from plastics, mostly by the blow-fill-seal technology.
[0031] As an example for the aforementioned considerations in table 1 are shown the results of tests investigating the stability of formulations containing the steroid hormone testosterone in containers of different material.
[0000]
TABLE 1
Stability of formulations containing testosterone
in containers of different material
Remaining drug
Primary packaging material
Formulation
after storage (%)
LDPE
Oil-based
≈30%
PP
Oil-based
≈50%
Glass
Oil-based
≈80%
Glass
Methanolic
100%
LDPE + TiO 2
Oil-based
100%
[0032] The term “remaining drug after storage” is the amount of testosterone remaining in the formulation after storage for 22 hours. The remaining drug was measured by HPLC technique.
[0033] It is obvious that there is a complex interaction of the drug with the oily formulation and of the oily formulation with the primary packaging material. For clinical-pharmaceutical reasons however the oil-based formulation and a unit-dose device for packaging was preferred. Thus some effort was made by the applicant using complicated procedures to solve this problem. Surprisingly however after adding titanium dioxide to the plastic material by this simple step it was possible to increase the shelf-life of the pharmaceutical formulation.
[0034] The features disclosed in the foregoing description and in the claims may, both separately and in any combination thereof, be material for realizing the invention in diverse forms thereof.
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The present invention relates to the use of a container, made of an inorganic additive containing plastic material, for reducing physical/chemical interaction between the container and an oil, fat and/or wax containing formulation contained therein.
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FIELD OF THE INVENTION
This invention relates generally to keyboard switch assemblies for inputting data to computers and other electronic devices and, more particularly, to an integrated keyboard key assembly with a built-in balancing mechanism for preventing the key from tilting or rotating when the key top on the key is pressed eccentrically by an operator.
BACKGROUND OF THE INVENTION
A known mechanism for preventing key tops from tilting and rotating employs an element known as a U-shaped wire or swing rod rotatably supported between a key top and a corresponding key seat. This mechanism minimizes the tipping moments that may be applied to the key plunger guide which guides the strokes of the key top on the key seat when the force exerted on the key top and the key plunger is not directly over the center above the key plunger guide. Small keys such as typical single keys do not require a swing rod mechanism to maintain their orientations because forces generated by normal use are small enough to be resisted by key plunger guides in an incorporated electrical switch. The problem is common for large keys or so-called multiple-key keys that span over multiple key seats. When a multiple-key key not equipped with a swing rod mechanism is depressed at its edge eccentrically, a higher force of actuation is demanded because of the tipping moments caused by the eccentric loading that produce higher friction in the key plunger guide.
For large key tops or so-called multiple-key key tops, the swing rod is connected in a movable fashion between the key top and the key seat. A sketch of a typical swing rod 20 for use with a large key top 10 is shown in FIG. 1. When eccentric actuation occurs from the top of the key top 10, the eccentric force is deflected by the swing rod 20 which is rotatably supported in the keyboard adjacent the key seat by supports 30 and transmitted to the opposite edge of the key top 10. Consequently, even if the key is actuated eccentrically, the opposite side of the key top 10 is also pulled down by means of the swing rod 20, and uniform force transmission is achieved and the key plunger guide 40 in the key seat is free of any significant tipping moments. Examples of swing rod mechanisms for use in multiple-key keys are illustrated in a number of references, e.g., U.S. Pat. No. 5,387,261 to Yamada et al. (Feb. 7, 1995); U.S. Pat. No. 5,003,140 to Abell, Jr. et al. (Mar. 26, 1991); U.S. Pat. No. 4,950,093 to Ertl (Aug. 21, 1990); U.S. Pat. No. 4,830,526 to Hosono (May 16, 1989); and U.S. Pat. No. 4,771,146 to Suzuki et al. (Sept. 13, 1988), which are hereby incorporated by reference.
Large multiple-key key tops are assembled to respective key seats provided on a keyboard in several steps using special tools because a swing rod mechanism must be installed to the large key tops and to their respective key seats. On the other hand, the absence of a swing rod mechanism permits assembly of small key tops to respective key seats in a single-step operation, resulting in substantial savings in manufacturing costs.
To improve the efficiency of the assembly of the multiple-key key tops to the key seats, a number of mechanisms have been proposed. For instance, Ertl '093 discloses a support mechanism that includes a means for maintaining the swing rod at an oblique position relative to the key seat during assembly and a guide mechanism for guiding and receiving the pair of free ends of the U-shaped swing rod to the key seat. Abell '140 discloses the use of a key top stabilizer that is integrated with the key top and has a serpentine flexible connecting section interconnecting the key top to a pair of arms that extend to a shaft for engaging pivots provided in the key seat during assembly. The pair of arms and the shaft form a structure similar to that of the traditional swing rod, but are integrated with the key top. Yamada '261 discloses a mechanism for single-step assembly of keys to respective key seats using a semilunar recess that is affixed to each key top and can be snapped over a swing rod during assembly of the keyboard switch. The swing rod is rotatably affixed to and supported by the key seat in a position permitting the semilunar recess to snap onto it in a single step for assembly.
SUMMARY OF THE INVENTION
There is a need for a more efficient, simple mechanism for mounting and replacing multiple-key key tops to a keyboard easily without the need for tools.
It is a feature of this invention to provide a multiple-key key with an integrated key base and a built-in swing rod mechanism.
It is another feature of the invention to provide a multiple-key key that can be easily inserted via a key plunger into the corresponding key slot or plunger guide without the need for special tools or the need to assemble an external swing rod mechanism.
It is another feature of this invention to provide a multiple-key key that can be easily adapted to replace multiple single keys without the need to reconfigure the keyboard.
In accordance with one aspect of the present invention, a key assembly for use on a keyboard comprises a key top having a first constraint, a key plunger for detachably penetrating through a key plunger guide provided in the keyboard, and at least one support plunger extending generally parallel to and spaced from the key plunger. A key base is provided with at least one support plunger guide through which the at least one support plunger movably extends and a second constraint spaced from the first constraint. The at least one support plunger guide is supported on at least one corresponding key plunger guide provided in the keyboard. The key assembly further includes a swing rod having a center portion, a first arm extending from the center portion to a first tip that is spaced from and generally parallel to the center portion, and a second arm extending from the center portion to a second tip that is spaced from and generally parallel to the center portion. The center portion is rotatably and slidably connected to the first constraint and the first and second tips are rotatably connected to the second constraint.
In accordance with another aspect of the invention, a multiple-key unit comprises a U-shaped wire having a cross-part extending to two free ends that are substantially parallel to the cross-part. A base portion is provided with at least one guiding support and a wire guide rotatably and slidably connected to the cross-part. The multiple-key unit further comprises a top portion including a wire support rotatably connected to the two free ends and a contact leg for releasably mating with a first contact guide provided in a keyboard. The top portion has at least one support leg slidably disposed in the at least one guiding support and supported by a second contact guide provided in the keyboard.
Another aspect of this invention is a keybutton assembly comprising a key top which includes a mating stem extending in a first direction for disengageably mating with a mating sleeve and contacting a key contact provided in a keyboard. The keybutton assembly further includes a key bottom and a means for supporting the key top with respect to the key bottom for balanced movement generally in the first direction between a pressed position with the application of a pressure on the key top and a relaxed position upon the release of the pressure. The mating stem is spaced from the key contact in the relaxed position and contacts the key contact in the pressed position.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of this invention, illustrating all their features, will now be discussed in detail. These embodiments depict the novel and nonobvious keyboard key assembly of this invention shown in the accompanying drawings, which are included for illustrative purposes only. These drawings include the following figures, with like numerals indicating like parts:
FIG. 1 is a schematic illustration of a prior swing rod mechanism for a large key.
FIG. 2 is an exploded perspective view illustrating an embodiment of a double integrated keyboard key assembly of the present invention.
FIG. 3 is a partial cross-sectional view illustrating the assembled double integrated keyboard key assembly of FIG. 2 along line A--A.
FIG. 4 is an exploded perspective view illustrating another embodiment of a double integrated keyboard key assembly of the present invention.
FIG. 5 is a partial cross-sectional view illustrating the assembled double integrated keyboard key assembly of FIG. 4 along line B--B.
FIG. 6A is an exploded perspective view illustrating a triple integrated keyboard key assembly of this invention.
FIG. 6B is an exploded perspective view illustrating a quad integrated keyboard key assembly of this invention.
FIG. 7 is a partial cross-sectional view illustrating the assembled quad integrated keyboard key assembly of FIG. 6B.
DETAILED DESCRIPTION OF THE INVENTION
The integrated keyboard key design of this invention may be used for various large key tops or multiple-key key tops. The double key top 1A, triple key top 1B, and quad key top 1C are described herein. It is understood, however, that other multiple-key key top designs may also be achieved based on this disclosure, and are within the scope of the present invention.
A. Double Key
Referring to FIG. 2, a double integrated keyboard key or keybutton assembly comprises a double key top or key top 1A, a key bottom, key base, or key bracket 2, and a swing rod or U-shaped wire 3. The swing rod 3 is a generally U-shaped member that includes a center portion, cross-part, or shaft portion 31 extending with a pair of arms to a pair of swing tips or free ends 32 that are desirably inwardly bent. The swing rod 3 advantageously has a generally uniform, round cross-section. The swing rod 3 may be made of bent metal such as aluminum or steel.
The key top 1A has a length that is longer than its width, with the length and width defining a generally horizontal plane. A contact leg, mating stem, or key plunger 13 extends from the interior surface of the key top 1A generally vertically and downwardly toward the key base 2. A support leg, stem, or plunger 12 is spaced from the key plunger 13 along the length of the key top 1A and desirably extends in generally the same direction as the key plunger 13. The support plunger 12 is desirably shorter than the key plunger 13. The key plunger 13 advantageously has a tab or protrusion 19 near its bottom end toward the key base 2. The key top 1A further includes a wire support which may comprise a pair of upper restraints, supports, grooves, hooks, slots, or stoppers 11 that are desirably disposed near a rear edge and spaced along the length of the key top 1A. The upper stoppers 11 extend toward the rear edge of the key top 1A and are desirably sized to engage the swing rod 3. Although one upper stopper 11 may be sufficient, a pair of upper stoppers 11 are advantageously provided for stability. The pair of upper stoppers 11 are desirably spaced such that they may engage either the center portion 31 or the pair of swing tips 32 (as shown in FIG. 2) of the swing rod 3. The upper stoppers 11 are advantageously sized to permit rotation or to permit both rotational and horizontal sliding motions of the swing tips 32 relative to the upper stoppers 11.
As shown in FIG. 2, the key base 2 is generally vertically spaced from the key top 1A and includes a wire guide which may comprise a pair of lower restraints, supports, grooves, hooks, or slots 21 disposed generally along the front edge and spaced along the length of the key base 2. The lower slots 21 extend toward the front edge of the key base 2 and are desirably sized to engage the swing rod 3. The lower slots 21 are advantageously spaced from the upper stoppers 11 in a manner to support the swing rod 3 for balanced vertical displacements between the key top 1A and the key base 2 as required to achieve the proper key stroke for a given keyboard. Although one lower slot 21 may be sufficient, a pair of lower slots 21 are advantageously provided for stability. The pair of lower slots 21 are desirably spaced such that they may engage the center portion 31 (as shown in FIG. 2). The lower slots 21 are advantageously sized to permit rotation or to permit both rotational and horizontal sliding motions of the center portion 31 of the swing rod 3. In the embodiment shown in FIG. 2, the upper stoppers 11 are sized to permit both rotational and horizontal sliding motions of the swing tips 32 and the lower slots 21 are sized to permit generally only rotation of the center portion 31 of the swing rod 3 for stability and balance. It is understood that the positions of the upper stoppers 11 and lower slots 21 may shift along the width of the double key without affecting the function of the swing rod 3.
The key base 2 of FIG. 2 further includes a support plunger guide, stem guide, mating sleeve, or guiding support 22 providing a hollow channel of a size through which the support plunger 12 of the key top 1A may extend generally vertically. Advantageously, the support plunger guide 22 provides sufficient clearance in the hollow channel to allow the support plunger 12 to move freely therethrough. The support plunger 12 and support plunger guide 22 are provided to facilitate assembly of the key top 1A to the key base 2 by positioning them relative to each other. In one embodiment, a mechanism such as a small tab or stopper (not shown) inside the hollow channel of the support plunger guide 22 may advantageously be used to engage a small hook 17 at the free end of the support plunger 12 to prevent the support plunger 12 from sliding completely out of the hollow channel and becoming disengaged from the support plunger guide 22. The key plunger 13 of the key top 1A advantageously extends past the key base 2 when assembled. FIG. 2 shows an open region 18 in the key base 2 to accommodate the key plunger 13. The key top 1A and key base 2 may be made of any suitable material such as plastic, and may be formed by molding.
Referring to the assembled key shown in FIG. 3, the swing tips 32 are snapped onto the upper stoppers 11 of the double key top 1A and the center portion 31 of the swing rod 3 is snapped onto the lower slots 21 of the key base 2. Advantageously, the center portion 31 is rotatable relative to the lower slots 21 and the swing tips 32 are rotatable and horizontally slidable relative to the upper stoppers 11. The key top 1A is allowed to travel vertically relative to the key base 2 between a top position and a bottom position during a key stroke, while the swing rod 3 moves by rotation of the center portion 31 and rotation and horizontal sliding motion of the swing tips 32, and balances the forces along the length of the double key. The support plunger 12 also moves vertically inside the support plunger guide 22. The support plunger 12 is desirably not long enough to extend through the support plunger guide 22.
To assemble the key assembly with the keyboard, the key plunger 13 is inserted into a key slot, contact guide, or stem guide 40 provided in a key seat of the keyboard as shown in FIG. 3. The key guide 40 of the key seat resiliently supports the key plunger 13 for movement of the key plunger 13 during compression of a key stroke to produce a key contact or electrical contact. Advantageously, a hook or support 26 in the key guide 40 engages the tab or protrusion 19 of the key plunger 13 to support the key plunger 13 relative to the key guide 40. The support plunger 12 and plunger guide 22 advantageously rest on top of another key guide (not shown) of an adjacent key seat for stabilized support of the double key. Because the support plunger 12 is not long enough to penetrate the support plunger guide 22 into the key guide, the contact provided inside the key guide becomes a dummy contact. The support plunger 12 acts as a false or dummy key plunger and the support plunger guide 22 acts as a false or dummy key plunger housing. The key base 2 may also advantageously be supported on the keyboard.
The swing rod 3 ensures that uniform force transmission is achieved for smooth operation of the double key and the key guide 40 is free of any significant tipping moments even when the key top 1A is actuated eccentrically. The eccentric force is deflected by the swing rod 3 which is rotatably supported in the front edge of the integrated key base 2 and transmitted to the opposite rear edge of the key top 1A. The swing rod 3 supported between the key base 2 and key top 1A balances the eccentric force and are advantageously provided so that the double key can be adapted to replace two single keys by occupying two single key slots.
Another embodiment of the double integrated keyboard key assembly is shown in FIGS. 4 and 5. In this embodiment, the swing rod 3' is also a generally U-shaped member that includes a center portion 31' extending with a pair of arms to a pair of swing tips or free ends 32' that are not inwardly bent as opposed to the inwardly bent free ends 32 shown in FIG. 2. In place of the upper stoppers 11 of FIG. 2, a pair of upper restraints or stoppers 11' in this embodiment are disposed near the corners of the key top 1A' to engage and support the free ends 32' of the swing rod 3'. This embodiment illustrates a different mechanism for connecting the swing rod 3' to the key top 1A'. It is understood that other similar mechanisms are also within the scope of this invention.
As best seen in FIG. 4, the key plunger 13' of the key top 1A' includes a pair of tabs or protrusions 19' near its bottom end toward the key base 2. Either of the two tabs 19' may engage the hook or support 26 provided in the key guide 40 to support the key plunger 13' relative to the key guide 40. As a result, the double key may be oriented in different directions relative to the keyboard, either along a row or a column of keys, thereby making the key more versatile.
B. Triple Key
The triple key is shown in FIG. 6A with a triple key top or cap 1B and a swing rod 3 that is similar to the swing rod 3 shown in FIG. 2 and spans the length of the triple key. The triple key top 1B includes a contact or key plunger 13 and a pair of support plungers 12 that are spaced over three equivalent single key seats on a keyboard (not shown). The triple key top 1B further includes a wire support which may comprise a pair of upper restraints, supports, grooves, hooks, slots, or stoppers 11 that are desirably disposed near a middle width portion and spaced along the length of the key top 1B. Although one upper stopper 11 may be sufficient, a pair of upper stoppers 11 are advantageously provided for stability. The pair of upper stoppers 11 are desirably spaced such that they may engage either the center portion 31 or the pair of swing tips 32 (as shown in FIG. 4) of the swing rod 3. The upper stoppers 11 are advantageously sized to permit rotation or to permit both rotational and horizontal sliding motions of the swing tips 32 relative to the upper stoppers 11.
The key bottom or base 2 includes a wire guide which may comprise a pair of lower restraints, supports, grooves, hooks, or slots 21 disposed generally along the front edge and spaced along the length of the key base 2. The lower slots 21 extend toward the front edge of the key base 2 and are desirably sized to engage the swing rod 3. The lower slots 21 are advantageously spaced from the upper stoppers 11 in a manner to support the swing rod 3 for balanced vertical displacements between the key top 1B and the key base 2 as required to achieve the proper key stroke for a given keyboard. Although one lower slot 21 may be sufficient, a pair of lower slots 21 are advantageously provided for stability. The pair of lower slots 21 are desirably spaced such that they may engage either the center portion 31 (as shown in FIG. 4) or the pair of swing tips 32 of the swing rod 3. The lower slots 21 are advantageously sized to permit rotation or to permit both rotational and horizontal sliding motions of the center portion 31 of the swing rod 3. In the embodiment shown in FIG. 6A, the upper stoppers 11 are sized to permit both rotational and horizontal sliding motions of the swing tips 32 and the lower slots 21 are sized to permit only rotation of the center portion 31 of the swing rod 3 for stability and balance. The lower slots 21 and upper stoppers 11 are shown to be spaced horizontally from each other by approximately the width of a single key, similar to the spacing for the double key shown in FIG. 2, but the spacing may be changed without adversely affecting the function of the swing rod 3. It is also understood that the positions of the upper stoppers 11 and lower slots 21 may shift along the width of the triple key without affecting the balancing function of the swing rod 3 along the length of the triple key.
The key base 2 of FIG. 6A further includes a pair of support plunger guides 22 providing hollow channels of sizes through which the corresponding support plungers 12 of the key top 1B may extend generally vertically. Advantageously, the support plunger guides 22 provide sufficient clearance in the hollow channels to allow the corresponding support plungers 12 to move freely therethrough. The support plungers 12 and support plunger guides 22 position the key top 1B relative to the key base 2 and facilitate the assembly of the two components. In one embodiment, a mechanism such as small tabs or stoppers (not shown) inside the hollow channels of the support plunger guides 22 may advantageously be used to engage small hooks 17 at the free end of the support plungers 12 to prevent the support plungers 12 from sliding completely out of the hollow channels and becoming disengaged from the support plunger guides 22. The key plunger 13 of the key top 1B advantageously extends past the key base 2 when assembled. FIG. 4 shows an open region 18 in the key base 2 to accommodate the key plunger 13.
As best seen in the assembled view of FIG. 5, the triple key includes a spring 5 supported between an upper spring constraint, guide, or support 16 provided in the key top 1B and a lower spring constraint, guide, or support 25 provided in the key base. The spring 5 is illustrated as a coil spring, and the upper spring support 16 and lower spring support 25 are rounded tabs sized to support the spring 5. The spring 5 is advantageously provided as a force compensator for the large keys with larger weight than a single key. The spring 5 maintains a resistance that is generally similar to that for a single key and thus requires a pressing force by a human finger that is similar to the pressing force necessary for a single key. The appropriate spring constant for the spring 5 may be determined by those of ordinary skill in the art without undue experimentation. The location of the spring 5 is desirably near the middle region of the key, but may be away from the middle region without affecting the function of the spring 5. The spring 5 may also be used in conjunction with the double key of FIG. 2, but is not necessary because the weight of the double key is not sufficiently different from the weight of the single key. It is understood that other types of resilient springs or members that exert a reaction force under compression and other corresponding upper and lower spring supports may be used.
The triple key can further include a cross member 4, as illustrated in FIG. 6B, supported between a pair of upper cross constraints 14, 15 provided in the key top 1B and a pair of lower cross constraints 23, 24 provided in the key base 2. The cross member 4 shown comprises a pair of blades rotatably connected at the center. The blades advantageously have generally rounded, transverse tabs at the ends that are rotatably supported by the upper and lower cross constraints (14, 15, 23, 24). Each of the upper cross constraints includes the angled member, hook, or tab 14 and a protruding member or tab 15 that cooperate with the rounded tabs on the cross member 4 to connect the cross member 4 to the key top 1B . The lower cross constraint 23 is similar to the upper cross constraints, having an angled member, hook, or tab similar to the angled tab 14 and a protruding member or tab similar to the protruding tab 15. For added stability, the lower cross constraint 24 comprises a pair of angled members, hooks, or tabs that cooperate with the rounded tab extending in both transverse directions as shown in FIG. 6B. The rounded tabs of the cross member 4 are desirably supported for both rotation and horizontal sliding motion relative to the respective lower cross constraints 23, 24 or upper cross constraints 14, 15.
The cross member 4 is advantageously provided to balance the force on the triple key top 1B along the width of the key, because the width spans over two single key widths. Therefore, the cross member 4 serves the same function as the swing rod 3, but along the width rather than the length of the triple key. It is understood that other suitable cross constraints may also be used for balancing the force on the key. Indeed, a second swing rod (not shown) oriented along the width of the triple key top 1B may be used in place of the cross member 4.
Referring to the assembled triple key shown in FIG. 7, the swing tips 32 are snapped onto the upper stoppers 11 of the triple key top 1B and the center portion 31 of the swing rod 33 is snapped onto the lower slots 21 of the key base 2. Advantageously, the center portion 31 is rotatable relative to the lower slots 21 and the swing tips 32 are rotatable and horizontally slidable relative to the upper stoppers 11. The cross member 4 is rotatably connected between the upper cross constraints 14, 15 and lower cross constraints 23, 24. The swing rod 3 balances the force on the triple key top 1B along the length of the key while the cross member 4 balances the force on the triple key top 1B along the width of the key. The key top 1B is allowed to travel vertically relative to the key base 2 between a top position and a bottom position during a key stroke, while the swing rod 3 moves by rotation of the center portion 31 and rotation and horizontal sliding motion of the swing tips 32, and the cross member 4 moves by rotation and horizontal sliding motion of its rounded tips.
To assemble the key assembly with the keyboard, the key plunger 13 is inserted into a key slot, contact guide, or stem guide 40, as illustrated in FIG. 5, provided in a key seat of the keyboard. The key guide 40 of the key seat resiliently supports the key plunger 13 for movement of the key plunger 13 during compression of a key stroke to produce a key contact or electrical contact. The support plunger 12 and plunger guide 22 advantageously rest on top of another key guide (not shown) of an adjacent key seat for balanced support of the double key. Because the support plunger 12 is not long enough to penetrate the support plunger guide 22 into the key guide, the contact provided inside the key guide becomes a dummy contact. The support plunger 12 acts as a false or dummy key plunger. The key base 2 may also advantageously be supported on the keyboard.
The swing rod 3 and the cross member 4 form a balancing or stabilizing mechanism to ensure that uniform force transmission is achieved for smooth operation of the triple key and the key guide 40 is free of any significant tipping moments even when the key top 1B is actuated eccentrically. The eccentric force along the length of the triple key is deflected by the swing rod 3 which is rotatably supported along the length of the integrated key. The eccentric force along the width of the triple key is deflected by the cross member 4 which is rotatably supported along the width of the integrated key. The swing rod 3 and cross member 4 balance the eccentric forces and are advantageously provided so that the triple key can be adapted to replace three single keys by occupying three single key slots.
C. Quad Key
The quad key differs from the triple key only in that the quad key top 1C takes up the room of four single keys while the triple key top 1B takes up the room of only three single keys, as shown in FIG. 4. The remaining components and operation of the quad key are similar to those of the triple key.
In FIG. 6B, the quad key top 1C has only two support plungers 12 as in the triple key top 1B. In an alternative embodiment, the quad key top 1C may include an additional support plunger 12 and the key base 2 may include a corresponding support plunger guide 22 disposed over the fourth single key seat on the keyboard (not shown). This additional support plunger 12 is not necessary, however, because the two support plungers 12 and key plunger 13 as configured are sufficient to position and support the quad key top 1C relative to the key base 2.
As illustrated in the double-key, triple-key, and quad-key embodiments discussed above, the integrated key assembly can be adapted to a wide range of multiple-key applications beyond the three embodiments shown. The use of multiple tabs or protrusions 19' on the key plunger 13 to orient the double key in various directions relative to the keyboard as shown in FIGS. 4 and 5 is also applicable to the triple and quad keys (not shown). The integrated key assembly in accordance with this invention can be easily used to replace multiple single keys in existing keyboards without the need to reconfigure the key seats in the keyboards.
It will be understood that the above-described arrangements of apparatus and the methods therefrom are merely illustrative of applications of the principles of this invention and many other embodiments and modifications may be made without departing from the spirit and scope of the invention as defined in the claims.
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A multiple-key key assembly includes an integrated key top and key base unit with a built-in stabilizer. The key top includes a key plunger for mating with a key plunger guide provided in the key seat of a keyboard to support the key assembly on the keyboard and for making key stroke contacts with depression of the key top. The stabilizer includes a swing rod connected in a movable fashion between the key top and the key base. When eccentric actuation occurs from the top of the key top, the eccentric force is deflected by the swing rod and uniform force transmission is achieved to provide smooth operation of the integrated key. A support plunger provided in the key top is guided by a support plunger guide provided in the key base for added stability. The integrated structure with the built-in stabilizer allows the integrated key assembly to be adapted to a wide range of multiple-key applications, including double and quad keys. The integrated key assembly can be easily assembled to or disassembled from the keyboard by connecting or disconnecting the key plunger to the key plunger guide without the need for special tools.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to DE Application 10 2016 205 924.6 filed Apr. 8, 2016, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The disclosure relates to a method and an apparatus for connecting a sandwich element and a metal element.
BACKGROUND
[0003] Sandwich elements of this type are known for example under the brand name LITECOR® and have a plastic core which is sheathed by two metal cover sheets. The sandwich element is therefore lower in weight than full steel sheets but also very resistant to bending and buckling. Such composite materials can be used in the vehicle industry, for example in vehicle bodies, as planar components such as a roof, door, tailgate or hood, and point the way to efficient components which are lower in weight and less expensive than metal elements of steel or light metals such as aluminum or magnesium.
[0004] Within the context of the disclosure, metal elements are steel sheets or light metal sheets such as aluminum sheets or magnesium sheets.
[0005] An assembly of a motor vehicle body having a sheet component, which is reinforced by a reinforcing component which is made of a fiber composite material and is mounted in a planar manner on said sheet component, is disclosed in DE 10 2012 203 888 A1. As discussed in DE 10 2012 203 888 A1, such hybrid components cannot be connected to other components in the region of the reinforcing component by conventional joining methods used in vehicle body construction, such as spot welding. Therefore, DE 10 2012 203 888 A1 proposes that the reinforcing component have at least one cutout so that the sheet component can be connected to another sheet component in the region of the cutout using a conventional joining method. The sheet component is a reinforcing sheet of a side skirt. The reinforcing component consists of a carbon fiber reinforced plastic, whereas the sheet component consists of a weldable iron material.
[0006] EP 2 689 882 A2 discloses a device and a method for friction stir welding. In this, two different metal sheets, i.e. an aluminum sheet and a steel sheet, are connected to one another. A filler material is used to close a connection crater.
[0007] US 2010/0089977 A1 also discusses the friction stir welding of different materials. In this, an aluminum sheet is connected to a magnesium sheet, wherein combinations of copper, tin and zinc and other powders could strengthen the magnesian and aluminous friction stir welding material.
[0008] In motor vehicle construction, in particular in relation to the vehicle body, it is advantageous if this is particularly light. This saves on plastic and therefore also reduces the emission of harmful gases, such as CO 2 . The structural components, i.e. vehicle body components, should be designed for very different loads in different regions. With this, the components must also be produced so that the greatest potential for a lightweight construction can be achieved with as little material wastage as possible. Reinforcing measures can therefore also be provided in regions which are exposed to particularly high loads. For example, the components can be formed from a base element and have thickened portions in some sections as reinforcing measures. So-called “tailored roll blanks” are known. However, tailored roll blanks are very complex to produce and, in this respect, also very expensive. It is also disadvantageous that, in the event of a single, even slight, rolling error, it is necessary to dispose of the entire component since this then no longer meets the requirements. However, it is also conceivable to provide separate reinforcing elements on the base element, which reinforcing elements can be made of fiber reinforced plastic. As already disclosed in DE 10 2012 203 888 A1, conventional joining methods are unsuitable. Reinforcing elements can be connected to the base element by means of adhesive connections and can reinforce this base element so that the expected loads can be absorbed by the vehicle body component. However, it is not possible to achieve the best possible connecting performance using adhesive connections. Additional mechanical connections are still necessary in this respect, although they can destroy the fibers of the fiber reinforced plastic with the result that the desired reinforcement is negated. For example, reinforcing elements can be fastened to the base element with rivets which inevitably destroy the fibers in the connecting region. It is moreover possible to reduce shearing and fracturing forces of the original connection whereby corrosion problems can also occur.
[0009] A possible connection of an aluminum sheet to a fiber reinforced plastic is discussed in the article “Friction spot joining of aluminum AA6181-T4 and carbon fiber-reinforced poly (phenylene sulfide): Effects of process parameters on the microstructure and mechanical strength” (material and design 66 (2015), 437-445), wherein reference is made to EP 2 329 905 B1.
[0010] EP 2 329 905 B1 discloses a refill friction stir welding method in which a light metal sheet is connected to a fiber reinforced plastic. The friction stir welding device has a pin, a sleeve and a clamping ring. This device is said to enable the closing of the friction welding crater by means of the friction stir welding device in the course of the welding procedure, wherein, although the fiber reinforced plastic is melted, the fibers are said to remain undamaged. After the rotation has stopped, the materials harden so that the formerly melted regions adhere to one another. However, it is explicitly indicated here that the known disadvantages of adhesive connections are avoided since a separate adhesive is omitted.
[0011] The sandwich elements (LITECOR®) mentioned at the outset are suitable for use as planar components such as doors, roof, tailgate or hood. These components are conventionally screwed to other components such as hinges or bearing elements.
SUMMARY
[0012] The disclosure provides a method for connecting a sandwich element to a metal element so that a component, in particular a motor vehicle component, can be produced which, despite lower production costs, fulfills the necessary rigidity and/or crash requirements whilst giving the greatest possible consideration to weight. However, the disclosure is also based on the object of providing a device which is suitable for carrying out the method.
[0013] It should be pointed out that the features and measures described individually in the description below can be combined with one another in any technically useful manner and disclose further configurations of embodiments of the disclosure.
[0014] A method for producing a connection between a sandwich element and a metal element is disclosed, wherein the sandwich element has a dissimilar interlayer arranged between two cover elements. The method according to the disclosure comprises at least the following steps: providing the sandwich element and the metal element; placing the sandwich element and the metal element on top of one another so that they overlap at least in some regions; adding a fastener from the sandwich-element side, wherein the fastener is received with its base body entirely in the sandwich element; and carrying out a friction welding process from the opposite metal-element side so that a hybrid connection is formed, which has a mechanical connection between the fastener and the sandwich element and a material-locking connection between the fastener and the metal element.
[0015] Friction stir welding or refill friction stir welding is carried out from the metal-element side as the friction welding process. Within the context of the disclosure, the metal element is a steel sheet or light metal sheet, such as an aluminum sheet or a magnesium sheet. Within the context of the disclosure, the sandwich element has a dissimilar interlayer arranged between two preferably similar cover elements. The cover elements can be steel sheets or light metal sheets, such as aluminum sheets or magnesium sheets, wherein the mutually opposing cover elements can each consist of different materials. The dissimilar interlayer can be a plastic, e.g. a polymer. Within the context of the disclosure, a sandwich element can also be a carbon fiber reinforced plastic (CFRP). Motor vehicle components such as A, B, C or D pillars, but also other structural elements of the vehicle body, such as sills, i.e. components of the entire vehicle body, can be produced by means of the disclosure. These components produced according to the disclosure are more economical in relation to steel or light metals and moreover offer advantages in terms of weight. The metal element can therefore be regarded as a base element which is reinforced by the sandwich element, which means that the sandwich element can be regarded as a reinforcing element.
[0016] One example of a feature of the disclosure is that a friction welding process takes place from the metal-element side opposite the sandwich element. Therefore, despite the high frictional heat on the metal-element side, any thermal influence on the sandwich material is negligible. This is because only the metal element and the fastener are plasticized in some regions. However, a material-locking connection between the fastener and the metal element is produced, wherein the fastener is securely received in the sandwich element. The unplasticized part of the fastener remains in its original solid state.
[0017] So that the fastener can be securely received in the sandwich element, it can be constructed as a rivet. Therefore, a mechanical connection, i.e. a rivet connection, can ideally firstly be produced between the sandwich element and the metal element. The device designed for this will be discussed in more detail later. The rivet is driven into the metal element with its head region from the sandwich-element side, such that it breaks through the sandwich element. With this, the rivet reaches into the metal element with its head region, although it does not break through it. Therefore, a mechanical connection, i.e. a rivet connection, is firstly constructively generated between the sandwich element and the metal element. The fastener can furthermore have a type of external thread on its base body so that the mechanical connection is further secured.
[0018] It is constructive for the sandwich element to be positioned with respect to the metal element so that the sandwich element, i.e. the overlapping region, is arranged between the fastener and the metal element.
[0019] The fastener has a cylindrical base body and can be constructed to be sharply conical at its head region. However, the fastener can also be constructed to be U-shaped or flat at its head region.
[0020] Opposite the head region, the fastener has a widening of the otherwise cylindrical base body. The widening can also be described as an abutment flange, which abuts against the free surface of the sandwich element and thus constitutes a means for arresting the driving-in of the fastener, as it were, and prevents too deep a penetration into the metal element. The abutment flange can be interrupted as seen in the circumferential direction and therefore does not have to be of a continuous construction as seen in the circumferential direction.
[0021] In another example, a pre-punched hole, into which the fastener can be introduced, can be introduced in the sandwich element. Starting from the free surface here, the pre-punched hole extends completely through the entire sandwich element. The fastener has a cylindrical base body with a preferably flat head region and, opposite this, a foot region on which an abutment flange can be optionally provided. The cylindrical base body has a longitudinal extent up to the head region, which corresponds to the longitudinal extent of the pre-punched hole, i.e. the material thickness of the sandwich element. Only the abutment flange optionally arranged on the foot region projects beyond the pre-punched hole, i.e. the free surface of the sandwich element. The inside diameter of the pre-punched hole can be smaller than the external diameter of the cylindrical base body so that the fastener can be introduced into the pre-punched hole with press fit, as it were. Since the fastener is adapted to the material thickness of the sandwich element, its head region comes to abut directly against the corresponding surface of the metal element. It can be seen that it is therefore possible to dispense with an abutment flange. However, this can still be provided to reliably prevent the fastener from being driven too deeply into the metal element from the sandwich-element side. This procedure therefore dispenses with firstly establishing a mechanical connection to the metal element, although the fastener is still securely received in the sandwich element as already described above. A screw connection can also be provided on the cylindrical base body by means of a corresponding thread, i.e. an internal thread in the pre-punched hole and an external thread on the cylindrical base body.
[0022] As seen in cross-section, the fastener can have a width which is constructed to correspond to the preferred refill friction stir welding device, i.e. the external diameter of its sleeve. It is also possible for the fastener to be of a wider construction so that its external diameter projects beyond the sleeve.
[0023] If the fastener is to be inserted from the sandwich-element side, the material-locking connection is produced by friction welding, i.e. by the preferred refill friction stir welding (RFSSW or RFSEW) starting from the metal-element side.
[0024] It is constructive for the fastener to be formed from a similar material to the metal element. In this respect, the fastener can consist for example of steel or light metal, such as aluminum or magnesium. A similar weld connection can therefore be produced.
[0025] Corresponding starting points of the friction stir welding device are provided to correspond to the number of additional material bodies provided. The friction stir welding device is discussed in more detail below. The form-locking connecting regions here are preferably spaced from one another in a manner similar to spot welding connections. On an active side of the metal element, i.e. at the side on which the friction stir welding device acts by means of the friction stir welding head, the metal element is of a substantially flat construction, without craters and/or bumps, after the joining procedure (RFSSW or RFSEW).
[0026] The friction stir welding procedure is ideally carried out directly opposite the fastener from the metal-element side. The friction stir welding device has a non-rotatable outer clamping ring, a rotatable sleeve and a rotatable pin. A stir zone, i.e. a mixing zone between the fastener, ideally only its head region, and the metal element, is generated by means of the rotatable elements, in particular by the rotatable sleeve. The metal element, but also the fastener, is therefore plasticized by the frictional heat produced. Of the fastener, only the head region 16 is constructively plasticized, i.e. not the entire fastener. This is favorable since the thermal influence of the friction welding procedure, i.e. the frictional heat produced, is therefore negligible with regard to the sandwich element. This effect is still further promoted if, as seen in cross-section, the fastener is wider than the rotatable sleeve of the friction stir welding device.
[0027] It is expedient if, during the friction stir welding procedure, the stir zone is guided through the metal element and into the head region of the fastener.
[0028] If the fastener is received in the metal element with its head region, as a rivet, it is constructive if only the head region received in the metal element is plasticized. If the head region is sharply conical, the head region is leveled, as it were. If the head region is constructed in a U shape, only the limbs of the U are plasticized. However, the material-locking joining plane of the fastener and the metal element is arranged in the region of the metal element.
[0029] If the fastener is received in the previously established pre-punched hole without its head element penetrating into the metal element, the stir zone is guided through the metal element into the head region of the fastener. However, the entire fastener is again not plasticized in this case, only the head region thereof. In this case, the material-locking joining plane of the fastener and the metal element is arranged in the region of the sandwich element.
[0030] As seen in cross-section, the stir zone here is favorably preferably smaller than the width of the fastener. This was already mentioned above in relation to the external diameter of the sleeve, which is smaller than the width of the fastener. There therefore remains an outer annular region of the fastener which is not plasticized. It is constructive for this annular region to correspond to the expected heat influence zone around the stir zone in terms of its dimensions. Therefore, as a result of the stir zone being advantageously restricted to a partial head region of the fastener not only in terms of its width but also in terms of its depth, the heat entering the sandwich element is negligible since the heat influence zone is restricted to the metal element and the fastener. However, the friction welding device plunges with its rotatable elements into the head region of the fastener so that the stir zone is guided into the head region. A material-locking joining plane of the metal element and the fastener is therefore generated, which is arranged in the region of the sandwich element.
[0031] A material-locking connection between the metal element and the fastener is generated by the procedure described. The two elements are welded to one another, as it were. As a result of the fastener either being introduced from the sandwich element as a rivet or being securely received or, for example, pressed (press fit) in a pre-punched hole of the sandwich element as a cylindrical body, a hybrid connection is produced which has a mechanical connection and a material-locking connection. A connection is therefore generated with maximum connecting qualities, not only in terms of shearing and fracturing stresses. Structural components can therefore also be considerably more flexible in design.
[0032] The device-related part of the object is achieved by a device having the features of claim 9 . The device according to the disclosure is designed to carry out the method described above for connecting a sandwich element to a metal element and has a friction welding device, preferably a friction stir welding device, which is further preferably a refill friction stir welding device. The term friction welding device, which covers each of the preferred configurations, is used for simplicity below. Provision is constructively made for the friction welding device to be arranged at one end of a supporting arm, at the opposite end of which at least one holding and supply device for at least one fastener is arranged.
[0033] Therefore, the fastener can be supplied from one side, namely from the sandwich element side, wherein the friction welding device can act from the opposite side, i.e. from the metal-element side, so that the friction welding process can be carried out.
[0034] It is favorable if the supporting arm is constructed in a C shape so that the supply and holding device and the friction welding device are arranged opposite one another.
[0035] It is expedient if the supply and holding device has a delivery element with which a mechanical connection can be produced. The mechanical connection can be a rivet connection or a press fit, wherein an additional screw connection is also conceivable. For a rivet connection, the fastener is constructed as a rivet which is driven into the metal element with its head region by the delivery element of the supply and holding device, such that it breaks through the sandwich element. For a press fit, a pre-punched hole is firstly introduced into the sandwich element, into which the fastener is pressed. The delivery element can be used for this, wherein its power can be reduced, or the supply and holding device is constructed to have a corresponding power so that it is possible to dispense with the delivery element. As mentioned above, corresponding threads can also be provided; or only the fastener has a type of external thread, i.e. engagement teeth as it were, which further reinforce the selected mechanical connection.
[0036] It is favorable for both the friction welding device and the supply and holding device to be movable from an idle position into an operating position and vice versa relative to the supporting arm, i.e. relative to the respective end at which the relevant devices are arranged. In the idle position, the devices are spaced from one another so that at least mutually overlapping elements, i.e. the sandwich element and the metal element, can be brought into a clearance. The two devices can preferably be transferred from the idle position into the operating position at the same time. In this operating position, both devices are in contact with the respective surfaces of the relevant element. The friction welding device is therefore in contact with the free surface of the metal element. The supply and holding device is in contact with the free surface of the sandwich element. Both devices are arranged opposite one another. If the fastener is received in the sandwich element, i.e. supplied thereto, the friction welding process begins, wherein the supply and holding device assumes the holding function. The fastener can also be additionally held here, wherein it is also possible for the sandwich element to press against the metal element. During the friction welding process, the sleeve, together with the pin, firstly plunges into the metal element whilst rotating, whereby the material is plasticized accordingly. If the fastener is a rivet which is arranged with its head region within the metal element, then the head region is likewise plasticized by the heat produced. If the fastener lies with its head region against the corresponding surface of the metal element, the sleeve plunges in a rotating manner into the head region of the fastener and therefore plasticizes the metal element as well as the relevant head-region portion. The material-locking joining plane of the metal element and the fastener is therefore produced in each case within the sandwich element or within the metal element. From a certain plunging depth, the pin is moved in opposition to the plunging movement of the sleeve, i.e. withdrawn as it were. At the same time as the rotatable sleeve is withdrawn into its starting position, the rotatable pin is in turn guided in the opposite direction towards the free surface of the metal element so that, after the refill friction stir welding process, the free surface is crater-free and flat. The friction welding device, but also the supply and holding device, is transferred into its respective idle position. Further connections can now be established, or the mutually connected elements (sandwich element/metal element), i.e. the component formed, in particular a structural component of a motor vehicle, is removed from the device when the necessary connections have been established.
[0037] A method for producing a connection between a sandwich element and a metal element is disclosed herein. In this method, the sandwich element has an interlayer arranged between two cover elements. The method includes providing the sandwich element and the metal element; placing the sandwich element and the metal element in face-to-face contact at least partially overlapping; adding a fastener from the sandwich-element side while a base of the fastener extends within the sandwich element; and friction welding, from the metal-element side, to form a hybrid connection having a mechanical connection between the fastener and the sandwich element and a welding connection between the fastener and the metal element. The friction welding may be a friction stir weld process. A portion of the metal element and a head region of the fastener may be plasticized during the friction stir welding. The fastener may be a rivet driven into the sandwich element such that a head of the rivet reaches the metal element. A holed may be pre-punched into the sandwich element to receive the fastener. The fastener may be of a similar material to a material of the metal element. A welding joining plane of the fastener and the metal element may be arranged within the metal element or the sandwich element.
[0038] A connection assembly includes a sandwich element, a metal element, a supporting arm, a supply and holding device, and a friction welding device. The sandwich element has an interlayer between two cover layers. The supporting arm has first and second ends. The supply and holding device is mounted to the first end to introduce a fastener into the interlayer. The friction welding device is mounted to the second end to weld the metal element to the fastener to form a hybrid connection between the sandwich element and the metal element having a mechanical connection between the fastener and the sandwich element and a welding connection between the fastener and the metal element.
[0039] A method for connecting a sandwich element and a metal element includes driving a fastener into the sandwich element placed upon the metal element such that a base of the fastener is disposed within the sandwich element; and friction welding the metal element to the fastener to form a hybrid connection including a mechanical connection between the fastener and the sandwich element and a welding connection between the fastener and the metal element.
[0040] Further advantageous details and effects of the disclosure are explained in more detail below with reference to example embodiments illustrated in the figures, which show:
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 shows a cross-section of an apparatus for connecting a sandwich element to a metal element in an idle position;
[0042] FIG. 2 to FIG. 5 shows the apparatus from FIG. 1 in successive steps;
[0043] FIG. 6 shows a method according to an embodiment in successive steps in a first variant configuration;
[0044] FIG. 7 shows the method according to an embodiment in successive steps in a second variant configuration;
[0045] FIG. 8 shows the method according to an embodiment in successive steps in a third variant configuration;
[0046] FIG. 9 shows the method according to an embodiment in successive steps in a fourth variant configuration; and
[0047] FIG. 10 shows a cross-section through two connected elements as a detail of the embodiment of FIG. 9 .
DETAILED DESCRIPTION
[0048] As required, detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure.
[0049] In the different figures, the same parts are always provided with the same reference numerals and, for this reason, are generally also described only once.
[0050] FIG. 1 shows an apparatus 1 which is designed for connecting a sandwich element 2 to a metal element 3 . The sandwich element 2 has an interlayer arranged between two cover elements. The cover elements can be formed from a steel sheet or from a light metal sheet, such as an aluminum sheet or magnesium sheet. The interlayer can be a plastic, for example a polymer. The metal element 3 can be a steel sheet or a light metal sheet, such as an aluminum sheet or a magnesium sheet.
[0051] The apparatus 1 has a supporting arm 4 , which is constructed for example in a C shape. The supporting arm 4 has a friction welding device at a first end of two ends. The friction welding device may be a friction stir welding device or a refill friction stir welding device 6 . A supply and holding device 7 is arranged upon the supporting arm 4 at a second end opposite the refill friction stir welding device 6 . The refill friction stir welding device 6 has an outer clamping ring 8 , a rotatable sleeve 9 and a rotatable pin 11 . The supply and holding device 7 includes at least one material body, such as a fastener 12 or a plurality of fasteners 12 . The fasteners 12 can be supplied in the manner of a magazine. The supply and holding device 7 can have a delivery element. A rivet connection can be produced by means of the delivery element. In one example the fastener 12 is a rivet.
[0052] As can be seen in FIG. 1 , the supply and holding device 7 is arranged on the sandwich-element side 13 , whereas the refill friction stir welding device 6 is arranged on the metal-element side 14 .
[0053] The sandwich element 2 and the metal element 3 are placed on top of one another so that at least one overlap is formed, in which the desired connection can be produced. In FIG. 1 , both the refill friction stir welding device 6 and the supply and holding device 7 are arranged in their respective idle position on the supporting arm 4 .
[0054] Both devices 6 and 7 can be transferred, relative to the supporting arm 4 , from the idle position into an operating position, which can be seen in FIGS. 2 to 4 . In FIG. 5 , both devices 6 and 7 are again in the idle position.
[0055] In the connecting step illustrated in FIG. 2 , both the refill friction stir welding device 6 and the supply and holding device 7 are placed on a surface of the respective element 2 or 3 . As a rivet, the fastener 12 is delivered with its cylindrical base body through the sandwich element 2 in the direction of the metal element 3 . The fastener 12 reaches into, without breaking through, the metal element 3 with its head region 16 . The supply and holding device 7 can also rotate as can be seen in FIG. 2 from the rotation arrow 17 .
[0056] The fastener 12 may have an external thread on its cylindrical base body so that the mechanical connection produced by the riveting procedure is further reinforced. The rotation of the supply and holding device 7 can therefore effect a screwing movement of the fastener 12 with its external thread. The fastener 12 may also be threadless. The fastener 12 optionally has an abutment flange 18 ( FIG. 6 ) at its end opposite the head region 16 .
[0057] When producing the mechanical connection between the sandwich element 2 and the metal element 3 by means of the fastener 12 , the refill friction stir welding device 6 serves as a counter bearing and presses the metal element 3 in the direction of the sandwich element 2 .
[0058] The welding process, i.e. the refill friction stir welding process, is illustrated in FIG. 3 . In this welding process, the sleeve 9 plunges in a rotating manner into the metal element 3 , whilst the pin 11 is moved back in opposition thereto. In prior art examples, the sleeve 9 and the pin 11 were both plunged into the metal element 3 and the pin 11 is only moved in the opposite direction after reaching a predeterminable plunging depth. With this welding process, the metal element 3 , in some regions, but also the head region 16 of the fastener 12 , is plasticized. This can be seen in FIG. 3 from the relatively short fastener 12 compared to a length of the fastener 12 shown in FIGS. 1 and 2 . Both of the elements 2 and 3 are connected to one another with material locking as a result of the plasticization. A joining plane 29 can be seen in FIG. 10 further discussed below. The supply and holding device 7 has a counter bearing function and presses the sandwich element 2 in the direction of the metal element 3 .
[0059] FIG. 4 shows a further step of the refill friction stir welding process in which the pin 11 is moved in a direction toward the metal element 3 , whereas the sleeve 9 is moved in an opposite direction thereto. As a result, the metal element 3 is substantially crater-free and flat at the surface on which the refill friction stir welding device acts or operates, as can be seen in FIG. 5 .
[0060] A hybrid connection is therefore generated between the sandwich element 2 and the metal element 3 . The hybrid connection has a mechanical connection between the fastener 12 and the sandwich element 2 and a material-locking or welding connection between the fastener 12 and the metal element 3 .
[0061] Successive steps shown from the left in the plane of the drawing to the right in the plane of the drawing according to FIGS. 1 to 5 are illustrated schematically in FIGS. 6 to 9 .
[0062] In FIG. 6 , the fastener 12 is constructed as a rivet, wherein the head region 16 is constructed in the shape of a tapering cone. As can be seen in the center of FIG. 6 , the sleeve 9 plunges into the metal element 3 and rotates concentrically about a cone-shaped tip 19 of the fastener 12 so that the cone-shaped tip 19 is leveled. The sleeve 9 does not plunge into a cylindrical base of the fastener 12 . Instead, the plunging action ends at a spacing from the surface of the sandwich element 2 . A welding joining plane of the fastener 12 and the metal element 3 is arranged within the metal element 3 . A mechanical connection of the fastener 12 at the sandwich element 2 is formed by the rivet connection. The sandwich element 2 is therefore connected to the metal element 3 .
[0063] In FIG. 7 , the fastener 12 is constructed in a U-shape at its head region 16 , as seen in cross-section, and has two limbs 21 of the U, as seen in cross-section, between which there is a clearance 22 which is delimited by a base 23 . The clearance 22 may be filled by penetrating material of the metal element 3 during the driving-in procedure, so that an additional mechanical connection is generated. The limbs 21 of the U are constructed for contact with the sleeve 9 as it plunges in a rotating manner into the metal element 2 . As can be seen, the sleeve 9 does not plunge into the cylindrical base body surrounded by the sandwich element 2 . Instead, the plunging action ends at a spacing from the surface of the sandwich element 2 and at a spacing from the base 23 . The welding joining plane of the fastener 12 and the metal element 3 is arranged within the metal element 3 , wherein the limbs 21 of the U furthermore remain. A mechanical connection between the fastener 12 and the sandwich element 2 is formed by the rivet connection. The sandwich element 2 is therefore connected to the metal element 3 . The limbs 21 of the U-shape are unplasticized and received in the metal element 3 to form a further mechanical connection to the metal element 3 . In FIGS. 6 and 7 , the fastener 12 has been introduced through the sandwich element 2 without pre-machining and such that the head part 16 reaches into the metal element 3 so that the rivet connection is generated.
[0064] In the embodiments illustrated in FIGS. 8 and 9 , the sandwich element 2 is pre-machined and has a pre-punched hole 24 . The pre-punched hole 24 reaches completely through the sandwich element 2 . The fastener 12 is pressed and/or screwed into the pre-punched hole 24 by the supply and holding device 7 . For screw-in purposes, the fastener 12 can have an external thread, as described above and the pre-punched hole 24 can also have an internal thread corresponding thereto.
[0065] An inside diameter of the pre-punched hole 24 may be smaller than an external diameter of the fastener 12 . The fastener 12 can therefore be either pressed into the pre-punched hole 24 with a force locking using a press fit or screw process or may be rotated and pressed into the pre-punched hole 24 with force and form locking. The fastener 12 may therefore be securely held in the sandwich element 2 .
[0066] In FIG. 8 , the fastener 12 has an external diameter which corresponds to an external diameter of the sleeve 9 . The sleeve 9 penetrates through the metal element 3 into the fastener 12 so that the fastener 12 , i.e. its head region 16 , but also the metal element 3 , are plasticized in the relevant region. The welding joining plane of the fastener 12 and the metal element 3 is therefore arranged within the sandwich element 2 and not within the metal element 3 . A hybrid connection is nevertheless also present in this example as shown in FIG. 8 .
[0067] In FIG. 9 , the fastener 12 is wider than the sleeve 9 . As also shown in FIG. 8 , the sleeve 9 plunges into the fastener 12 , i.e. into its head region 16 , although unplasticized webs 26 of the head region 16 remain on both sides of the effective region of the sleeve 9 . The welding joining plane of the fastener 12 and the metal element 3 is arranged within the sandwich element 2 and the remaining webs 26 .
[0068] FIG. 10 shows a cross-section through the two mutually connected elements 2 and 3 and through the fastener 12 . The metal element 3 is arranged below the plane 29 of the drawing. The sandwich element 2 is arranged to partially extend above the plane 29 . On its sandwich side, i.e. opposite the head region 16 , the fastener 12 has an abutment flange 18 which abuts against the sandwich element 2 .
[0069] The sleeve 9 is plunged into the metal element 2 until it reaches into the fastener 12 , i.e. into the head region 16 , as illustrated by a stir zone 27 . The webs 26 are to the left and right of the stir zone 27 .
[0070] The stir zone 27 is surrounded by a heat influence zone 28 as a result of a frictional heat produced. As can be seen in FIG. 10 , the heat influence zone 28 is spaced from the sandwich element 2 so that thermal influence on the sandwich element 2 is minimized or eliminated. In this respect, the properties of the sandwich element 2 are not impaired by the frictional heat which plasticizes the metal element 3 , but also the fastener 12 . The welding joining plane is indicated by the reference sign 29 in FIG. 10 . This joining plane 29 is located within the sandwich element 2 .
[0071] While example embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosure. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the disclosure.
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A method for producing a connection between a sandwich element and a metal element is disclosed herein. In this method, the sandwich element has an interlayer arranged between two cover elements. The method includes providing the sandwich element and the metal element; placing the sandwich element and the metal element in face-to-face contact at least partially overlapping; adding a fastener from the sandwich-element side while a base of the fastener extends within the sandwich element; and friction welding, from the metal-element side, to form a hybrid connection having a mechanical connection between the fastener and the sandwich element and a welding connection between the fastener and the metal element.
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BACKGROUND OF THE INVENTION
A. Field of the Invention
The integrated modular spraying system includes a tank, a hose spool, an elongate flexible hose and a pump. This system is suitable for applying various types of chemicals in either liquid or powder form. An applicator wand or gun is normally attached to one end of the flexible hose to facilitate application of the chemical. The invention is particularly suitable for use by exterminating companies for application of insecticides around the exterior of residential homes. The plastic tank used in the present invention includes a modular design which forms a frame to support the hose spool.
B. Description of the Prior Art
Exterminating companies use various systems for applying chemicals around and in homes. One common approach is a backpack sprayer with a hand operated pump which is described in FIG. 1 of U.S. Pat. No. 4,651,903. In typical backpack sprayers, a hand operated lever operates a pump to transfer the liquid from the backpack to a target. This type of sprayer creates several difficulties for the operator. In the exterminating business, it is common for employees to visit between ten and twenty residential homes per day and to treat these homes for various pests. In this connection, the employee is typically assigned a company truck for hauling his equipment, inter alia, the backpack sprayer and suitable chemicals. At each stop, the employee first must lift and vigorously shake the backpack sprayer to mix the contents and then strap the sprayer to his back, carry it from the truck to the target and then constantly pump the lever to apply the necessary chemical. After he has completed the application, he carries the backpack to the truck and removes it. Several times during the day it might also be necessary to refill the backpack sprayer.
Backpack sprayers of this nature, when filled with liquid, may weigh from approximately thirty-five to forty-five pounds. It is therefore stressful for employees to carry around this load on a daily basis and to be continually taking it on and off. In addition, the pump requires repetitive pumping actions which may lead to various types of cumulative trauma distress including, but not limited to, carpel tunnel syndrome. The heavy pack makes operators more prone to falls and ankle and back injuries. When refilling, mixing or using the backpack, some of the chemicals may spill on the exterior and may ultimately come in contact with the clothing or skin of the operator. Although relatively economical to purchase and maintain, backpack sprayers have disadvantages from the operator's perspective.
Another common approach used by exterminating companies to apply chemicals in and around houses is a truck-mounted tank with pump and hose reel. With this type of apparatus, the operator parks the truck as close as possible to the home or other target. The operator then pulls a sufficient length of flexible hose from the reel to treat targets which are remote from the truck. After the application of the chemical is complete, the hose reel is rotated to retract and rewind the hose. Most hose reels have manual cranks for this purpose. A typical prior art truck-mounted system is Part No. 2000-15RP-M-H which is offered by Norel, a division of Oldham Chemical Company, located in Memphis, Tennessee. This truck-mounted system includes a metal frame supporting a plastic tank, a pump and a hose reel. The tank holds approximately fifteen gallons of liquid and the hose reel comes with approximately 150 feet of three-eights inch flexible hose. The entire apparatus weighs approximately one hundred pounds and is approximately twenty-eight inches long, thirty-eight inches wide and nineteen inches tall. This system is more user friendly than a backpack sprayer because the operator does not have to put the backpack on and off or carry it to and from each target on a repetitive basis. However, the truck-mounted system is substantially more expensive to purchase and maintain than the typical backpack sprayer. Typical truck-mounted systems provide 150 feet of hose.
The present invention is a truck-mounted spraying system which is more economical to manufacture and operate than conventional truck-mounted systems because it uses an integrated modular design. This modular design also allows for a compact apparatus which weighs approximately fifty pounds dry and which will fit inside of a two foot×two foot×two foot cube, for a twelve gallon model. In the preferred embodiment, the invention is equipped with 500 feet of three-eights inch hose. Other larger models could also be fabricated using this same integrated modular design. This compact design leaves more free space in a pickup truck which can be used for other purposes. The compact design allows the integrated modular spraying system to be mounted underneath the bed of larger trucks. This compact design allows for mounting of several different units in the back of one pickup truck. This multi-unit approach allows the operator to fill each unit with a different type of chemical.
Modern types of chemicals include micro-encapsulated spheres which provide for time release of the chemical. The present invention is particularly suited for use with micro-encapsulated chemicals which tend to be substantially higher in price than traditional chemicals and, therefore, tend to be applied in smaller amounts. Use of micro-encapsulated chemicals is more environmentally sound because of the time release aspect and because less of the chemical is released in the initial phases of treatment.
SUMMARY OF THE INVENTION
The present invention includes an integrated modular tank with a well formed in a wall and two opposing buttresses extending from the tank. A hose spool is supported by these buttresses and freely rotates in the well. A recess is formed in the top of this integrated modular tank to receive a pump for transferring the chemical from the tank through the hose to a remote target. In a typical application, the pump will include a twelve volt D.C. motor which is connected to the battery of a truck as a source of electricity.
The integrated modular spraying system can be mounted in the back of a pickup truck. In the alternative, it can be suspended underneath the bed of a larger truck or it could be mounted on a frame in or above the truck bed. When used by exterminating companies, the truck will typically be parked on the street in front of a residential home or in the driveway. The system can also be used in connection with apartments, condominiums or any other structure. In commercial applications, the truck will be parked as close as reasonably possible to a warehouse, plant or other commercial structure. The operator will turn the engine of the truck off and will turn the pump on. He will then pull a sufficient length of hose off of the hose spool so that he can apply the chemical to a remote target. In most situations, an applicator wand which contains an on/off valve and a removable tip will be attached to the end of the hose.
One feature of the present invention includes a pigtail ring assembly which facilitates 360° radial payout of the hose from any lateral direction. If, for example, the operator gets to the back side of the house or other structure and needs more hose, the pigtail ring assembly facilitates pulling more hose off the reel without requiring the operator to walk back to the vehicle. After the chemical has been applied to the target, the hose is removed from the pigtail ring assembly and the operator turns a crank to manually rewind the hose on the hose spool. This process is repeated by the operator at each stop during the day. From the operator's perspective, this system is more user friendly than conventional backpacks. From the owner's perspective, this system is more economical to purchase and maintain than prior art truck-mounted systems.
The integrated modular spraying system is suitable for applying various chemicals. The term "chemical" as used herein includes both liquids and dry flowables. Almost any kind of liquid could be applied with this system except those which would attack the tank. It is particularly suitable for pest control situations using modern safer, more costly liquid insecticides. It could also be used in horticultural applications to apply liquid fertilizers, herbicides and fungicides. Micro-encapsulated spheres in liquids can also be applied with this system. An alternative embodiment is suitable for applying dry flowables. The term "dry flowables," as used herein, includes boric acid dust, insecticidal dust, silica aerogel, antibiotic powder, powder baits and other dusts and powders.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above-recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is 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.
FIG. 1 is a perspective view of the integrated modular spraying system mounted in the back of a pickup truck with an operator spraying chemical around the exterior of a residential home.
FIG. 2 is a perspective view of the integrated modular spraying system with the hose spool full of flexible hose. The articulated handle for the hand crank assembly is shown in the extended position.
FIG. 3 is an exploded view of the integrated modular spraying system with the hose spool removed from the well, the tank cap removed from the fillwell and the pump cover removed from the pump recess.
FIG. 4 is a top plan view of the integrated modular spraying system.
FIG. 5 is a left side elevation view of the integrated modular spraying system as shown in FIG. 2.
FIG. 6 is a section view of the integrated modular spraying system along the line 6--6 of FIG. 4.
FIG. 7 is a section view of the hose spool and tank along the line 7--7 of FIG. 4.
FIG. 8 is a section view of the hose spool along the line 8--8 of FIG. 7.
FIG. 9 is an enlarged section view of the venturi nozzle and a portion of the agitator hose.
FIG. 10 is an enlarged section view of the swivel assembly shown in FIG. 7.
FIG. 11 is a bottom plan view of the tank.
FIG. 12 is a section view of a portion of the bottom of the tank along the line 12--12 of FIG. 11. This figure shows the tank mounted to the bottom of a pickup truck with angle iron.
FIG. 13 is a perspective view of a mounting frame.
FIG. 14 is section view of a portion of the bottom of the tank similar to FIG. 12, except the mounting frame shown in FIG. 13 is secured to the bottom of the system and the entire apparatus is secured to the bed of a pickup truck.
FIG. 15 is a section view of the tank cap.
FIG. 16 is a section view of an alternative embodiment of the tank cap, including a removable and lockable inner cap such as those used on conventional automobiles.
FIG. 17 is a perspective view of the pigtail ring assembly and three bolts for connecting the assembly to the integrated modular tank.
FIG. 18 is a partial section view of the tank as it engages the pigtail ring assembly.
FIG. 19 is an enlarged, exploded perspective view of the swivel assembly shown in FIG. 10.
FIG. 20 is a section view of the seal 104 shown in perspective in FIG. 19.
FIG. 21 is a partial section view of the tank with the pump mounted thereon.
FIG. 22 is a top plan view of an alternative embodiment of the integrated modular spraying system which is suitable for spraying dry flowables.
FIG. 23 is a section view of the tank along the line 23--23 of FIG. 22, showing how the system operates with a dry flowable.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the integrated modular spraying system is generally identified by the numeral 1 and is mounted on the bed 22 in the back 24 of a pickup truck 25. The operator 26 has pulled a sufficient length of flexible hose 28 from the integrated modular spraying system 1 and is applying a chemical 30 along the exterior of a residential home 32.
Attached to the end of the hose 28 is a wand 34 which includes an on/off valve or trigger 36. The wand 34 also includes a removable nozzle 38 which typically is available in different orifice sizes. The on/off valve 36 can be selectively actuated by the operator 26 to control the application of chemical.
The hose 28 is shown feeding through the pigtail ring assembly 40 which facilitates pulling the flexible hose 28 off of the hose spool 42. When the operator 26 has finished applying chemical on or about the house 32, he will disengage the hose 28 from the pigtail ring assembly 40 and will manually turn the hand crank assembly 44 to rewind the flexible hose 28 about the hose spool 42. He will use one hand to turn the hand crank assembly 44 and the other hand to guide the hose 28 as it is wound about the hose spool 42.
Referring to FIG. 2, the integrated modular spraying system 1 is shown in enlarged perspective view. The tank 54 is preferably formed from high density polyethylene or other suitable material. In the preferred embodiment, use of rotomolding and the integrated modular design of the tank 54 and the hose spool 42 reduce manufacturing costs for the present invention.
Referring to FIG. 3, the integrated modular spraying system 1 is shown in exploded perspective view. The interior 64 of the tank 54 can be accessed by the opening in the fillwell 66. A tank cap 68 threadably engages the fillwell 66. A pump 70 is mounted in a recess 72 formed in the top wall 74 of the tank 54. A pump cover 76 is sized and dimensioned to cover the pump 70 and the recess 72. The first pump cover screw 78, a second pump cover screw 80 and a third pump cover screw 82 removably attach the pump cover 76 to the tank 54. A well 84 is formed in front sidewall 86 of the tank 54. A first buttress 88 extends from the tank 54 and a second buttress 90 likewise extends from the tank 54, further defining the shape of the well 84. The pigtail ring assembly 40 nestles in a receptacle 92 formed in front sidewall 86 of the tank 54. A hole 94 is formed through the first buttress 88 and a second hole 96 is formed in the second buttress 90. Holes 94 and 96 are aligned along the same center line axis.
The tank 54 is defined by a back sidewall 3, a left sidewall 4, a right sidewall 5, a front sidewall 86, a top wall 74, a bottom wall 176, the first buttress 88 and the second buttress 90. A semicircular recess 149 is formed in left sidewall 4 adjacent the first buttress 88. A second semicircular recess 148 is formed in right sidewall 5 adjacent the second buttress 90. The first recess 149 and the second recess 148 add rigidity and strength to the design and are ascetically appealing.
The hand crank assembly 44 includes a protruding shaft 98 which is threaded on the end 100. As shown by the indicator lines, the shaft 98 of the hand crank assembly 44 fits through the aperture 96 in the second buttress 90. The threaded shaft 98 engages the hose spool 42 and when turned imparts rotational force to the hose spool 42. On the side of the hose spool 42 opposite from the hand crank assembly 44 is a male swivel body 102, a seal 104, a female swivel body 106, a washer 250 and a fitting 108. The male swivel body 102 is mounted in a stationary position in the hole 94 of the first buttress 88 as better seen in the section view shown in FIG. 7. The female swivel body 106 is rigidly attached to the interior of the hose spool 42. The female swivel body 106 rotates about the male swivel body 102 when the operator turns the hand crank assembly 44, causing the hose spool 42 to freely rotate.
Referring to FIG. 4, the tank 54 is shown in top plan view. The pump cover 76 has been removed to make it easier to see the pump 70 which is positioned in the recess 72. The pump 70 is secured in the recess 72 by a first pump mounting screw 118, a second pump mounting screw 120, a third pump mounting screw 122 and a fourth pump mounting screw 124, as better seen in FIG. 20.
The electric motor in the pump 70 is connected by a first wire 126 and a second wire 128 to a twelve volt power source such as the battery in the vehicle. The outlet port of the pump 70 is connected to a "T" fitting 130 which has a first outlet 132 and a second outlet 134. The first outlet 132 connects to an output hose 136 which delivers the chemical to the flexible hose 28 via the swivel assembly 198 for application to a remote target.
The second outlet 134 of the "T" fitting 130 connects to a bypass hose 138. At the other end of the bypass hose 138 is a fitting and bypass valve 140. A handle 142 can be manually actuated to open or close the bypass valve 140. When in the open position, the bypass valve 140 allows chemical to flow from the "T" fitting 130 through the bypass hose 13 through the fitting and bypass valve 140 back to the agitation hose 144, as better seen in FIG. 6. When the bypass valve 140 is in the closed position, chemical moves through the output hose 136 to the hose 28 for application to a remote target. A hose aperture 150 is formed in the top of the first buttress 88 to receive the output hose 136 and fitting 234 so that it can be connected to the male swivel body 102 of the swivel assembly 198, as better seen in FIG. 6.
Applicant recommends a twelve volt, 2.6 gallon per minute, 60 PSI pump for this particular application with a twelve gallon tank. Applicant believes that a SHURflo 8,000 series pump with the above specifications is suitable for this application. The SHURflo Company is located in Santa Ana, California. Those skilled in the art will understand that other pumps with different operating parameters may also be suitable for this application.
The output pressure for the aforementioned SHURflo pump can be adjusted with an allenhead wrench which can be inserted through the aperture 166 in the pump cover 76. The aforementioned pump is equipped with a pressure switch and sensor. If the sensor determines that pressure at the output side of the pump has reached a predetermined value, for example 50 PSI, then the switch shuts the pump off. If the operator 26 turns the on/off valve 36 on the wand 34 on, the pressure on the output side of the pump drops to near 0 PSI. The sensor immediately senses the pressure drop and the switch turns the pump on to restore pressure on the output side to a predetermined level. Those skilled in the art will recognize and understand the operation of this prior art pressure switch and sensor.
When the on/off valve 36 on the wand 34 is on and the bypass valve 140 is closed, the sensor turns the pump 70 on to deliver chemical to the wand 34. If the on/off valve 36 is off and the bypass valve 40 is closed, the sensor turns the pump 70 off. If the on/off valve 36 is off and the bypass valve 140 is open, the sensor will turn the pump 70 on and the system will operate in the agitation or recirculate mode to stir and mix the chemical in the tank 54. If the bypass valve 140 is open, it is assumed that the operator 26 will leave the on/off valve 36 in the wand off to facilitate agitation and recirculation.
Referring to FIG. 5, the tank 54 is shown from a left side elevation view. The pump cover 76 is mounted on the top of the tank 54. The wires 126 and 128 extend underneath the pump cover 76 and are attached to the electrical system of the vehicle. A slot 160 is formed in the bottom side of the pump cover 76 and a recess 162 is likewise formed in the side of the pump cover 76 to receive and fit over the handle 142 of the bypass valve 140. This recess 162 allows the operator 26 to grasp the handle 142 and actuate the bypass valve 140 when the pump cover 76 is in place. A screw recess 164 is likewise formed in the side of the pump cover 76 to receive the screw 78. An aperture 166 is formed in the side of the pump cover 76 allowing access to the pump 70 for adjustment of output pressure as described above.
Referring to FIG. 6, the tank 54 is shown in partial section view along the line 6--6 of FIG. 4. The bottom 176 of the tank 54 includes a sump 178 which is lower than the floor 179 on the inside 64 of the tank 54. One end of the pump suction hose 180 is connected to a filter screen 182 and the other end is connected to the barbed portion of the inlet fitting 184. The inlet fitting 184 includes a barbed portion 183, a threaded portion 185, a hex portion 187 and an elongated portion 189. The end of the elongated portion 189 of the inlet fitting 184 is crimped in a 90° elbow fitting 181 which connects to the suction side 179 of the pump 70.
The screen 182 and the suction hose 180 rest in the sump 178 of the tank 54. A boss 186 is formed in the bottom 188 of the recess 72 to threadably engage the threaded portion 185 of the inlet fitting 184. A second boss 190 is also formed in the bottom 188 of the recess 72 to threadably receive the agitator fitting 192. The inlet fitting 184 and the agitator fitting 192 are preferably formed from brass or Delrin thermoplastic. One end of the agitator hose 144 is connected to the barbed extension protruding from the agitator fitting 192. The other end of the agitator hose 144 is connected to a venturi nozzle assembly 194, as is better seen in FIG. 9.
The liquid level of the chemical is indicated by the wavy line 196 on the interior 64 of the tank 54. The chemical enters the screen 182 as indicated by the flow arrows. When the operator 26 turns the on/off valve 36 on, negative pressure is created by the pump 70 in the suction hose 180 which causes the chemical to move up the hose to the suction side of the pump as indicated by the flow arrows. Assuming that the bypass valve 140 is in the closed position, the chemical then passes through the pump 70 and the "T" fitting 130 through the output hose 136 and the fitting 234 to the swivel assembly 198 into the hose 28 for application to a remote target.
If the bypass valve 140 is open, the chemical passes through the "T" fitting 130 to the agitator hose 144 and through the venturi nozzle 194. This causes the agitator hose 144 to swing to and fro on the interior 64 of the tank 54, agitating and mixing the chemical. A jet action is also created by the venturi nozzle 194, further agitating the chemical.
Referring to FIG. 7, the hose spool 42 is shown in section view with a portion of the tank 54 along the line 7--7 of FIG. 4. The hose spool 42 includes a barrel 208, a first rim 212 positioned on one end of the barrel 208 and a second opposing rim 212 positioned on the other end of the barrel 208. A cylindrical recess 214 is formed in the first rim 210 to receive the female swivel body 216. An opposing cylindrical recess 218 is formed in the second rim 212 to threadably receive the shaft 98 of the hand crank assembly 44. The barrel 208 is hollow and includes an access port 220 which receives the hose 28. The access port 220 facilitates assembly of the swivel assembly 198.
The first buttress 88 includes a hole 94 therethrough which receives the male swivel body 102. A fitting 234 is positioned in the hose channel 150. The fitting 234 threadably engages the male swivel body 102 holding it in a stationary position so that the male swivel body 102 does not rotate when the hose spool 42 is rotated. The second buttress 90 includes an aperture 94 which forms a bearing for the shaft 98 of the hand crank assembly 44. A liner can also be placed in the aperture 94 to reduce wear on the tank 54. When the handle 218 is rotated, the shaft 98 rotates imparting rotational movement to the hose spool 42 which causes the female swivel body 106 to rotate about the stationary male swivel body 102 held in a stationary position in the first buttress 88.
The hand crank assembly 44 is preferably formed from cast aluminum. However, those skilled in the art will recognize that other substances may be suitable for this application. The handle 218 is articulated and can fold into a recess 217 in the arm 219 as shown by the arrow. The elongate handle 218 has a central bore aligned along the longitudinal axis. A T-shaped shaft 221 is mounted in the bore. A spring 223 slips over one end of the T-shaped shaft and is held in place by a nut 225 and washer. When the handle 218 is folded towards the recess 217 in the arm 219 as shown by the arrow, the spring 223 is compressed allowing the handle 218 to move from the extended position to the retracted position as will be readily understood by those skilled in the art.
Referring to FIG. 8, the hose spool 42 is shown section view along the line 8--8 of FIG. 7. The triangular-shaped barrel 208 imparts rigidity to the hose spool 42.
FIG. 9 is an enlarged view of the agitator hose 144 and the venturi nozzle assembly 194. A restriction 220 is formed in the longitudinal bore 222 of the venturi nozzle assembly 194. A tangential passageway 224 intersects the longitudinal bore 220 downstream of the restriction 220. A venturi effect or jet action is created by the restriction 220 which causes the chemical to move through the bore 224 as shown by the flow arrows in the drawing. This jetting action serves to agitate the chemical in the tank 54. This jetting action also causes the agitator hose 144 to move about on the inside of the tank 54 which helps to keep the chemical mixed. When chemical is flowing through the venturi assembly 194, this may be referred to as the recirculation or agitation mode.
FIG. 10 is an enlargement of the swivel assembly 198 showing the first buttress 88 and the first rim 210 of the hose spool 42. An aperture 94 is formed through the first buttress 88 to receive the male swivel body 102. A bore 230 is formed along the longitudinal axis of the male swivel body 102. An inlet port 232 is drilled in the side of the male swivel body 102 and is in fluid communication with the bore 230. A fitting 234, not shown in this figure, is positioned in the hose channel 150 and threadably engages the inlet port 232, thus holding the male swivel body 102 in a stationary position in the first buttress 88. Fluid passes from the pump 70 through the outlet hose 136 through the fitting 234 and the inlet port 232 into the bore 230, as shown by the flow arrows.
One end of the male swivel body 102 forms an elongate stationary axle 236 which expands to an enlarged shoulder 238. Both the axle 236 and the shoulder 238 are load bearing members which support the female swivel body 106 and the hose spool 42. The female swivel body 106 includes a central bore 240 sized and dimensioned to receive the elongate stationary axle 236. The bore 240 expands to an enlarged diameter 243 to fit over the shoulder 238 of the male swivel body 102. The female swivel body 106 rotates about the stationary elongate axle 236 and the shoulder 238.
A seal chamber 244 is formed in the annular area between the axle 236 of the male swivel body 102 and the enlarged diameter 243 in the female swivel body 106. A seal 104 fits inside of the seal chamber 244 to provide a fluid-tight seal between the male swivel body 102 and the female swivel body 106. An outlet port 246 is formed in one end of the female swivel body 106 and threadably receives a fitting 108 which is crimped about one end of the flexible hose 28. A washer 250 is positioned between the fitting 248 and the back side 252 of the recess 214 thus securing the female swivel body 106 in a fixed position.
The left rim 210 of the hose spool 42 includes a circular shoulder 254 and circular locating boss 256. The opposing rim 212 likewise includes a circular shoulder 258 and a locator boss 260. The purpose of the locator bosses 256 and 260 is to provide as tight a fit as possible for the hose spool 42 between the first buttress 88 and the second buttress 90. The locator bosses 256 and 260 serve to minimize the amount of slop between the male swivel body 102 and the female swivel body 106. Depending on manufacturing tolerances, the length of the elongate stationary axle 236, the shoulder 238 and the size of the seal chamber 244 must be long enough to allow for a certain amount of slop between the hose spool 42 and the buttresses 88 and 90 and still maintain a fluid-tight seal.
FIG. 11 is a bottom plan view of the tank 54. A protrusion 270 extends from the bottom 176 of the tank 54. This protrusion forms the sump 178, better seen in FIG. 6. A first lateral channel 272, a second lateral channel 274 and a third lateral channel 276 connect with the sump 178. The aforementioned lateral channels angle downward towards the sump 178 to facilitate drainage of any residual liquids to the sump 178 to fully empty the tank 54 and to add structural rigidity to the bottom 176.
FIG. 12 is a section view of the tank 54 in section view along the line 12--12 of FIG. 11. The lateral channel 274 angles downward towards the sump 178 to drain all liquids toward the sump 178. The tank 54 includes a foot 280 which extends around the outside perimeter of the tank 54. In order to secure the tank 54 to the truck bed 22, a first angle iron 282 and a second angle iron 284 are welded or otherwise attached to the bed 22 of the pickup truck 25. A plurality of attaching screws 286 and 288 pass through the angle iron and threadably engage the foot 280 along the bottom perimeter of the tank 54. At least two angle irons are recommended for securing the tank 54; however, as a matter caution, additional angle irons could be added to the other sides of tank 54.
FIG. 13 is a perspective view of a mounting bracket 300 which can be stamped from metal or formed from plastic as a matter of manufacturing convenience.
A first hole 302, a second hole 304, a third hole 306 and a fourth hole 308 are placed in the bottom of the mounting bracket 300. A first mounting bracket screw 312 engages the first hole 302. A second mounting bracket screw 312 engages the hole 304. A third mounting bracket screw 314 engages the hole 306 and a fourth mounting bracket screw 316 engages the fourth hole 308. These screws attach the mounting bracket 300 to the bed 22 of a pickup truck 25 or other surface.
Referring to FIG. 14, the mounting bracket 300 is secured to the bed 22 of the pickup truck 25 by mounting screws 312 and 316. A plurality of screws 318 and 320 pass through the mounting bracket 300 and engage the foot 280 around the bottom of the tank 54. This mounting system can also be used to mount the tank 54 on a frame above the bed of a truck to allow more storage underneath the frame and tank.
Referring to FIG. 15, the tank cap 68 is shown in section view. The interior diameter 350 of the tank cap 68 is threaded to threadably engage the fillwell 66, as best seen in FIG. 3.
Referring to FIG. 16, the tank cap 68 is shown in an alternative embodiment with a neck 352 formed in the center of the cap. The interior diameter of the neck 352 is threaded to receive a conventional locking gas cap 354. In this alternative embodiment, the tank cap 68 would be rigidly attached to the fillwell 66 by a screw or other means. This would limit access to the interior 64 of the tank 54 through the neck 352. The locking gas cap 354 would be a means for easily and economically controlling access to the interior 64 of the tank 54. The locking gas cap 354 is readily available at any auto parts store and contains a one-way vent which allows air into the interior 64 of the tank 54 but does not allow vapor to exit from the gas cap 354.
Referring to FIG. 17, the pigtail ring assembly 40 is shown in perspective view. The ring includes a base 360 which has a first hole 362, a second hole 364 and a third hole 366 formed therein. A first bolt 368 is sized and dimensioned to pass through the first hole 362. A second bolt 370 is sized and dimensioned to fit through the second hole 364 and a third bolt 372 is sized and dimensioned to fit through the third hole 366.
The pigtail ring assembly 40 includes an upstanding vertical portion 374 which is bent into a diagonal portion 376, which is then bent into a circular portion 378 which finishes with an elongate portion 380 to complete the construction of the pigtail ring assembly 40. There is a gap 382 between the elongate portion 380 and the diagonal portion 376 which allows the hose 28 to be freely inserted or removed from the pigtail ring assembly 40.
FIG. 18 is a section view of the pigtail ring assembly 40 attached to the tank 54. A first boss 400 is formed in the side of the tank 54 and is rotomolded with a female threaded insert 402 in place. The metal insert 402 receives the bolt 373 which passes through the hole 366 in the base 360 of the pigtail ring assembly 40. A second boss 404 is formed in the side of the tank 54 and likewise receives a metal female threaded insert to threadably engage the bolt 368. Another boss, not shown in the drawing, is formed in the side of the tank 54 with a female threaded insert to receive the bolt 370.
FIG. 19 is an exploded perspective view of the swivel assembly 198. An inlet port 232 is bored in the side of the male swivel body 102 to receive the fitting 234. A bore 230 is formed along the interior longitudinal axis of the male swivel body 102 and is in fluid communication with the fitting 234. A axle 236 protrudes from one end of the male swivel body 102 and an enlarged shoulder 238 abuts against the axle 236. The tip 420 of the axle 236 is tapered to facilitate assembly and rotation. A seal 104 fits over the axle 236. The female swivel body 106 has an interior bore 240 which is sized and dimensioned to fit over the axle 236, and an enlarged diameter 243 which is sized to fit over the shoulder 238, enabling rotation of the female swivel body 102 and hose spool 42. An outlet port 252 is formed in the end of the female swivel body 106 and receives the fitting 108.
Those skilled in the art will recognize that the various types of seals 104 are suitable for this application. Applicant believes that a TEFLON®, which is E.I. DuPont de Nemours and Company's trademark name for tetrafluoroethylene, rotary seal, part no. 115HB-206, obtainable from Bal Seal Engineering Company, Inc., located in Santa Ana, California, is particularly well suited for this purpose. The outside diameter of this particular seal is 0.750 inches and the inside diameter is 0.500 inches. The aforementioned seal is formed from TEFLON and contains two interior springs. The first spring 422 exerts pressure towards the outside diameter of the seal, thus holding it in place inside the seal cavity 244. The second spring 424 exerts pressure towards the outside diameter and the inside diameter of the seal to prevent loss of fluid. The second spring 424 creates a U-shaped cup 425 which allows fluid pressure to be exerted against the exterior lip 426 and the interior lip 427, thus helping to form a fluid-tight seal between the male swivel body 102 and the female swivel body 106. Applicant has also found that it is suitable to manufacture the male swivel body 102 and the female swivel body 106 from Delrin thermoplastic. Those skilled in the art will recognize that other substances may also be suitable for manufacture of the swivel bodies.
FIG. 20 is a partial section view of the recess 72 showing how the pump 70 mounts to the tank 54. It should be noted that the bottom of the recess 72 is sloped on an angle of one to three degrees towards left sidewall 4 which facilitates drainage of any liquid which might enter the recess 72. A first boss 450 is formed in the tank 54. A second boss 452 is likewise formed in the tank 54. A third and fourth boss, not shown in this drawing, are also formed underneath the recess 72 in the tank 54. The first boss 450 threadably receives screw 122 and the second boss 452 threadably receives the screw 124. The other screws, 118 and 120, likewise threadably engage the other bosses not shown in this drawing. A anti-vibration washer 354 insulates the tank 54 from the mounting bracket 356 of the pump 70. Another anti-vibration washer 358 separates the screw 124 from the mounting bracket 356. The washers, 354 and 358, are designed to dampen any vibration caused by the pump 70. Those skilled in the art will recognize that other means may be used for dampening vibrations of the pump 70 and/or attaching the pump 70 to the tank 54.
Another boss 190 is likewise formed in the wall of the tank 54 to receive the inlet fitting 184. The integral inlet fitting 184 includes a barbed portion 181, a threaded portion 185, a hex portion 187 and an elongated portion 189. The agitator fitting 192, not shown in the drawing, is of similar integral construction.
FIG. 21 is a top plan view of an alternative embodiment the integrated modular spraying system suitable for applying dry flowables. The alternative embodiment of the integrated modular spraying system 2 includes an air pump 500 which is powered by a twelve volt D.C. electric motor. The air pump for a twelve gallon tank should have an output in the range of 0.5 to 2.0 cubic feet per minute. Those skilled in the art will recognize that many different pumps are suitable for this application. A first wire 502 and a second wire 504 are connected to the electrical system of the vehicle to power the air pump 500. This alternative embodiment does not include an agitation hose or a recirculation feature like the liquid pump. Most of the other structural members are the same. For example, a tank cap 68 fits on top of the fillwell 66. The hose spool 42 fits in a well 84 and is supported by a first buttress 88 and a second buttress 90. The hose spool 42 includes a first rim 210 and a second rim 212. A hand crank assembly 44 enables the operator 26 to rewind the hose 28 after the job has been completed. Automatic rewind devices may be substituted in this embodiment and the prior embodiment for the hand crank assembly 44 to rewind the hose about the spool 42.
The air pump 500 pumps air through the inlet line 506 which connects with an inlet hose 508, better seen in the next figure. Aerosolized dust exits the tank 54 through the fitting 510 and enters the outlet hose 536 which is connected to the swivel assembly 198 in the same fashion as for the liquid embodiment.
FIG. 22 is a section view of the tank 54 along the line 22--22 of FIG. 21. A dust substrate is located along the floor 179 of the interior 64 of the tank 54. The inlet hose 508 rests in the sump 178 and includes a check valve 514 at the end thereof. Air bubbles 516, 518 and 520 pass through the dust substrate after leaving the check valve 514. When an air bubble reaches the top of the substrate 522, it implodes creating a dust cloud as shown by the particles 524. These dust particles 524 create an aerosolized strata in the upper section 526 of the interior 64 of the tank 54. These aerosolized particles exit through an outlet fitting 228 and pass through a 90° elbow 510 which is connected to the outlet hose 536. These aerosolized particles then enter the swivel assembly 198 and pass through the hose 28 in the same fashion as liquids.
While the foregoing is directed to the preferred embodiment 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 which follow.
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The integrated modular spraying system is suitable for applying chemicals, including liquids and dry flowables, to various remote locations. The system includes an integrated modular tank which is preferably rotomolded from thermoplastic. A well is formed in the side of the tank and is further defined by two opposing buttresses which receive and support a freely rotating hose spool. A pump is located in a recess in the tank for pumping chemicals from the tank through the flexible hose. The hose can be peeled off from the hose spool for a substantial length to enable an operator to spray a chemical at locations remote from the integrated modular spray apparatus. After application of the chemical is complete, the hose spool can be rotated to rewind the flexible hose about the spool. In an alternative embodiment, the apparatus is suitable for applying dry flowables, including various insecticidal dusts and powders, using an air pump instead of a liquid pump.
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The present patent application is the National Stage of International Application No. PCT/KR2011/004588, filed Jun. 23, 2011, which claims the benefit of Korean Patent Application No. 10-2010-0069947, filed on Jul. 20, 2010, in the Korean Intellectual Property Office, the disclosures of which are incorporated herein in their entirety by reference.
BACKGROUND
1. Field
Considering the present invention of clean energy generation from wave power, for encouraging active investment and research activities to the wave power generator, power generation system is to have relatively high conversion efficiency from wave energy and complementing irregular output from uncertainty of environment by nature, and to enhance the practicality and the value thereof as a clean energy resource, especially by virtue of the improved return on investment thereof.
2. Description of the Related Art
Our future is being threatened by exhaustion of fossil fuel resources, increasing cost pressure of energy due to reduced production and cost advancing pressure from oil-producing countries, and serious environmental pollution coming out from energy consumption.
In addition, conventional power generation system using fossil fuels, there are various power generation systems using various kinds of energy resources such as nuclear energy, tidal energy, water energy, wind energy, solar energy, bio energy, and so on.
However, nuclear energy even having economic feasibility has been restrictively developed only in some countries due to the Nuclear Nonproliferation Treaty and radioactive contamination, meanwhile water energy and tidal energy require proper site location satisfying system requirements, anticipated excessive investment and long-term construction period, while solar energy and wind energy require storage cell due to intermittent generation and higher cost.
Accordingly, development of wave power generation system using clean energy is still needed.
Considering those systems consuming fossil fuels, future-oriented new power generation systems using clean energy resources must be competitive in construction costs and operation cost to the conventional electric power systems including land occupations, anticipative investments, construction periods, social costs from environmental pollution, and so on. In addition, the wave power generation system must have high annual operation rate and be free from expensive storage equipment or auxiliary power generation.
Meanwhile, since water having heavier mass has higher kinetic energy than air having lighter mass the technology converting kinetic energy of moving seawater, i.e., research of generating electricity from wave power is now in advance.
In particular, considering that most countries have long coastal lines faced to ocean, energy resources from sea wave are out of count. However, frequency and wave power in near shore and offshore have high fluctuations according to environment of the locations and seasons, whereas relatively lower wave height often occurs according to season's weather condition.
Accordingly, if the disadvantage of practice caused by lower wave height and uneven wave period could be eliminated, uncountable wave power will be secured at no cost.
Technologies of converting wave power into energy have been opened already as an oscillating water column type, a movable body type (including a raft type), a raft conversion type, a shoulder cam type, an energy amplification and concentration type and air turbine type.
The oscillating water column type is most commonly used, but has a number of drawbacks. For example, the oscillating water column type takes long time to construct a large-scale bottom structure and uses inefficient air turbine, leading to cost ineffectiveness and necessarily changing output power due to a change in atmospheric pressure. In the case of the raft conversion type, an oil pressure pump with relatively less number of strokes is cost-ineffective and considered unsafe, so that it is no more a thing of interest. Both the oscillating water column type and the raft conversion type are available to generate power only when a wave height reaches a certain level. In addition, both of them are not efficient in energy conversion, and are adapted in a small range of usable wave.
As a raft is the most adequate medium to convert wave energy into useful energy, using mass movement of the raft, so that the raft conversion type may be the most promising method to generate power using wave energy. However, there are still many issues blocking the development of the raft conversion type, including low efficiency of the conversion type, variability of seasonal output power, concerns over stability against an abnormal wave and a gap in expenses between wave power generation and fossil-fuel power generation. Therefore, more researches and development need to be done to address the above troubling problems.
SUMMARY
The following description relates to providing a wave power generator which has a relatively high energy conversion efficiency with an increased investment-to-efficiency rate, so that the practicality and value of wave may be improved as a clean energy source.
The above objectives may be achieved by a wave power generator including one or more raft vessels, each having in a central point thereof a node that moves freely according to wave height and leads a flow of fluid inside of the raft vessel with a constant water level; and an energy generating unit connected in series to a vertical axis C on a cross section of the node of each raft vessel and configured to generate energy using kinetic energy of the raft vessel.
At this time, the wave power generator may further include an air balance tank configured to connect an end of the first raft vessel and an end of a second raft vessel, each raft vessel constituting the one or more raft vessels, spaced apart from one another and connected to each other; connection lines configured to connect the air balance tank to the first raft vessel and the second raft vessel; an air compressor connected to the air balance tank; and a controller configured to control internal air pressure of the air balance tank via the air compressor.
The air balance tank may be a convex U-type tank.
The raft vessel further may include a piezoelectric element for generation of electricity at one end thereof.
The raft vessel may have a length which is half a wave cycle and a height which is two times higher than a wave height, and wetted parts inside of the raft vessel may be coated or treated with less-resistant laminated surface.
The energy generating unit may include a gear box, a multipolar generator and a cross-flow water turbine with a sirocco fan, with the latter directly connected to the vertical axis C on the cross section of the node of the raft vessel.
The wave power generator may further include guide walls formed in surroundings of the cross-flow water turbine to guide fluid flowing into the water turbine.
Other features and aspects will be apparent from the following detailed description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating movement of a raft vessel on a sea wave and movement of fluid inside of the raft vessel according to an exemplary embodiment of the present invention;
FIG. 2 is a schematic cross-sectional view of a generating system;
FIG. 3 is a plan view of FIG. 2 ;
FIG. 4 is a conceptual plan view illustrating an air balance tank;
FIG. 5 is a P-P line cross-sectional view of FIG. 4 ;
FIG. 6 is a block diagram illustrating a method for controlling a wave power generator according to an exemplary embodiment of the present invention; and
FIG. 7 is a comparative diagram illustrating comparison of transferring wind power energy and wave power energy.
Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.
DETAILED DESCRIPTION
The following description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses, and/or systems described herein. Accordingly, various changes, modifications, and equivalents of the methods, apparatuses, and/or systems described herein will suggest themselves to those of ordinary skill in the art. Also, descriptions of well-known functions and constructions may be omitted for increased clarity and conciseness.
FIG. 1 is a diagram illustrating movement of a raft vessel on a sea wave and movement of fluid inside of the raft vessel according to an exemplary embodiment of the present invention; FIG. 2 is a schematic cross-sectional view illustrating a generating system; FIG. 3 is a plan view of FIG. 2 ; FIG. 4 is a conceptual plan view of an air balance tank; FIG. 5 is a P-P line cross sectional view of FIG. 4 ; FIG. 6 is a block diagram illustrating a method for controlling a wave power generator according to an exemplary embodiment of the present invention; and FIG. 7 is a comparative diagram illustrating comparison transferring wind power energy and wave power energy, respectively.
The present invention is provided under a condition that water holds 800 times greater energy than air since the mass of water is greater than that of air.
A general consensus is that using a flow of fluid (water) in a raft vessel 11 is more effective than using air vibration in order to convert wave power into useful energy, and the present invention is based on the general consensus.
Kinetic energy (p) of fluid is acquired using the following [Equation 1].
P ( W )=½ ρAV 3 [Equation 1]
P: Kinetic Energy of Fluid
ρ: Density of Fluid
A: Flow Cross Section of Fluid
V: Flow Velocity
FIG. 1 is a diagram illustrating movement of a raft vessel on a sea wave and movement of fluid inside of the raft vessel. In FIG. 1 , (a) indicates a tranquil state without a waveform, (b) shows a state with a waveform tilted upward to the left, and (c) points out a state with a waveform tilted upward to the right.
Referring to FIG. 1 , if fluid, that is, water, fills only half the raft vessel 11 , to control mass of the raft vessel 11 , the fluid moves according to displacement movement of the raft vessel 11 led by a waveform, as shown in FIG. 1 .
In this case, a central part of the raft vessel 11 is a node N or a node axis N with constant water level. On the basis of the node N, reciprocating movement of water occurs according to displacement movement of the raft vessel 11 led by a waveform. That is, when two ends A and B of the raft vessel 11 moves from locations shown in (a) of FIG. 1 to locations shown in (b) or (c) of FIG. 1 , fluid inside of the raft vessel 11 moves along together. In other words, when the fluid of the raft vessel moves from (a) of FIG. 1 to (b) or (c) in FIG. 1 , the fluid volume S 1 is the same as the fluid volume S 2 with constant water level.
In the case where the raft vessel 11 has a length L which is half a wave cycle and a height H which is two times higher than a wave height, water inside of the raft vessel 11 may flow most effectively.
Theoretically, energy of flowing water is proportional to the cubed value of a flow velocity of the water as shown in the above [Equation 1]. In addition, the steeper inclination of a flow cross section of water, the faster a flow velocity of water is
Specifically, while an inclination angle of the raft vessel 11 gradually changes according to a waveform and a wave cycle, water returns to a horizontal state at a faster rate, and thus, the flow velocity does not rapidly change at the location of the node N. Thus, the flow velocity is determined by a volume of water which moves to either end of the raft vessel 11 according to inclination of a wave form during a wave cycle.
However, a safety measure, such as conduction, is required, since fluid inside of the raft vessel 11 may change and preponderate a center of mass of the raft vessel 11 and increase an underwater depth of the raft vessel 11 , increasing a value of an inclination angle of the raft vessel 11 to be greater than an inclination angle of a corresponding waveform.
However, such technical problems may be addressed if the raft vessel is provided with excessive buoyancy and an air balance tank 40 to both ends thereof, as described in the following. Specifically, the air balance tank 40 is designed, in response to an abnormal buoyancy of the raft vessel 11 , to prevent emergence of one end of the raft vessel 11 having relatively less mass on water surface using an attractive force led by a negative force which occurs between water surface and the raft vessel 11 when the raft vessel 11 floats abnormally.
In addition, instability of the independent raft vessel 11 against an unexpected abnormal wave may be minimized by repellent force of a lever L (See, FIG. 4 ) connecting a plurality of the raft vessels 11 . The connection technique of the lever L may be referred in Korean Patent Application No. 10-2009-0007890, invented by the same inventor of the present invention.
In conclusion, the most stable and effective energy conversion method may be installing water turbine 21 (as of today, a cross flow water turbine is known for the highest efficiency), which rotates at a location of the node N in one direction, regardless of in which direction water flows, in order to convert fluid energy of water into electrical energy, and then generating electrical power using a piezoelectric element 30 which is installed at one end of the raft vessel 11 with significant water pressure led by water crash energy and water level change with reference to FIGS. 2 and 3 .
Again, referring to FIG. 1 , as the raft vessel 11 becomes inclined due to a wave, water inside of the raft vessel 11 flows toward each end alternatively, according to a wave cycle based on the node N. As a result, a flow velocity V may be achieved on a cross section of the node N, and such flow velocity V is represented by [Equation 1] as below:
Flow Velocity (V)=Change Rate of Volume (dv)/Wave Cycle (s)/Cross Section of Node (a) [Equation 2]
That is, wave power energy is transferred to become a flow of fluid inside of the raft vessel 11 , so that the wave power energy is transformed into a flow velocity V on a flow path of a cross section a.
Meanwhile, as illustrated in FIG. 2 , it is possible to generate output power by connecting an energy generating unit 20 , which includes a water turbine 21 , a gear box 23 and a multipolar generator 25 , to a vertical axis C on a cross section of the node N of the raft vessel 11 .
In addition, guide walls 22 may be prepared in surroundings of the water turbine 21 to guide fluid flowing into the water turbine 21 so as to improve efficiency of the water turbine 21 . At this time, configuration, structure and an angle of the guide walls 22 are not limited as shown in FIG. 3 , but may be determined through a hydrodynamic review and a miniature experiment. That is, claims of the present invention are not necessarily limited as shown in the schematic diagrams of FIGS. 2 and 3 .
In addition, wetted parts of the raft vessel 11 may be coated or treated with a less-resistant laminated surface in order to streamline water flow.
As illustrated in FIGS. 4 and 5 , a pair of raft vessels 11 , that is, a first raft vessel 11 and a second raft vessel 12 , is prepared and then connected to each other via the lever L. In addition, a convex U-type air balance tank 40 is installed to connect an end of the first raft vessel 11 to an end of the second raft vessel 12 . Next, an air compressor 45 and a controller 50 in association with the air compressor 45 control internal air pressure of the air balance tank 40 so as to use the internal air pressure as excessive buoyancy. If the internal air pressure is reduced, a reduced air pressure may serve as ballast due to an attractive force led by a negative pressure. Ballast refers to water which fills a ballast tank to keep the balance of a ship.
At this time, a plurality of the air balance tanks 40 may be installed in parallel between the first and the second raft vessels 11 and 12 . In this case, connection lines 46 connect each of the plurality of the air balance tanks 40 to the air compressor 45 .
For your reference, when an upside-down bowl is put on water surface, it is hard to lift the bowl due to atmospheric pressure. That is, it is difficult to pick the bowl up the water surface because water attracts the bowl. The air balance tank 40 of the present invention is designed based on this principle. In the above example, the bowl may be picked up by filling inside of the bowl with air. Similarly, internal air pressure of the air balance tank 40 may be controlled by the air compressor 45 and the controller 50 in association with the air compressor 45 .
The controller 50 includes a Central Processing Unit (CPU) 51 , a memory 52 and a support circuit 53 , as illustrated in FIG. 6 .
The CPU 51 may be one of various computer processors which are able to be applied in industries in order to control a wave power generator of the present invention. The memory 52 interacts with an operation of the CPU 51 . That is, the memory 52 is a readable recording medium and may be installed in a local or remote area. The memory 52 is at least one or more memories, such as a Random Access Memory (RAM), a Read Only Memory, a floppy disk, hard disk and arbitrary memory which is easy to handle and stores data in a digital form. In addition, the support circuit 53 interactively supports typical processor operations of the CPU 51 . The support circuit 53 may include a cache, a power supply, a clock circuit, an input/output circuit and a sub-system.
For example, the memory 52 may store overall processes occurring in a wave power generator, especially a process to control air pressure of the air balance tank 40 in the air compressor 45 . Typically, the memory 52 may store a software routine. The software routine may be stored and executed in another CPU (not illustrated). According to an exemplary embodiment of the present invention, the processes are executed by a software routine. However, at least some of the processes may be executed by hardware. As such, the processes of the present invention may be executed by software able to be implemented in a computer system, hardware such as an integrated circuit, or a combination of software and hardware.
For your reference, wind power is considered as an example comparable to wave power. Comparison of transferring wind power energy and wave power energy is provided with reference to FIG. 7 .
Wind power energy has little to do with fetch distance and is determined by a wind velocity of an area where a wind turbine is installed. In addition, the wind power energy is not accumulated even though wind is generated for a long time, and, if there is no wind, the energy disappears.
On the other hand, in spite of occurring due to wind power, wave power is accumulated and transferred on a basis of particle movement of water according to fetch distance and time from an ocean. That is, as illustrated in FIG. 7 , valid wind velocity does not necessarily lead to an occurrence of wave in coastal areas. For this reason, a valid operational time period of a wind turbine is shorter than a valid operational time period of a water turbine.
In conclusion, waves are generated by wind blowing on the ocean and transferred from a relatively remote area to a coastal area, so that the wave has greater energy and lasts for a longer period than wind blowing on a coastal area. Therefore, in the long run, making investment and efforts to develop a technology of wave power generation may be much more efficient and lucrative than those for wind power generation.
According to the above exemplary embodiments of the present invention, wave power generation is relatively efficient in energy conversion, so that active investment and research may be promoted by overcoming uncertainties of the nature. Most of all, with an increased investment-to-efficiency rate, the wave power may be expected to become a highly practical and valuable clean energy source.
Although not mentioned in the above exemplary embodiments of the present invention, the present invention may be used with a method disclosed in Korean Patent Application No. 10-2009-0007890 invented by the same inventor of the present invention. In this case, if the efficiency of a water turbine 21 increases, the most efficient, stable and cost-effective way to generate clean energy.
A number of examples have been described above. Nevertheless, it will be understood that various modifications may be made. For example, suitable results may be achieved if the described techniques are performed in a different order and/or if components in a described system, architecture, device, or circuit are combined in a different manner and/or replaced or supplemented by other components or their equivalents. Accordingly, other implementations are within the scope of the following claims.
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The present invention relates to a wave power generator, and more specifically, to a wave power generator that can promote more aggressive investment and research activities by overcoming the uncertainties of natural environment through the relatively high energy conversion efficiency thereof, and enhance the practicality and the value thereof as a clean energy source by increasing the investment-to-efficiency rate. To this end, the present invention comprises: one or more raft vessels, each having in a central point thereof a node that moves freely according to wave height and leads a flow of fluid inside of the raft vessel with a constant water level; and an energy generating unit connected in series to a vertical axis C on a cross section of the node of each raft vessel and configured to generate energy using kinetic energy of the raft vessel.
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This is a division of application Ser. No. 002,309, filed Jan. 9, 1987, now U.S. Pat. No. 4,768,492, issued Sept. 6, 1899.
BACKGROUND AND SUMMARY
The invention arose during development efforts relating to a marine propulsion system having an engine in a closed or heat-retentive compartment causing problems of vapor lock, and or spewing.
After the engine is turned off, the temperature in the closed heat-retentive compartment in a marine propulsion system continues to rise. The fuel line and fuel pump are no longer cooled by the flow of incoming fuel from the cooler fuel tank. The stagnant fuel sitting in the fuel line and the fuel pump will begin to vaporize and or boil as the fuel line and fuel pump continue to heat up.
It is known in the prior art to provide insulation around the fuel lines to isolate the fuel from the heat.
The present invention addresses and solves the above noted fuel vaporization problem by providing a thermally inertial mass which is actively cooled during running of the engine, and which prevents vaporization of the fuel after the engine is turned off. A fuel line cooler in the compartment is in heat transfer relation with the fuel line and has an inlet communicating with the source of cooling water for the engine and has an outlet for discharging water. During running of the engine, water is circulated through the fuel line cooler. After the engine is turned off, the cooled water in the fuel line cooler provides the noted thermally inertial mass to prevent vaporization of the fuel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a marine propulsion system with a fuel line cooler in accordance with the invention.
FIG. 2 is an exploded isometric view of a portion of the system in FIG. 1.
FIG. 3 is an isometric view of a portion of the fuel line cooler of FIGS. 1 and 2.
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3.
FIG. 5 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 6 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 7 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 8 is a sectional view taken along line 8--8 of FIG. 7.
FIG. 9 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 10 is a sectional view taken along line 10--10 of FIG. 9.
FIG. 11 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 12 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 13 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 14 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 15 is a sectional view taken along line 15--15 of FIG. 14.
FIG. 16 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 17 shows a further embodiment of a fuel line cooler in accordance with the invention.
FIG. 18 is a sectional view like FIG. 4 and shows a further clamping arrangement.
FIG. 19 is a top view of the structure in FIG. 18.
FIG. 20 is an end view of the clamp in FIG. 18.
DETAILED DESCRIPTION
FIG. 1 shows a marine propulsion system 2 including an inboard engine 4 in a closed heat-retentive compartment 5 and drivingly connected through the boat transom 6 to stern drive 8 for rotating propeller shaft 10. The stern drive has a water outlet 12 for supplying cooling water to the engine. This cooling water is supplied by a sea water pickup pump 14, FIG. 2, for which further may be had to Kiekhaefer U.S. Pat. No. 2,466,440 and Bloemers et al U.S. Pat. No. 4,392,779, incorporated herein by reference. A portion of FIG. 2 is taken from the Mercruiser "Service Training Notebook" 90-90593 4-985, page 127, and shows a Mercury Marine MCM 120 engine with standard cooling. In such standard cooling embodiment, sea water from pickup pump 14 is supplied through water line 12 to thermostat housing 16. When the engine is cold, the water from input line 12 first fills the engine and then is diverted by thermostat 16 to output line 18 which in turns supplies the water to exhaust manifold 20 and exhaust elbow 22. The exhaust elbow discharges the water with the products of combustion, for which further reference may be had to Sarra U.S. Pat. No. 3,541,786, incorporated herein by reference. When the engine warms sufficiently, cooling water from inlet 12 flows through thermostat 16 to passage 24 and is then circulated by engine circulating pump 26 through engine 4. Fuel pump 28 pumps fuel from a remote tank (not shown) and delivers the fuel through fuel line 30 to fuel distribution means such as carburetor 32 for supplying fuel for combustion.
In accordance with the invention, a fuel line cooler 34 has an inlet 36 communicating with the source of cooling water for the engine, and has an outlet 38 for discharging water. Inlet 36 is a water hose which may be connected to line 12 by means of a T-fitting 39, FIG. 1, or to thermostat housing 16 upstream of the thermostat valve therein, FIG. 2, or various other connections for providing the cooling water. Though a standard cooling system is shown providing sea water as the cooling water for the engine, the invention is of course applicable to systems where sea water is provided to a heat exchanger through which engine cooling water is circulated, commonly known as a closed cooling system. Outlet 38 is connected to exhaust manifold 20, though may be connected to water passage 18, or to other outlets for discharging the water, or directly discharged overboard. Sea water pickup pump 14 supplies cooling sea water for both engine 4 and fuel line cooler 34. Fuel line cooler 34 is between fuel pump 28 and carburetor 32 and cools the fuel line downstream of fuel pump 28. Alternatively or additionally, cooling water from inlet 36 may be provided to a water cooled fuel pump, for example Mickle et al U.S. Pat. No. 3,835,822 and Alden U.S. Pat. No. 2,791,186, incorporated herein by reference.
Fuel line cooler 34 includes a water hose 40, FIGS. 2-4, concentric to fuel line 30 and defining an annular space 42 through which cooling water flows in direct contact with the exterior surface of fuel line 30. The inlet includes water hose 36 connected to fitting 44. A compression ring 46 around fuel line 30 is compressed in sealing relation by a compression nut 48 around fuel line 30 and tightened to threaded fitting 44 to which water hose 40 is clamped. Fitting 44 has an inlet port 52 which is exteriorly barbed at 54 to receive and retain water hose 36 communicating therethrough with annular space 42. Fitting 44 has an exterior hex configuration for tightening to hex nut 48 Fitting 44 also has a slightly reduced outside diameter portion 56 for receiving water hose 40 and clamped by a hose clamp or by a plastic clip 58 as provided by a press-on clamp with mating serrated barbed fingers 60 and 62 and retained by outer finger 64, such as an SNP 24 clamp. The outlet at 38 is comparable. Water hose 40 is a bellows-type hose axially expandable along the direction of fuel line 30 and enabling selective placement of inlet 36 and outlet 38 along the fuel line to selectively control the length of the fuel line to be cooled. Concentric axially expandable bellows hose 40 selectively enables cooling of substantially the entire fuel line between fuel pump 28 and carburetor 32, or cooling of only a portion of such fuel line by spacing one or both of the inlet 36 and outlet 38 from its respective end of the fuel line between fuel pump 28 and carburetor 32.
FIG. 5 shows an alternate embodiment and uses like reference numerals from the above figures where appropriate to facilitate clarity. The fuel line cooler is provided by a water hose 40a wound in a helical coil around fuel line 30a such that cooling water flowing through helical coil hose 40a cools the hose which in turn cools the fuel line.
FIG. 6 shows another embodiment and like reference numerals are used from the above figures where appropriate to faciliate clarity. The fuel line cooler includes a water hose 40b, The fuel line 30b is wound in a helical coil around water hose 40b.
FIGS. 7 and 8 show another embodiment and like references numerals are used from the above figures where appropriate to facilitate clarity. The fuel line cooler includes a clamp 70 clamping water hose 40c into heat transfer relation with fuel line 30c. Water hose 40c is clamped into direct heat transfer contact with fuel line 30c, FIG. 8, in parallel side-by-side relation. Clamp 70 has a central elongated shank 72 extending axially along and engaging a portion of fuel line 30c and having an axial locating groove 74 for receiving the fuel line. A first pair of opposing jaws 76 and 78 extend oppositely radially from central shank 72 and partially around water hose 40c and terminate at respective jaw ends 80 and 82. A second pair of jaws 84 and 86 are axially spaced from the first pair of jaws 76 and 78 and extend oppositely radially from central shank 72 and partially around water hose 40c. A third pair of jaws 88 and 90 are axially spaced from the second pair 84 and 86 and extend oppositely radially from central shank 72 and partially around water hose 40c. A hose clamp 92 is placed around water hose 40c and guided by outer shoulders 76a, 76b and 78a, 78b on jaws 76 and 78 and tightened by hose clamp screw 94. Hose clamps 96 and 98 are likewise provided around their respective jaws for clamping to the water hose.
FIGS. 9 and 10 show another embodiment and use like reference numerals from the above figures where appropriate to facilitate clarity. A rubber hose 100 has a fuel passage 102 therethrough for either receiving fuel directly or receiving fuel line 30d. Rubber hose 100 is affixed to water hose 40d, for example by vulcanizing. Alternatively, hose 100 and hose 40d are integrally molded rubber having a figure eight shaped configuration in cross section, FIG. 10, with one of the loops of the figure eight defining a water passage 104, and the other of the loops of the figure eight defining a fuel passage 102. Only a portion of water hose 40d need extend contiguously along integral with or affixed to hose 100, and other sections of the water hose may continue to respective inlet and outlet ports, for example as shown at water hose sections 106 and 108.
FIG. 11 shows another embodiment and uses like reference numerals from the above figures where appropriate to facilitate clarity. A portion of the flywheel housing 110 for a stern drive on the inboard side of the transom is shown. This housing section is formed with an extra upstanding base member portion 112 having a groove 114 therein receiving fuel line 30e and water hose 40e. A cap member 116 is mounted by bolts 118 and 120 to base member 112 and holds water hose 40e and fuel line 30e in heat transfer relation. Groove 114 is generally V-shaped, and fuel line 30e is in the bottom of the groove and water hose 40e directly contacts fuel line 30e. The profile of water hose 40e is higher than the outer edge of the V-shaped groove 114, and cap member 116 is curved around over the top of water hose 40e.
FIG. 12 shows another embodiment and uses like reference numerals from the above figures where appropriate to facilitate clarity. Base member 112a is similar to base member 112 and has a first groove 122 providing a fuel passage 124 for directly receiving fuel or for receiving fuel line 30f, and has a second groove 124 providing a water passage directly receiving water or receiving water hose 40f. Cap member 116a is mounted to base member 112a by bolts 118a and 120a and closes fuel passage 122 and retains fuel line 30f therein, if present, and closes water passage 124 and retains water hose 40f therein if present. Fuel line 30f is spaced and separate from water hose 40f by the material of base member 112a. Heat transfers between the fuel passage and the water passage through the base member material.
FIG. 13 shows another embodiment and uses like reference numerals from the above figures where appropriate to facilitate clarity. Base member 112b has a groove 126 providing a water passage directly receiving water or receiving the water hose. Cap member 116b is mounted to base member 112b by bolts 118b and 120b and has a fuel passage 128 for directly receiving the fuel or receiving the fuel line. Fuel passage 128 and water passage 126 are spaced and separated by the material of cap 116b, and heat transfers therebetween through the cap material.
FIGS. 14 and 15 show another embodiment and use like reference numerals from the above figures where appropriate to facilitate clarity. The side of engine block 4 has a raised base member 130 integrally formed therewith. Base member 130 has a serpentine S-shaped exposed groove 132 therein for receiving water hose 40g. A cap member 134 is mounted by bolts such as 136 to base member 130 and has a fuel passage 138 therethrough with threaded fittings 140 and 142 at its ends for connection to fuel line 30g. Cap 134 has a plurality of finger projections such as 144 extending into groove 132 along different portions of the serpentine path and deforming water hose 40g in a general C-shaped configuration, FIG. 15. Water hose 40g and fuel passage 138 are spaced by the material of cap 134 for heat transfer therethrough, with increased surface contact area provided by fingers 144.
FIG. 16 shows another embodiment and uses like reference numerals from the above figures where appropriate to facilitate clarity. A cast housing 146 is bolted to the engine block or fly wheel housing through bolt or stud receiving apertures such as 148 and 150. Housing 146 has a fuel passage 152 therethrough with threaded ends for attachment to the fuel line, and has a recessed exposed groove 154 for receiving water hose 40h. A hose clamp 156 retains water hose 40h in groove 154 in heat transfer relation with the cast housing. Fuel passage 152 and water hose 40i are in spaced relation separated by the cast housing material therebetween through which the heat is transferred.
FIG. 17 shows another embodiment and use like reference numerals from the above figures where appropriate to facilitate clarity. A clamp is provided by a clip 158 affixed, such as by braising, to fuel line 30i and retaining water hose 40i in snap-in relation and deforming water hose 40i around fuel line 30i in a C-shaped configuration in cross section. Two or more such clips 158 are provided. The clip has a central portion 160 braised to fuel line 30i and extending into oppositely curved portions 162 and 164 curving around and over the hose at 166 and 168 and forming a pair of oppositely facing spring clip legs terminating at facing edges 170 and 172 separated by a gap 174 through which hose 40i is inserted transversely to the axial direction of fuel line 30i.
FIGS. 18-20 show an alternative to the clamping arrangement of FIGS. 3 and 4 and is preferred to facilitate ease of removal and replacement of the water hose. The fuel line cooler 34a includes water hose or conduit 40a concentric to fuel line or conduit 30a and defining an annular space 42a through which cooling water flows in direct contact with the exterior surface of fuel line 30a. Compression ring 46a around fuel line 30a is compressed in sealing relation by compression nut 48a tightened to threaded fitting 44a at threaded interface 47a. Fitting 44a is around fuel line 30a and has a smaller inner diameter portion 44b engaging fuel line 30a adjacent compression ring 46a and inward of threads 47a. Fitting 44a has a larger inner diameter portion 44c radially spaced outwardly from fuel line 30a to define an annular gap coincident with annular space 42a. Portion 44c of fitting 44a has a port 202 therethrough communicating with annular space 42a. Port 202 is an opening extending radially through fitting 44a relative to the axial extent of fuel line 30a. Hose 40a is disposed circumferentially around fitting 44a and has an aperture 204 aligned with opening 202. A clamp 58a is disposed circumferentially around water hose 40a and clamps the hose to fitting 44a. Clamp 58a has mating serrated barbed fingers 60a and 62a, FIG. 20, between inner and outer fingers 59a and 64a. The clamp is closed to a clamped condition by squeezing grip portions 63a and 65a towards each other. The clamp is released to an unclamped condition by pulling finger 64a outwardly to enable the separation of the serrations of fingers 60a and 62a away from each other. The finger portions 59a-65a are like those in the above noted SNP 24 clamp known in the prior art.
Clamp 58a has an inner tubular portion 206 extending radially inwardly through aperture 204 in water hose 40a and through opening 202 in fitting 44a to communicate with annular space 42a. Clamp 58a has an outer tubular portion 208 communicating with inner tubular portion 206 along a common bore 210 therethrough. Tubular portion 208 has an outer barbed configuration as at 212 for connection to water hose 36, FIG. 4, or other fluid carrying conduit. Fitting 44a has an exterior hex configuration for tightening to hex nut 48a, as in FIGS. 3 and 4, at threaded interface 47a.
To facilitate removal and replacement of water hose 40a, one end of fuel line 30a is disconnected from the carburetor or from the fuel pump. Clamp 58a is then released, including withdrawal of inner tubular portion 206 out of opening 202 in fitting 44a and out of aperture 204 in water hose 40a. This enables the water hose 40a to be axially slid off of fitting 44a. The inlet and outlet of water hose 40a have the same clamping arrangements as such as 58a. Hence, in FIG. 18, if the left end of the fuel line is disconnected, water hose 40a is axially slid leftwardly such that the right end of the hose is slid off of the right end fitting, and the entire water hose 40a slides leftwardly past fitting 44a. The new replacement hose is then slide axially rightwardly over fitting 44a and the right end of the new hose engages the right fitting, and the left end of the new hose engages left fitting 44a. In the fitting and clamping arrangement in FIGS. 3 and 4, water hose 40 cannot be axially moved because barbed port 54 is on the fitting, and hence water hose 40 cannot be axially slid therepast.
Clamp 58a has a pair of legs 214 and 216, FIG. 19, extending axially along the outer surface of water hose 40a, and turned radially inwardly at tabs 218 and 220, respectively, FIG. 20, engaging the left axial end of water hose 40a, to locate clamp 58a on the water hose and fitting, particularly providing alignment of inner tubular portion 206 with opening 202 in fitting 44a and with aperture 204 in water hose 40a.
It is recognized that various equivalents, alternatives and modifications are possible within the scope of the appended claims.
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A fuel line cooler (34) is provided for a marine propulsion system (2) having a water cooled internal combustion engine (4) in a heat retentive compartment (5). The fuel line cooler (34) has an inlet (36) in communication with the source (14, 12) of cooling water for the engine (4), and has an outlet (38) for discharging water. The fuel line cooler (34) is cooled by sea water during running of the engine (4). Upon turn off of the engine (4), the cooled water in the fuel line cooler (34) is in heat transfer relation with the fuel and prevents vaporization and or spewing of the fuel.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention pertains to carpeting of artificial turf featuring improvements in the weaving method. The product can be used covering sports fields, acting as decorative accents in gardens, greenery and for other applications. It is based on a weaving method different from that for the products normally assembled by today's artificial turf industry, leading to several improvements as much during fabrication as it does for the end user.
[0003] 2. Description of Related Art
[0004] Nowadays different methods are implemented in the manufacturing of artificial turf. To the extent that it has been possible, the industry has labored intensely perfecting the appearance and performance of its output resulting in more benefits for the consumer. Continuously, materials used for its fabrication as well as the structure and design are being improved. Most artificial turf surfaces display similar characteristics such as: color, synthetic materials, similar weaving and manufacturing methods and installation, among others.
[0005] The materials and processes applied to this type of product include chemical compounds that may enhance its resiliency, occasionally generating unusual properties. However, they still do not totally appear like real turf. They create a surface with a texture and layout much too regular, very different from the look of natural grass. Therefore, the purpose of this report is to analyze our covering of artificial turf that features improvements in the weaving method, and will be illustrated below with graphics along with its advantages which will make evident the improvements that, doubtlessly surpass today's technology with respect to artificial turf carpeting.
[0006] Nowadays, a tufting machine uses an array of needles, a thread-feeding mechanism called a “creel” and a line for the finish. Carpets are constructed using three basic elements: a) cloth fabricated with intertwined flat polypropylene strings; b) threads that resemble the stems and leaves of grass made of polyethylene, polypropylene or nylon, and c) a coating applied to the lower face that may be made of latex or polyurethane. These days, the steps of the weaving process follow this approach: the tufting machine fastens the threads upon the cloth which comes in rolls and the threads are kept on bobbins or spools.
[0007] The cloth is placed on a special accessory allowing the machine to pull it as it is weaving. Afterwards, the spools of thread are fitted to a creel according to the number of needles used by the machine. The threads are guided by individual polyethylene tubes from the bobbin to the tufting machine. The thread enters the machine via a feeding system with rollers until it reaches the needles. The thread is strung through the eye of the needle, ready for insertion through the cloth. The action of the tufting machine introduces the threads through the cloth and cuts them at a set length.
[0008] Once the carpet exits the machine, the former is inspected and the weave is repaired as necessary. Subsequently the product is rolled up, made ready for the final coating. Following the process described above, and when the carpet has exited the weaving operation, the product must be coated with latex or polyurethane in order to bond the threads thereby providing strength, protection and consistency. The final coating consists of applying a material composed of latex or polyurethane on the lower surface of the carpet. The carpet is guided to a moving belt and enters an area where the material (latex or polyurethane) is applied as a liquid. Afterwards it reaches the oven that cures the coating. The carpet continues along a moving belt and when it exits the oven, it is perforated for the purpose of draining water that falls upon it when in use. Then, the carpet keeps moving along the belt until the coating cools completely. Finally, it arrives at the inspection and packaging station where the quality is checked, the carpet is rolled up and it is wrapped inside a polyethylene plastic film.
SUMMARY OF THE INVENTION
[0009] The invention described herein pertains to carpeting of artificial turf used on sports fields, as decorative touches in gardens and areas with greenery as well as for other applications. It features a weaving process differentiated from those normally implemented by the current artificial turf industry, leading to multiple benefits that impact not only the fabricator but also the final user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The objective of the invention presented here will be better understood with the following descriptions of examples from real operations. The descriptions relate to the graphics attached herein, including:
[0011] FIG. 1 that shows an exploded view of the artificial turf carpeting, subject of this report.
[0012] FIG. 2 that shows the horizontal view of the improved weave of the artificial turf carpeting, subject of this report.
[0013] FIG. 3 that shows the vertical view of the improved weave of the artificial turf carpeting, subject of this report.
[0014] FIG. 4 that shows the view from above demonstrating the concentration of the aggregates of threads produced by this new weaving process.
[0015] FIG. 5 is a perspective view of the dispensing container of FIG. 1 , showing an outermost plastic bag being dispensed from the roll.
[0016] FIG. 6 is a perspective view of the dispensing container of FIG. 1 , showing an arresting tab of the dispensing container catching an adjacent inner plastic bag through its handle hole.
[0017] FIG. 7 is a perspective view of the dispensing container of FIG. 1 , showing the outermost plastic bag being removed from a bag roll while the adjacent inner plastic bag is caught on the arresting tab.
[0018] FIG. 8 is a top view of a portion of a roll of plastic bags according to one embodiment of the invention, showing two adjacent bags connected bottom-to-top by a separable perforation.
DETAILED DESCRIPTION OF THE INVENTION
[0019] As a consequence of the improved process of weaving ( 3 ) the artificial turf carpeting, subject of this report, a wide range of benefits are achieved given that this new weaving process ( 3 ) reduces the amount of thread ( 1 ) while presenting the appearance of a heavier turf. In addition, the pattern of stitches applied to the lower surface of the carpet ( 4 ), where the coating of latex or polyurethane is spread, presents a larger surface for contact with the finishing material due to the great majority of the stitches being arrayed diagonally. Therefore the adhesion to the threads is strengthened ( 1 ) compared to the bond obtained from a rectilinear or standard weave. Given the greater concentration of threads ( 1 ) in certain areas coupled with a distribution simulating the pattern of a chessboard ( 5 ), the appearance of a turf closer to reality is achieved since natural turf does not grow in furrows, but rather in a dispersed fashion. This new weaving process ( 3 ) eliminates the appearance of turf as though it were an “agricultural field intentionally seeded” marked by parallel green lines, and produces a more natural looking turf. Once the aggregates are in place, this same configuration allows for a greater retention of those aggregates due to the position of the threads ( 1 ). In addition, an excessive scattering of the aggregate materials is avoided when performing sweeping tasks. In an important way, this property helps to avoid the migration of the aggregates toward the zones of reduced activities in the field of play and the depletion of those materials at the areas bearing more traffic. This improvement in the weaving process ( 3 ) is favored for the surface of a sports facility by maintaining greater consistency and thereby enhancing performance of the sport. The intervals separating tufts of “grass”, indicated in FIG. 4 , result in greater resiliency due to this improvement in the weaving process ( 3 ) associated with a suitable combination of threads ( 1 ). With this configuration of turf where a homogeneous dispersal of the thread lines ( 1 ) is built in, the players can depend on a uniform distribution of the turf and of the aggregates, and therefore better support yielding more natural running, jumping, stopping and turning. This design considerably reduces reflected light which helps to moderate vision fatigue for both players and the audience.
[0020] The fabrication of artificial turf carpeting presented in this report is carried out primarily by means of altering the configuration of the bank or array of needles compared to the standard in-line disposition of that formation, whereby one needle is installed along the same line as the following one, equidistant one from the other, whatever may be the separation between the needles. In this instance, the distance separating the needles in the standard disposition of needles measures ½″. This results in a distance between needles on one side and the other of ½″. By altering the configuration of the bank of needles in order to improve the weaving technique, 2 needles are placed ¼″ apart, resulting in a gap of ¾″ and 2 other needles are installed ¼″ apart, and so on repeating the same pattern all along the entire length of the bank or array of needles. The tufting machine includes a special accessory that displaces the bank of needles horizontally causing the needles to penetrate the cloth in a normal or standard manner. At the next stitch, the bank of needles moves horizontally rightward for ½″, resulting in a diagonal stitch. At the following stitch, the bank of needles keeps its place resulting in a straight stitch. With the next movement, the bank of needles moves horizontally leftward to a distance of ½″ to exactly the same starting point producing a diagonal stitch in the other direction from the previous diagonal one. Completing the cycle, the bank maintains its place forming another stitch in a straight line. This successive motion of the cycle develops into a pattern resembling something like “SS SS SS . . . ” material.
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The invention described herein pertains to carpeting of artificial turf used on sports fields, as decorative touches in gardens and areas with greenery as well as for other applications. It features a weaving process differentiated from those normally implemented by the current artificial turf industry, leading to multiple benefits that impact not only the fabricator but also the final user.
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FIELD OF THE INVENTION
This invention relates to a round to be fired in a mortar to seat or "bed" the mortar base plate on the ground without raising a projectile to a height that would expose the firing team to increased risk of detection. It is also directed to a "training" mortar round that closely simulates a real firing while reducing the training safety zone or template.
BACKGROUND OF THE INVENTION
In the operation of a military mortar, a mortar shell is fired from a firing tube or barrel that is supported by a base plate that rests on the earth. The elevation of the barrel is controllable by adjusting its angle with respect to supporting struts extending from the barrel to the ground.
If the ground under a mortar is soft, the first firing will compact the base plate into the soil. Any change in the position or orientation of the base plate will affect the angle at which the firing tube is supported, hence the accuracy of subsequent rounds. It is only when the base plate has been stabilized so as to not substantially change in its position or angular orientation after a firing that the mortar can be reliably adjusted to control its aiming point.
It is customary in firing a mortar to fire an initial round without reference to spotting the point of impact of the initial round for calibration of the aiming of the mortar. Customarily calibration and adjustment of the aim of the mortar only commences after the initial round is fired. The first round serves, therefore, only to "bed" the mortar, preparatory to more controlled subsequent firings.
In modern combat mortar teams are subject to retaliating fire. Radar systems exist which can trace the trajectory of a shell, estimating its point of origin. Once this is done, return fire can be focused on this estimated location.
It is customary under these circumstances for a mortar team to change its position after a relatively short time following the firing of its first shell. The time available before this should occur can be as short as a few minutes. It has been found that a response by an opponent cannot normally occur in a shorter time. As radar controlled retaliatory systems become more responsive, this time delay will tend to be decreased.
With such a short time window within which to engage in offensive fire, the discharge of a bedding round consumes a valuable portion of the time available before a mortar team must shift its location. It would be desirable to provide a means for bedding a mortar which would not provide an opponent with an initial, ineffectually aimed shell trajectory upon which to mount retaliatory fire.
It would also be desirable to provide a training round for use by mortar teams wherein the round consumed is less costly than a normal mortar round.
It is with these objects in mind that the following invention has been conceived.
The invention in its general form will first be described, and then its implementation in terms of specific embodiments will be detailed with reference to the drawings following hereafter. These embodiments are intended to demonstrate the principle of the invention, and the manner of its implementation. The invention in its broadest and more specific forms will then be further described, and defined, in each of the individual claims which conclude this Specification.
SUMMARY OF THE INVENTION
According to the invention, a mortar round is provided that has, in lieu of the customary projectile, a contained mass of flowable and dispersible material that, upon being fired from a mortar will disperse at a low altitude. The mass contained within the round should be sufficient to provide a reactive thrust on the mortar base plate that will simulate the firing of a live service round.
More particularly, such a round may be provided that includes:
(1) launching means for the round which, in turn may include:
(a) an ignition tube;
(b) a primer receptacle at an access to the ignition tube;
(c) guidance fins coupled to the ignition tube;
(2) a canister mounted through a seat on the ignition tube containing a dispersible filling and having a disintegratable sleeve defining the sidewall of the canister mounted on said seat, there being a reduced strength portion within said sidewall which provides a preferred failure path or region within said sidewall;
(3) a flowable filling having mass positioned within the sleeve
wherein:
(i) the mass of the filling is sufficient to simulate firing or actually bed a mortar upon firing; and
(ii) the reduced strength portion of said sidewall is sufficiently weakened upon firing so as to cause said canister to rupture upon leaving the muzzle of a mortar barrel thereby releasing the filling for dispersion into the surrounding space.
One means of achieving this is to provide the sleeve with a sidewall whose internal structure has been pre-conditioned to fail upon the firing of the mortar by reason of the presence of the preferred failure path or region within the sidewall. Reduced strength portions may be provided, for example, by the presence of thinned grooves or other weakened areas in the sidewall that provide the failure path or region. With the failure of such internal structure, the sleeve, with its filling, is held together integrally by the mortar launch tube or barrel while the round is within such tube, rupturing only after leaving the muzzle of the mortar barrel. This can be achieved by dimensioning the sleeve with a diameter that is less than the bore diameter of the launch tube by an amount that constitutes an expansion gap. Upon firing of the mortar, the inertial forces of acceleration (being on the order of 7000 G's) cause the flowable filling to apply an expansive force at the lower end of the sleeve, breaking the internal bonds within the sleeve. With the bonds broken the sleeve expands to the limit provided by taking-up the expansion gap. Thereafter further expansion is prevented by the confinement of the launch tube until the round leaves the mortar barrel.
A suitable sleeve can be formed by spirally wrapping strips of paper or thin plastic sheet that are bonded as by gluing, welding or other suitable means with each other, forming portions within the body of the sleeve wall that are thinned and will break under the stress of firing.
By selection of an appropriate wall thickness and paper strength the sleeve wall may be fabricated to lose most or all its structural integrity by the breaking of its internal bonds upon firing. Such a round may thereby be designed to rupture directly or shortly after leaving the muzzle of the launch tube, releasing the filling to disperse in the local area of the launch site.
A delayed release of the filling can be provided by providing the sleeve with a wall that ruptures in two stages. The first stage occurs when the bonds within the sleeve are only partially broken on firing. For example, the bonds within the lower end of the sleeve may be broken on firing, the upper portion of the sleeve remaining integral. This effect can occur naturally, or can be enhanced by providing an air gap above the filling in the sleeve so that only the portion of the sleeve below the air gap experiences expansive forces upon firing. Alternately, the sleeve wall may be constructed of a material that is only partially ruptured when the sleeve wall expands to occupy the expansion gap.
The second stage of rupture may then occur after the round has left the mortar muzzle. From that moment on, the round is rapidly decelerating under the effect of the drag created by the air. The nose-end of the bedding round can be made non-streamlined to increase this effect.
As the outer sleeve of the round commences to decelerate, the differential forces arising from the separation of the centre of pressure from the centre of mass of the canister will cause it to tumble, bursting open the sleeve sidewall. The resulting dispersal of the filling will thereby be delayed by the time it takes the canister sidewall to rupture completely.
Such a round may be provided with a variety of fillings such as powdered metals, clays or even a liquid such as water. The filling need only be self-dispersing upon the rupturing of the sleeve sidewalls. It should also be present in a quantity that provides enough mass to obtain the "bedding" effect.
By providing a filling that is flowing, the quasi-hydrostatic effect of generating an expansive force which, when applied to the sleeve walls upon firing will rupture the sleeve wall's integrity, can be created.
Suitable materials for the sleeve wall include plastic sheeting and paper. Paper has the advantage that it has little tendency to become brittle under very cold conditions. Plastic has the advantage that it is relatively impervious to moisture and can maintain its integrity when wet. With certain fillings, e.g. iron, it may be necessary to provide a moisture barrier, or a desiccant, to reduce the risk that the filling will become internally bonded, as by rusting. For this reason, it may be desirable to treat a paper-walled sleeve with a moisture barrier coating.
This same round can be utilized as a training round. The mere firing of a round that provides the full inertial reaction of a real round enhances the simulation of firing a real round.
As an additional training feature, an element of targeting and aiming adjustment experience can be added by a variant on the round as described. This can be effected by incorporating a smaller "marking" projectile within the sleeve, to be released upon the rupture of the sleeve wall.
Such a projectile may be of reduced mass and may have a non-streamlined form to limit its range. With these features present, training can be effected within a much smaller territory that would be required with full, regular rounds.
The foregoing summarizes the principal features of the invention and some of its optional aspects. The invention may be further understood by the description of the preferred embodiments, in conjunction with the drawings, which now follow.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a pictorial depiction of a prior art mortar.
FIG. 2 is a cross-sectional view of a prior art mortar barrel with a prior art round therein.
FIG. 3 is a cross-sectional view of the bedding or training round of the invention.
FIG. 4 is a pictorial view of a spiral tube being formed by winding strips of paper that have a gap therebetween.
FIG. 5 is a cross-sectional view of the mortar round of FIG. 3 with a light weight marking projectile contained therein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 a standard 81 mm field mortar 1 is depicted. A barrel 2 having a breech plug 3 extension at its lower end mounts on a base plate 4 with the ball-shaped end of the breech plug 3 fitted into a socket 5 within the base plate 4. Struts 6 extend downwardly from the barrel 2 to the ground to maintain the elevation of the mortar 1.
FIG. 2 depicts a standard mortar round 7 positioned within a barrel 2 prior to firing. The round has a body 8 mounted on a perforated ignition tube 9 carrying fins 10 and a primer 11. Propellant 12 in the form of donut-shaped rings is positioned around the ignition tube just before firing. The tube 9, fins 10 and primer 11 comprise a launching means that is combined with the propellant to provide a propulsion system.
The diameter of the body 8 customarily is nearly equal to the bore of the barrel, e.g. 81 mm., allowing only for a small space for air to escape as the round is slid down the barrel.
In FIG. 3, the mortar bedding round of the invention is depicted. It incorporates a canister 13 having a sleeve 14 having a sidewall 15. The forward end of the canister 13 is closed by a cap 16 shown attached by screws 17. However, other attachment means, as by crimping or glue bonding, may be employed for this capping means.
The rearward end of the canister 13 terminates at a seat 18 similarly attached to the sleeve sidewall 15. The seat has a diameter portion 19 nearly equal in dimension to the bore of a mortar barrel 2, but providing the gap necessary for air to escape upon loading of the round into a mortar barrel.
Within the canister 13 is a dispersible filling 20. This filling 20 may consist of or comprise finely divided particles of a heavy substance such as iron, other metallic powder, or clay. It may also consist of or comprise a liquid. The amount of filling 20 is chosen to provide the bedding round 13 with a mass equivalent to that of a regular round 7.
While shown as occupying the entire interior of the canister 13, the filling 20 may also leave space for an air gap 25 shown in FIG. 5, in conjunction with a marking projectile 26.
Fitted to the seat 18 are the ignition tube 9, fins 10, primer 11 constituting a launching means, and the propellant 12 of a normal round 7 to provide a full propulsion system. While it is not essential for these elements to be similar to those on a regular round 7, it is desirable to simulate a regular round 7 for realism in training. If such realism is not required, then alternate means for propelling the canister 13 may be provided. For use in bedding a mortar base 4 it is sufficient to provide any type of propulsion system for launching the canister 13.
The sleeve sidewall 15 may be formed of any material which will weaken on firing sufficiently to rupture when the round leaves the mortar barrel. Spirally wrapped paper 21 has been found suitable for this purpose. Cardboard, plastic film or other forms of sheeting that perform equivalently may also be employed.
The sleeve sidewall 15 may be dimensioned to permit it to expand on firing, due to the inertial pressure arising within the filling, thereby weakening the sidewall 15. The sleeve 14 in such case is arranged to have a diameter that provides an expansion gap suited to producing the requisite degree of expansion. A gap on the order of 1 millimetre of free-play in the mortar barrel, combined with the use of cardboard in the sidewalls 15, has been found suitable.
FIG. 4 shows the production of a paper sleeve wall 14 from the first of several overlying strips of paper 22 that are being spirally bonded with one or more bonding agents in layers as they are being wrapped on a mandrel 24. Gaps 23 may be left between strips to provide weak points that fail upon firing. Failure can occur by tearing of the paper or by separation of the paper layers. By choosing to overlie such gaps 23 with further paper strips 22 of selected thickness and widths, the vulnerability of the sleeve sidewall 15 to failure can be controlled. Multiple layers of varying widths may be employed with gaps that are aligned or displaced from each other in order to control the strength and bursting characteristics of the sidewall 15.
In this manner the filling 20 can be kept integral while the canister 13 is inside the barrel 2, but be released for dispersal once the canister sidewall 15 has ruptured, after the canister 13 leaves the barrel 12.
As a further variant of the invention shown in FIG. 5 the filling 20 may be limited in quantity to provide an air gap 25 within the canister 13. A marking projectile 26 of reduced weight may be placed within the canister 13, preferably at its forward end. By using a marking projectile 26 of reduced weight, and optionally an inefficient aerodynamic shape, the range of such marking projectile can be limited. This allows for training that includes aiming practice to occur within a smaller test area.
Conclusion
The foregoing has constituted a description of specific embodiments showing how the invention may be applied and put into use. These embodiments are only exemplary. The invention in its broadest, and more specific aspects, is further described and defined in the claims which now follow.
These claims, and the language used therein, are to be understood in terms of the variants of the invention which have been described. They are not to be restricted to such variants, but are to be read as covering the full scope of the invention as is implicit within the invention and the disclosure that has been provided herein.
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A mortar bedding or training round has a canister filled with a heavy, dispersible filling and a sidewall that will rupture after firing of the round. The canister sleeve may be dimensioned to provide an expansion gap within the barrel, allowing the canister sidewall to partially expand upon firing, weakening it for subsequent rupture upon leaving the mortar barrel. Such a round can bed a mortar without launching a projectile to a high altitude where it might be detected.
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[0001] This application is a divisional of U.S. patent application Ser. No. 13/379,115, filed Dec. 19, 2011, which is a U.S. National Phase of PCT/EP2010/063374, filed Sep. 13, 2010, which claims the benefit of priority to Swiss Patent Application No. 01433/09, filed Sep. 16, 2009 and European Patent Application No. 09011844.9, filed Sep. 17, 2009, the foregoing being incorporated by reference herein.
TECHNICAL FIELD
[0002] The invention relates to molded product and the method of producing it.
BACKGROUND
[0003] In the automotive industry, structural panels are used in a wide variety of applications where high strength and lightweight are required. Molded reinforced panels are particularly for use in an automotive vehicle as for instance a parcel shelf, ceiling cover, engine bay panels or load floor as well as for panels used at the outside of a car like an under-engine shields or outer wheel arch liner. Additional acoustic properties for the attenuation of noise can be a requirement, in particularly the sound absorption factor of the material. For instance, composite panels, eventually with a honeycomb core, are used in trim parts, sunroof panels, hard tops, parcel shelves, spare wheel covers and luggage floor assemblies. Depending on the material chosen, they can also be used as under floor, engine or engine-bay cover. Fiber reinforced composites are used as the main material or as a skin layer for these products, sometimes combined with additional layers for specific purposes.
[0004] Composite materials (or composites for short) are engineered materials made from two or more constituent materials with significantly different physical or chemical properties, which remain separate and distinct on a microscopic level within the finished structure.
[0005] Composites are made up of individual materials referred to as constituent materials.
[0006] There are two categories of constituent materials: Matrix and reinforcement. At least one portion of each type is required. The matrix material surrounds and supports the reinforcement materials by maintaining their relative positions. The reinforcements impart their special mechanical and physical properties to enhance the matrix properties. A synergism produces material properties unavailable from the individual constituent materials. Engineered composite materials must be formed to shape. The matrix material can be introduced to the reinforcement before or after the reinforcement material is placed into the mold cavity or onto the mold surface. The matrix material experiences a change in physical state, for instance for thermoplastic material a melting event, after which the part shape is essentially set. Depending upon the nature of the matrix material, this change in physical state can occur in various ways such as chemical polymerisation (duroplast) or solidification from the molten state (thermoplastic).
[0007] Most commercially produced composites use a polymer matrix material often called a resin solution. There are many different polymers available depending upon the starting raw ingredients. There are several broad categories, each with numerous variations. The most common are known as polyester, vinyl ester, epoxy, phenolic, polyimide, polyamide, polypropylene, PEEK, and others. The reinforcement materials are often fibers, but also commonly ground minerals. Composite material can be made by using a layer or mat of fibrous material at least partially consisting of reinforcing fibers like glass fibers, and a binder material, either in form of a powder, a liquid solution or as binder fibers. The materials are mixed and cured, normally by heat molding the material in a molding press producing directly the wanted product form.
[0008] US20050214465 discloses a process for producing a composite using polyamide as a matrix whereby the reinforcing materials are impregnated with a lactam melt activated for anionic polymerisation and afterwards heated. Another known process is the pultrusion process. The material produced can be granulated and later used in injection molding or extrusion methods.
[0009] Another technique used is mixing the reinforcement fibers with the thermoplastic melt. Also, here mostly followed by injection molding eventually followed by press molding to obtain the desired form of the products.
[0010] The use of a thermoplastic melt or impregnation with a melt renders the product obtained compact and non-porous, as the melt will fill up the spaces between the reinforcing material and close all existing pores.
[0011] U.S. Pat. No. 7,132,025 discloses a process using thermoplastic fibers as matrix material. These fibers are first blended with the reinforcing fibers and then dry-laid to give a blended web. The web is than consolidated with needling, heated and compacted to give the final product. The web is heated to a temperature above the softening point of the thermoplastic fibers using a conventional oven or by IR radiation and directly compressed to provide a compressed and partially consolidated thermo-formable semi-finished product.
[0012] US20050140059 discloses a process of producing molded parts made of fibers whereby the fibers are first heated between plates and then subjected to compression molding, using additionally air suction to obtain a better-shaped product. The fibers used are bicomponent fibers as binder fibers and other fibers like reprocessed cotton and polypropylene as the bulk fibers. Although the use of high-pressure steam or fluid air as alternatives for the heating of the material before compression molding are mentioned in the introduction, the actual disclosed process only uses heated plates to obtain 200° C. for one minute to heat and consolidate the fibrous material. The use of steam is not disclosed in combination with the used materials and the disclosed process.
[0013] WO2004098879 discloses a method of producing a composite material of a mixture of thermoplastic fibers and reinforcement fibers using a needled nonwoven web as the starting material. This web is combined with dual foils with a high melting and a lower melting thermoplastic material. The layered stack is than heated, using either IR-waves or hot air, up to such a temperature, that the thermoplastic fibers and the low melting thermoplastic material of the foil are heated above their melting temperature for a short time, long enough to enable a softening. Directly afterwards the layered material is pressed, for instance using rollers. The patent discloses as an example a combination of Polyamide-6 as the binder fiber and glass- and PET fibers as the reinforcement fibers.
[0014] Also, WO2007000225 discloses a method of producing a stiff part using a combination of low and high melting fibers, whereby the fiber web is heated above the melting temperature of the low melting fibers. The application further discloses the use of glass fibers or polyester fibers as high melting fibers and polypropylene or polyester as low melting fibers in a core material. This core material is layered between 2 outer thermoplastic foil layers. During the heating step the inner core material is expanding because of inner pressure in the fibers of the core, giving a lofting effect to the overall material. The final product contains partly highly compressed areas and partly this lofted areas. In practice, this is done with a combination of polypropylene and glass fibers and is called soft lofting.
[0015] A disadvantage of the state of the art is the high temperature needed to obtain the final composite. The heating temperature to be achieved is dependent on the matrix polymer. To form the composite, the matrix and reinforcement fibers are heated using a dry heating method like hot air, contact heating or infrared heating. The product is normally heated above the true melting point of the matrix polymer to compensate for the temperature loss for instance from the heating device to the molding device. Heating of a polymer above the melting point accelerates degradation.
[0016] Using a contact heater has the additional disadvantage that the product has to be compressed to obtain a good transfer of heat throughout the thickness of the product. Hot air is normally used at a temperature above the melting temperature of the binder polymer thus the polymer gets heat damaged, while the use of infrared heating is only feasible for thin materials. In thicker materials, the amount of energy needed to heat the inner core is damaging for the outer surface polymers. This method is normally used only for a thickness up till 4-5 mm.
[0017] Another disadvantage is the fact that most thermoplastic polymers used as matrix fibers and as reinforcement fibers have their melting temperature close to each other for instance the melting temperature of poly ethylene terepthalate (PET) is in the range of 230-260° C., for polypropylene between 140-170° C., for Polyamide-6 between 170-225° C. and for Polyamide-6.6 between 220-260° C. Using matrix fibers and reinforcement fibers both being thermoplastic polymers, for instance PA6.6 as matrix and PET as reinforcement, having to heat them above the melting temperature of the matrix fibers will also cause the reinforcement fibers to start melting or softening. This will lead to a collapse of the structure, forming a very compact composite.
[0018] The felts are widely used particularly in automotive industry for their thermal and acoustic insulation properties. The trend is towards recyclable materials; therefore, thermoplastic binders have taken a significant share in the last years. Fibers made of high performance polymers such as polyesters, polyamide are highly interesting due to their mechanical and heat resistance properties. But the necessary binding agent form the limitation to their utilization in molded 3D parts.
[0019] The binding agents used so far always have a lower melting point than the reinforcement fibers, rendering in relatively weak performance behaviour to the molded fiber web and limiting its utilization to tempered areas in the vehicle. None of these types of molded fiber webs is suitable for the high temperature exposure of the engine bay or compartment, particularly of the engine contact areas. Some of these binders are modified polymers (CO-PET as an example) having pour behaviours due to their modified structure particularly sensitive to hydrolysis phenomena.
[0020] The processes for molding such felts as known in the state of the art are a “cold” molding process where the felt is pre-heated by various means, and then transferred to a cold mold in which it is compressed in order to get the part shape or a “hot” molding processes, where the felt is introduced in a closed mold, in which a heat transfer media, like air, is introduced for bringing the binding agent to its melting point, and then released. The part is then cooled down, inside the tool or outside, with or without cooling assistance. (See for instance EP1656243, EP1414440, and EP590112).
BRIEF SUMMARY
[0021] It is therefore an object of the invention to find an alternative process to combine matrix and reinforcement fibers without the disadvantages of the current state of the art and to obtain a product that can be used in automotive applications, in particularly also in the engine bay or other areas with high temperatures.
[0022] With the composite product of claim 1 comprising of at least one polyamide-reinforcement layer consisting of a polyamide matrix and reinforcement fibers, characterised in that the polyamide-reinforcement layer is porous due to the consolidation of the matrix material in the form of fibers or powder or flakes, and the reinforcement fibers using a pressurised steam process, and the method of claim 8 using a steam process to consolidate a web of polyamide applied in the form of powder, flakes or fibers as matrix, and reinforcement fibers, it is possible to contain the lofty web structure of the reinforcement fibers, obtaining a porous reinforced material. This material has a good dynamic Young's modulus and is heat stable.
[0023] A method of preparing a lofty air permeable composite with increased stiffness of randomly disposed binding fibers and reinforcement fibers held together at fiber crossover locations by globules of the thermoplastic resin of the binding fibers has been developed.
[0024] In this method, high modulus reinforcing fibers are blended with matrix forming polyamide fibers or with polyamide powder or flakes to form a web by any suitable method such as air lay, wet lay, carding etc. This web is then heated using saturated steam to melt the resin matrix material at a temperature that is lower than the melting temperature of the polymer as measured using Differential scanning calorimetry (DSC) according to ISO11357-3. For example, the melting temperature T m of polyamide-6 (PA-6) is 220° C. as measured using DSC. However, the melting temperature of the same PA-6 in the steam process according to the invention is for example 190° C.
[0025] The web is placed in a pressure-resistant mold with at least one steam permeable surfaces. The mold is closed and clamped to withstand the internal pressure. Saturated steam of at least 9 bars absolute is applied to melt the binder. Saturated steam above 20 bars absolute is not economical anymore. Preferably a range of 11 to 15 bars absolute is a good working range. The actual shift of the melting temperature of the polyamide is dependent on the steam pressure generated in the cavity the product is steam molded in. The choice of the pressure used is therefore also dependent on the melting temperature of the reinforcement fibers. For instance, using PA-6 as binder fibers the preferred pressures are 11 bars absolute to 15 bars absolute.
[0026] By using steam instead of the usual hot air, hot plates or IR wave it is possible to shift the melting point of Polyamide to a lower temperature using the effect of the water molecules in the steam. The effect of water on polyamide is known and is normally considered a disadvantage; many prior art describes ways to avoid the effect or try to prevent it. Unexpectedly it is just this effect, which makes it possible to combine PA (polyamide) applied in the form of powder, flakes or fibers with other thermoplastic fibers with similar melting points as measured with DSC, like PET (polyester), using PA as the sole binding material, keeping the reinforcement fibers, like PET, in its fibrous form. It is now possible to obtain a heat stable molded product with a porous structure thereby enhancing the acoustic properties, like absorption and airflow resistivity, as well as the thermal conductivity.
[0027] The effect of steam is based on a reversible diffusion mechanism. Using Polyamide in form of small fiber diameter or particle size the melting and solidifying is fast and provides short production cycles. Once the steam is released from the mold the Polyamide transforms into the solid state and the part can be demolded as a stiff part. This is an advantage compared to other thermoplastic binders that need to be explicitly cooled inside or outside the mold before obtaining a structural part which is handable.
[0028] Because the overall temperature used, can now be kept much lower in comparison with the heating methods without steam, the resilience of the PET fibers is staying intact, leading to a more lofty material. Furthermore, it was found that the binding of the PA was enough to obtain the required stiffness of the final product. Because the PET fibers keep their resilience and the PA molten matrix material only binds the crossing points. The material keeps its lofty appearance due to the void volume in the web. Therefore, the final product will still be air permeable. Furthermore, it was found that also using glass fibers as the reinforcement fibers together with polyamide fibers as the matrix the use of steam is advantageously. Due to the precise regulation of the binding properties less energy is needed for the process, both during heating and during cooling.
[0029] In the normal heating process the material is heated up to the melting point of the thermoplastic matrix material. The cooling down of the material is slow due to the slower convection of the heat out of the product and because the material has fallen together due to lack of resilience of the reinforcement fibers and has become compacter. Therefore, the molten condition will continue for a longer period. It is therefore more difficult to regulate the amount of binding. Furthermore, during this cooling period, the material stays floppy because of the longer melted state of the binding matrix and is therefore more difficult to handle. Particularly when handling larger automotive trim part like a headliner or a load floor for a truck or larger vehicle.
[0030] Unexpectedly it was also found that as soon as the steam was taken away from the material the process of melting immediately stopped and the material obtained its solid state again. This is an advantage in the ability to reduce production cycle times due to immediately hand able material. The fact that the melting process can be stopped immediately is also a very precise way of regulating the binding properties and therefore the porosity of the material. Which is important for the air permeability properties of the material.
[0031] The material used for the polyamide matrix can be in the form of powder, flakes or fibers. However, the use of fibers in combination with reinforcement fibers is the most preferred because fibers mix better and during the handling of the web formed before consolidation the fibers tend to stay in the mixed position. Flakes or powder can fall between the reinforcement fibers out of the web or on the bottom of the forming mold.
[0032] As polyamide, all types of polyamide are feasible, particularly CoPA (Copolyamide) Polyamide-6 (PA-6) or Polyamide-6.6 (PA6.6). However also different types of polyamide or a mixture of different types of polyamide will work as a binder according to the invention. It is expected that normal used additives in the basic polyamide recipe are part of the basic polyamide material as claimed, for example chemical compounds to obtain Ultra Violet Resistance.
[0033] The reinforcement fibers can be any thermoplastic polymer based material with a melting temperature according to the DSC measurement, which is higher than the melting temperature of the polyamide binder in a steam environment. PET with a melting temperature of between 230-260° C. would work well as a reinforcement fiber. The reinforcement fibers can also be any mineral material, in particularly glass fibers (GF), carbon fibers or basalt fibers. Also, mixtures of both groups of reinforcement fibers can be used, for instance PET together with GF. The choice of material is based on the overall heat stability requirements of the final product and on the price of the individual materials.
[0034] The reinforcement fibers can be cut fibers, endless filaments or rovings dependent on the material properties needed.
[0035] These and other characteristics of the invention will be clear from the following description of preferential forms, given as non-restrictive examples with references to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 Graph of the dynamic young modulus of different samples.
[0037] FIG. 2 Graph of the loss factor of the same samples.
[0038] FIG. 3 Comparison of the acoustic absorption of a web consolidated using hot molding plates or the steam process according to the invention.
[0039] FIG. 4 Comparison of the thermal conductivity of a web consolidated using hot molding plates or the steam process according to the invention.
DETAILED DESCRIPTION
[0040] For the composites, according to the invention, matrix-forming binder fibers were mixed with reinforcement fibers and carded to form a web. Webs were pre-bonded using needling for handling purposes. (But any kind of pre-bonding processes can be used.) To prevent the composite samples from sticking or solidification to the mold particularly at release of the steam pressure from the tool, a thin nonwoven as surface cover can be used. The nonwoven used does have a neglectable influence on the main features like thickness, acoustic behaviour or stiffness of the final product. The webs for the polyamide-reinforcement layer according to the invention were consolidated using saturated steam as specified.
[0041] State of the art samples were compared with polyamide reinforcement layers according to the invention. The state of the art composites were bought according to the availability on the market.
[0042] Composite 1 A state of the art composite based on polypropylene as the binder and glass fibers as the reinforcement material, having a density of 881 kg/m 3 known in the market as Symalite.
[0043] Composite 2 A state of the art felt based material made of bicomponent PET as the binder material and cotton as the reinforcement material having a density of 314 kg/m 3 .
[0044] Composite 3 A composite according to the invention made of 45% PA binder fibers and 55% of glass fibers as the reinforcement fibers. Starting weight of the web was 1000 gram per m 2 . The composite was molded according to the invention using 11 bars absolute of saturated steam for 9 sec. The final density of the formed polyamide reinforcement layer is 384 kg/m 3 .
[0045] Composite 4 A composite according to the invention made of 55% PA binder fibers and 45% of glass fibers as the reinforcement fibers. Starting weight of the web was 1000 gram per m 2 . The composite was molded according to the invention using 11 bars absolute of saturated steam for 9 sec. The final density of the formed polyamide reinforcement layer is 303 kg/m 3 .
[0046] The dynamic young modulus over a temperature range was measured, and from this the tensile loss factor was calculated according to ISO 6721-4. The measurements and calculations were done using a 0.1 dB Metravib Viscoanalyser Type VA 2000. See FIGS. 1 and 2 for the results on all composites
[0047] For composite parts used in the automotive industry heat stability requirements are increasing. Particularly in the engine bay directly due to new motor generations generating more heat, as well as due to the option to keep the heat inside using isolation to optimise the overall use of fuel, leads to higher heat stability requirements. Normally the test for engine bay material is a long-term heat stability test at 120° C. or at 150° C. However, the actual temperature can rise easily to 180-190° C. for a short time. This temperature range can occur close or around hot engine sides, like exhaust line, manifold or compressors.
[0048] One requirement of the heat stability test is to know if the composite product keeps its form and shape during the exposure to heat. For instance, a parcel shelf placed under a sunny window should not sag after a while. An engine bay cover should keep its stiffness. The tensile loss factor over this temperature range is important for the stiffness retention of the product, when in use.
[0049] FIG. 1 shows the dynamic young modulus. Composite 1 the state of the art product based on a PP matrix and Glass fibers as reinforcement shows in absolute terms a higher modulus than composite 3 and 4 according to the invention. This is mainly due to the higher overall density. However, the trend is to obtain the same or better stiffness performance at a lower density saving weight in the car. More important however is that the state of the art composite 1 shows a significant loss of dynamic young modulus over the temperature range measured. Therefore, products made of combinations with PP tend to get softer at higher temperature. Composite 2 is a combination of CoPET/PET bicomponent binding fibers and cotton as the reinforcement material showing an overall too low dynamic young modulus to be self-supporting.
[0050] The composites per the invention show a much better behaviour over the temperature range measured. It was found that the dynamic young modulus of the polyamide reinforcement layer does not change more than 20% over a temperature range of 150° C. to 210° C. Rendering an overall more heat stable product.
[0051] FIG. 2 shows the tensile loss factor over the temperature range measured on the composite products. Composites 1 is state of the art based on polypropylene (PP) as matrix binder fiber produced with a molding method without steam. Although the products have a good loss factor up till 160° C., it rapidly loses its heat stability due to melting.
[0052] Composite 2 is a combination of CoPET/PET bicomponent binding fibers together with cotton as the reinforcement fibers. Therefore the bad loss factor over the measured temperature range is basically due to the CoPET, already softening at 80° C. and above 110° C. starting to melt. Although this is dependent on the CoPET used. Higher melting CoPET has other disadvantages including an increase in cost. In an absolute way, a composite material using PET alone would give a product with a good heat stability, it is not known today how this can be achieved, without heat damaging the reinforcement fibers due to the very high melting T needed.
[0053] Composite 3 and 4 are combinations of PA binder with glass fiber reinforcement fibers consolidated using steam according to the invention. Both have a stable tensile loss factor (−) of less than 0.15 over a temperature range of 60-210° C.
[0054] The polyamide reinforcement product can be compressed fully or partially to obtain a formed product. Due to the consolidation process using saturated steam according to the invention it is possible to obtain a product with a lower density and still obtain the wanted stiffness. Because the heating process using saturated steam melts the polyamide binder fibers at a much lower temperature than the thermoplastic reinforcement fibers, and all across the thickness at a nearly same time, the resilience on web structure of the reinforcement fibers can be kept. By reducing the amount of matrix forming polyamide to such a level that the overall product is just fully bonded, a porous reinforcement layer can be obtained with a density that is only 5 to 80% of the bulk density of the materials of the composite. However preferably a range from 5 to 60%, even more preferably 5 to 25% is obtainable and more advantages due to the lower costs of the overall part. Therefore, it is possible to obtain a product that is not solid but stays porous, rendering in a better acoustic absorber (see FIG. 3 ) due to the porosity of the material as well as a better thermal conductivity (see FIG. 4 ). By adjusting the density either by more compacting or by increasing the amount of PA matrix it is possible to adjust both the acoustic properties as well as the thermal conductivity.
[0055] Sample A and B were produced using the same web material of 65% Glass fibers and 35% PA binder fibers. Composite A was consolidated using the saturated steam according to the invention and Composite B was consolidated using compression between hot plates. Both were treated such that a fully bonded product was achieved.
[0056] The acoustic absorption properties of the composites formed were measured using an impedance-tube, according to the ASTM (E-1050) and ISO (10534-1/2) standards for impedance tube measurements (measurement between 200 and 3400 Hz). The thermal conductivity was measured using a guarded hot plate according to ISO8301.
[0057] The acoustic absorption and the thermal conductivity were found to be better in the steam treated product than in the hot plate treated product. This is partly due to the necessity to use more compression during the heating process using hot plates to obtain a fully bonded product. Therefore, obtaining a denser product B in the first place, hence a less porous product, showing a decrease in both thermal conductivity and acoustic property.
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Composite molded product comprising of at least one polyamide-reinforcement layer consisting of a polyamide matrix and reinforcement fibers, characterised in that the polyamide-reinforcement layer is porous due to the consolidation using a pressurised steam process.
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FIELD
The present invention relates to a gabion, particularly to a gabion, and especially to a multi-compartmental gabion, which can be used without a lining material.
BACKGROUND
Gabions are temporary or semi-permanent fortification structures which are used to protect military or civilian installations from weapons assault or from elemental forces, such as flood waters, lava flows, avalanches, slope erosion, soil instability and the like.
WO-A-90/12160 discloses wire mesh cage structures useful as gabions. The cage structure is made up of pivotally interconnected open mesh work frames which are connected together under factory conditions so that the cage can fold concertina-wise to take a flattened form for transportation to site, where it can be erected to take an open multi-compartmental form for filling with a suitable fill material, such as sand, soil, earth or rocks.
WO-A-00/40810 also concerns a multi-compartmental gabion which folds concertina-wise for transportation, and which comprises side walls extending along the length of the multi-compartmental gabion, the side walls being connected at spaced intervals along the length of the gabion by partition walls which are formed from two releasably connected sections, which after use of the gabion can be released, and the gabion unzipped for recovery purposes.
Existing gabions have certain disadvantages with respect to construction and longevity. For example, such gabions frequently comprise a wire mesh cage structure lined with a geotextile material, the lining adding to the cost and complexity of the gabion structure, and constituting a significant limitation on the functionality of the gabion after deployment over a long period of time. Particularly in harsh environmental conditions (intense sunlight, wind, rain, snow, sand or salt spray, or a combination of any two or more of these), the geotextile material tends to degrade and this can weaken the functionality of the gabion by, for example, the occurrence of rips, tears or holes in the liner, through which the gabion fill material can fall.
Accordingly, there is a need for an improved gabion. There is also a need for an improved multi-compartmental gabion.
DETAILED DESCRIPTION
According to the present invention there is provided a gabion comprising side walls connected together at spaced intervals by partition walls, the side walls comprising at least one substantially closed side wall element panel, wherein the or each substantially closed side wall element is manufactured of a relatively rigid sheet material.
According to the present invention there is provided a multi-compartmental gabion comprising opposed side walls connected together at spaced intervals along the length of the gabion by a plurality of partition walls, the side walls comprising a plurality of side wall element panels, at least one side wall element panel comprising a substantially closed panel, wherein the or each substantially closed side wall element is manufactured of a relatively rigid sheet material.
The substantially closed panel acts in use of the gabion to prevent a gabion fill material (sand, earth, soil, stones or fines, for example) from falling through the side wall without the aid of a gabion lining material.
Preferably, the rigidity of the material is sufficient to prevent excessive bulging of the side wall element panel when the gabion is filled with a fill material.
Other desirable characteristics of the sheet material include, either alone or in combination:
Durability Toughness Tear resistance Scratch and erosion resistance Corrosion resistance Thermal stability Ultraviolet stability Low density Low cost Recyclability
Suitable materials include steel, aluminium, titanium, other metals, alloys, plastics or certain natural materials, or combinations of two or more thereof. Where a metal is used, it is preferably either treated for corrosion resistance, e.g. by galvanisation and/or painting or is inherently corrosion resistant, e.g. a stainless steel.
Where the sheet material is a plastics material it may be polyethylene (PE), polypropylene (PP) or a composite such as glass fibre reinforced polymer (GFRP). The molecular weight of the chosen plastic can be selected to suit the application (e.g. LDPE, HDPE, LDPP, HDPP). Where plastics are used, they are preferably ultraviolet stabilised e.g. by the addition of fillers to prevent them becoming discoloured and/or brittle upon extended exposure to sunlight.
In certain circumstances, it may be desirable to add coloured fillers to the plastics material to provide a desired aesthetic effect. In one aspect of the invention, more than one colour filler is added to the plastics material and partially blended therewith to create a non-homogeneous coloured/marbled effect. For example; green and brown; white and grey; or yellow and brown colour fillers could be added to provide camouflage for vegetated, snowy or dessert environments, respectively. Because such colours are integral with the sheet material (i.e. not a surface decoration), they are less susceptible to removal by erosion (e.g. by sand in a sandstorm).
It is desirable to make the sheet material as thin as possible to reduce the folded volume of the gabion when being stored or transported. A major advantage of using thin-sheet materials is weight saving, which reduces transportation costs and facilitates manual deployment/rearrangement of the gabion.
The substantially closed panel is preferably provided with means for receiving a hinge member for the purpose of connecting the substantially closed panel pivotally to a neighbouring side wall element panel. The hinge receiving means are preferably provided on a region of the closed panel of greater thickness than an adjacent region of the panel. This helps to prevent tearing of the panel by the hinge member in use of the gabion when the side walls of the gabion act to restrain the gabion fill material. The region of the closed panel of relatively greater thickness is preferably provided at or in the region of an interconnection edge of the closed panel. Preferably, the region of relatively greater thickness is an elongate panel region alongside or at the interconnection edge.
In one example, illustrated by FIG. 7 , the hinged connections 10 comprise helical springs 112 threaded through apertures 114 disposed towards the edges off each wall 116 , 118 , which are manufactured of sheet material. In FIG. 8 , it can be seen that when a force F is applied to the hinged connection 110 , the apertures 114 tend to deform. Upon application to sufficient force, as illustrated in FIG. 9 , the apertures 114 tear-through, thereby disconnecting the hinged connection. One solution is to provide thicker sheet material. Where mesh-type walls are used, this is not necessarily a problem because the wires of the mesh can be thicker for a given overall gabion weight. However, to use sheet metal of the same thickness as the wire diameter could give rise to a prohibitively heavy gabion.
It is therefore desirable, additionally or alternatively to the aforementioned variants, to reinforce the sheet material walls in regions of increased stress.
The elongate panel section of relatively greater thickness may be provided by a folded over edge section of the substantially closed panel. In order to facilitate the folding over of the panel under factory conditions, the corners of the panel at either or both ends of the edge being folded may be removed prior to folding.
If further reinforcement is required, the edge of the sheet material can be folded a number of times or rolled-up.
Additionally or alternatively, additional reinforcing members may be affixed at or near to the edges of the sheet material. Preferably, such reinforcing members are strips that can be welded, glued or otherwise fastened in-situ.
Apertures in the sheet material may pass through one or more layers.
Where the sheet material is provided with reinforcement, the reinforcement may be faired to minimize/prevent snagging with other objects and/or a user's hands.
Fairings may be provided by way of trimming corners, removing burrs and/or providing rounded edges.
Suitably, the substantially closed panel is provided with means for connecting the panel pivotally to a neighbouring panel in the gabion. When such means comprise one or more apertures in the panel, for receiving a hinge member for example, the gabion may be provided with means for covering the one or more apertures to prevent or hinder a gabion fill material from escaping through said one or more apertures. Suitable covering means include cover strips, cover sheets, cover tapes, cover bands, cover ribbons, cover plates, cover coatings, cover layers, cover tabs, covering adhesives and covering gels, doughs, putties and the like. Alternatively, or as well, the one or more apertures may be provided with blocking means for at least partly blocking the egress of fines and other gabion fill materials from the gabion in use thereof. Suitable blocking means include blocking strips, blocking sheets, blocking tapes, blocking bands, blocking ribbons, blocking plates, blocking coatings, blocking layers, blocking tabs, blocking adhesives and blocking gels, doughs, putties and the like.
Other forms of pivotal connection between neighbouring side wall element panels are also contemplated within the scope of the invention—for example an interconnecting edge of a first neighbouring panel may be provided with a protruding portion interconnecting with a corresponding inset portion in the corresponding interconnection edge of a second neighbouring panel. A locking member may extend through the protruding portion and be received in the second neighbouring panel interconnection edge either side of the inset portion to lock the protruding portion into the inset portion in a pivotal fashion.
Alternatively, an elongate locking member may be provided in the interconnection edge of a first neighbouring side wall element panel, extending slightly beyond the interconnection edge at the top and bottom of the panel, and one or more linking members may then secure the locking member to the second neighbouring side wall element panel in the region extending slightly beyond the interconnection edge. Many other forms of pivotal connection may also be suitable in the realisation of the invention.
The gabion of the invention may be provided with a plurality of side wall element panels, each comprising a substantially closed panel having releasable interconnections which when released allow the side wall element panels to open with respect to the gabion to allow access from the side of the gabion to any contents of the gabion compartments.
According to the present invention there is provided a multi-compartmental gabion as hereinbefore described comprising opposed side walls connected together at spaced intervals along the length of the gabion by a plurality of partition walls, the spaces between neighbouring pairs of partition walls defining, together with the side walls, individual compartments of the multi-compartmental gabion, individual compartments of the multi-compartmental gabion being bounded by opposed side wall sections of the respective opposed side walls, the partition walls being pivotally connected to the side walls, and the side wall sections of the individual compartments comprising at least one substantially closed side wall element panel, pivotal connections being provided between neighbouring side wall element panels allowing the multi-compartmental gabion to fold concertina-wise for storage or transport.
At least one side wall element panel may be formed from a closed panel having an interconnection edge adjacent a neighbouring side wall element panel, an elongate panel being provided at or in the region of the interconnection edge, the thickness of the elongate panel being greater than the side wall element panel in the region thereof adjacent the elongate panel, the elongate panel section being provided with means for receiving a hinge member for pivotally connecting the side wall element panel to a neighbouring side wall element panel.
The partition walls may likewise be formed from closed panels. However, the partition walls may also be formed from an open mesh material, for example.
One multi-compartmental gabion of the invention therefore facilitates post-deployment recovery of the gabion by providing at least one openable side wall section along the length of the gabion. Preferably, a plurality of openable side wall sections are provided. More preferably all of the side wall sections, except those at the ends of the gabion in a gabion having more than two compartments, are openable. Most preferably, all of the side wall sections along the length of the gabion are openable. By “openable” is meant that the pivotal connection between the connected side wall element panels of the side wall section is provided by a hinge member provided on one or both of the connected side wall element panels and by a releasable locking member cooperating with the hinge member releasably to secure the pivotal connection therebetween. In some preferred embodiments of the invention, a first hinge member is provided on a first neighbouring side wall element panel and a second hinge member is provided on a second neighbouring side wall element panel, the releasable locking member cooperating with both the first hinge member and the second hinge member releasably to secure the pivotal connection. Opening of an openable side wall section is achievable by releasing the locking member and pulling apart the resulting unconnected side wall element panels.
Each side wall section may comprise a single side wall element panel, in which case the openable pivotal connection between neighbouring side wall element panels is located between neighbouring side wall sections. In this case the pivotal connection between neighbouring side wall element panels and the partition wall marking the boundary between corresponding neighbouring side wall sections is also openable to allow the first neighbouring side wall element panel to be released both from the second neighbouring side wall element panel and from the partition wall. Alternatively, each side wall section may comprise a plurality of side wall element panels, in which case the openable pivotal connection may be provided between neighbouring side wall element panels of a given side wall section. However, even when side wall sections comprise a plurality of side wall element panels, openable pivotal connections may be provided between neighbouring side wall sections as well as or instead of between neighbouring side wall element panels of a given side wall section. Multi-compartmental gabions comprising a plurality of side wall sections, with different numbers of side wall element panels constituting different side wall sections are also contemplated.
Deployment of the gabion of the invention will generally be effected by transporting the folded gabion to a deployment site, unfolding the gabion and filling each individual compartment of the gabion with a fill material. Generally the fill material will be dictated at least partly by the availability of suitable materials at the deployment site. Suitable fill materials include, but are not limited to, sand, earth, soil, stones, rocks, rubble, concrete, debris, snow, ice and combinations of two or more thereof.
There are a number of reasons why it could be desirable to open side wall sections of the gabion. For example, when the deployed gabion is to be decommissioned, it is often desirable to recover the gabion for environmental or aesthetic reasons, or simply out of consideration for the local population. Recovery of the gabion of the invention is facilitated by opening up all of the openable side wall sections of the gabion, at least partly removing the fill material from the compartments, and removing the gabion from site.
By way of further example, if the deployed gabion is damaged in use it may be desirable to replace or repair the damaged section of the gabion. Access via the openable side walls of the damaged section facilitates this. Similarly, when it is desired for reasons unconnected with damage to move, alter or replace a gabion section (for example if the position or orientation of the gabion requires alteration), such replacement is again facilitated by the capacity to remove at will fill material from selected gabion sections.
Although certain embodiments of the invention are characterised by the presence of at least one openable side wall section, and preferably by a plurality of openable side wall sections, it will often be desirable to provide each individual compartment of the gabion, optionally with the exception of the end compartments of the gabion (when the gabion has more than two compartments), with openable side wall sections. Accordingly there is provided in accordance with the invention a multi-compartmental gabion as described wherein the pivotal connection between the connected side wall element panels of each of the side wall sections, or between each neighbouring side wall section, optionally with the exception of the end side wall sections, is provided by a hinge member provided between the first side wall element panel of a given side wall section and a second neighbouring side wall element panel of the given or a neighbouring side wall section, and a releasable locking member cooperating with the hinge member releasably to secure the pivotal connection. Preferably, a first hinge member is provided on the first side wall element panel and a second hinge member is provided on the second neighbouring side wall element panel, and the releasable locking member cooperates with both first and second hinge members releasably to secure the pivotal connection.
Furthermore, although a multi-compartmental gabion will be in accordance with the certain aspects of the invention if a plurality of openable side wall sections are provided on one side wall, it is also contemplated that openable side wall sections may be provided on both side wall sections of an individual compartment to allow access to the fill material from both sides. Accordingly the invention provides a multi-compartmental gabion as described wherein the pivotal connection between the connected side wall element panels of at least a plurality of opposed side wall sections is provided by a hinge member provided between a first side wall element panel of a given side wall section and a second neighbouring side wall element panel of the given or a neighbouring side wall section, and by a releasable locking member cooperating with the hinge member releasably to secure the pivotal connection. Also contemplated within the scope of the invention is a multi-compartmental gabion as described wherein the pivotal connection between the connected side wall element panels of at least a plurality of opposed side wall sections is provided by a first hinge member provided on a first side wall element panel of a given side wall section and by a second hinge member on a second side wall element panel of the given or a neighbouring side wall section and by a releasable locking member connecting the first hinge member to the second hinge member.
Also contemplated is that openable side wall sections may be provided alternately on first and second opposed side walls along at least part of the length of the gabion. In this way when a gabion is being recovered, cooperating excavating equipment or personnel can be deployed on opposite sides of the gabion to remove fill material from neighbouring compartments simultaneously or in rapid succession if simultaneous excavation is undesirable for safety or other reasons. Thus, the invention provides a multi-compartmental gabion as described wherein the pivotal connection between the connected side wall element panels of at least a plurality of side wall sections staggered on alternating opposite side walls along at least part of the length of the gabion is provided by a hinge member provided between a first side wall element panel of a given side wall section and a second neighbouring side wall element panel of the given or a neighbouring side wall section, and by a releasable locking member cooperating with the hinge member releasably to secure the pivotal connection. Also contemplated within the scope of the invention is a multi-compartmental gabion as described wherein the pivotal connection between the connected side wall element panels of at least a plurality of side wall sections staggered on alternating opposite side walls along at least part of the length of the gabion is provided by a first hinge member provided on a first side wall element panel of a given side wall section and by a second hinge member on a second side wall element panel of the given side wall section and by a releasable locking member connecting the first hinge member to the second hinge member.
A side wall section preferably comprises a single side wall element panel, or two side wall element panels. However, a side wall section, a plurality of side wall sections, or each side wall section may, if desired comprise more than two side wall element panels. In this case pivotal connections are preferably provided between each side wall element panel. Accordingly the invention provides a multi-compartmental gabion as described wherein one or more side wall sections comprise a single side wall element panel. The invention also provides a multi-compartmental gabion as described wherein one or more side wall sections comprise two side wall element panels pivotally connected together (preferably openably pivotally connected together). Also contemplated within the scope of the invention is a multi-compartmental gabion as described wherein one or more side wall sections comprise more than two side wall element panels, with pivotal interconnections being provided between each neighbouring pair of side wall element panels.
One multi-compartmental gabion of the invention comprises a plurality of connected compartments, each compartment being bounded at opposed ends by a pair of opposed partition walls, and being bounded at opposed sides by a pair of opposed side wall sections, each side wall section comprising at one side wall element panel. In at least one, two, three or more individual compartments of the multi-compartmental gabion, at least one such side wall element panel is arranged to be openable, the mechanism of opening being operable when the compartment is loaded with a fill material.
The concertina-wise folding of the gabion may be effected by the side wall sections folding in towards the central longitudinal axis of the gabion, or by the side wall sections folding out away from the central longitudinal central axis of the gabion. The former manner will generally be preferable as the resulting folded gabion will have a relatively smaller cross-sectional surface area in a plane orthogonal to the central longitudinal axis of the gabion.
In one preferred embodiment of the invention the pivotal interconnection between connected walls and/or wall sections and/or wall elements is achieved by providing interconnected walls, wall sections and/or wall elements with a row of apertures along or in the region of an interconnection edge thereof and by providing a coil member helically threaded through a plurality of apertures along the interconnection edge. In the case of a straightforward (i.e.—non-openable) pivotal connection, a single coil member may be helically threaded through the connection edge apertures of two (or more) neighbouring walls, wall sections and/or wall elements to achieve pivotal interconnection therebetween. Accordingly, there is provided in accordance with the invention a multi-compartmental gabion as described wherein at least one pivotal connection is provided by the presence of a coil member helically threaded through connection edge apertures of connected walls, wall sections or wall elements.
In another preferred embodiment of the invention the openable pivotal interconnection between connected side wall element panels is achieved by providing the interconnected side wall element panels with a row of apertures along or in the region of an interconnection edge thereof and by providing a first coil member helically threaded through a plurality of apertures along the interconnection edge of a first side wall element panel, a second coil member helically threaded through a plurality of apertures along the interconnection edge of a second side wall element panel (connected to the first side wall element panel along the interconnection edge) and a releasable locking member threaded through overlapped first and second coil members. Thus, in the case of an openable pivotal connection, a pair of coil members may be helically threaded through the respective opposed connection edge apertures of two neighbouring side wall element panels, and a releasable locking member inserted through the overlapped coils of the opposed pair of coil members. Accordingly, there is provided in accordance with the invention a multi-compartmental gabion as described wherein at least one openable pivotal connection between neighbouring side wall element panels is provided by the presence of a pair of coil members helically threaded through respective connection edge apertures of neighbouring side wall element panels and by a releasable locking member threaded through the respective coil members when overlapped.
Thus, there is provided in accordance with the invention a multi-compartmental gabion as described wherein the or at least one hinge member comprises a helical coil.
The releasable locking member may be of any suitable shape or size and may for example comprise an elongate locking pin. The pin may be provided with a gripping protrusion at one end to facilitate manual insertion and/or removal of the locking pin. The gripping protrusion may for example comprise a loop at one end of the locking pin. Accordingly there is provided in accordance with the invention a multi-compartmental gabion as described wherein at least one locking member comprises an elongate locking pin.
The side walls, side wall sections, side wall element panels and/or partition walls preferably comprise one or more panel sections of any suitable material, for example steel, aluminium, titanium, any other suitable metal or alloy, or from a plastics, ceramic or natural material such as timber, sisal, jute, coir or seagrass. Normally, steel is preferred, in which case the steel is preferably treated to prevent or hinder steel erosion during deployment of the gabion. The panel is a substantially closed panel which acts in use of the gabion to contain a gabion fill material without the need for a gabion compartment lining material, such as a geotextile liner. However, the gabion of the invention may be used together with a suitable lining material if necessary. In the case of a closed panel, connection edge apertures where needed will normally be machined or otherwise provided in or in the region of the panel edge.
The gabion of the invention may comprise pivotally interconnected, substantially closed, side wall element panels which are connected together under factory conditions so that the gabion can take a flattened form for transportation to site where it can be erected to take a form in which panels thereof define side, partition and end walls and an open top through which the compartments of the gabion may be filled. Preferably, under factory conditions said panels define side, partition and end walls and are pivotally interconnected edge to edge and are relatively foldable to lie face to face in the flattened form for transportation to site and can be relatively unfolded to bring the gabion to the erected condition without the requirement for any further connection of the side, partition or end walls on site.
In preferred embodiments of the invention, the side walls of the gabion each comprise a plurality of side panels pivotally connected edge to edge and folded concertina fashion one relative to another. The side walls are preferably connected by partition walls which are pivotally connected thereto, the gabion structure being adapted to be erected on site by pulling it apart by the end walls so that when it is moved from the flattened form to the erected condition the side walls unfold and define with the end walls and partition walls an elongated wall structure having a row of cavities to be filled with a fill material and of which each partition wall is common to the pair of cavities adjacent the partition wall.
BRIEF DESCRIPTION OF THE FIGURES
The invention will now be more particularly described with reference to the following drawings, in which:
FIG. 1A shows a perspective view of a multi-compartmental gabion in accordance with the invention; FIG. 1B shows a perspective view of a multi-compartmental gabion folded inwardly in accordance with the invention; FIG. 1C shows a perspective view of a multi-compartmental gabion folded outwardly in accordance with the invention;
FIG. 2 shows the multi-compartmental gabion of FIG. 1 filled with a gabion fill material;
FIG. 3A shows a perspective view of a multi-compartmental gabion in accordance with a second embodiment of the invention; FIGS. 3B-3D show the folding process of the multi-compartmental gabion;
FIG. 4 shows in close-up perspective view the pivotal connection between neighbouring side wall element panels of the gabion of FIG. 1 , 2 or 3 ;
FIG. 5 shows in close-up perspective view the optional openable pivotal connection between neighbouring side wall element panels of the multi-compartmental gabion of FIG. 1 , 2 or 3 , before the releasable locking member is installed;
FIG. 6 shows in close-up perspective view the openable pivotal connections were made between the components of the FIG. 5 drawing.
FIG. 7 shows a close-up of a hinged connection of a gabion according to the invention;
FIG. 8 shows a close-up of a hinged connection of a gabion according to the invention under load;
FIG. 9 shows a close-up of a hinged connection of a gabion according to the invention being broken;
FIGS. 10 to 15 show different partial cross-sections through edges of the walls;
FIGS. 16 to 19 show different partial cross-sections through edges of the walls; and
FIG. 20 shows a side view of a wall of the gabion.
Referring in more detail to FIGS. 1 and 2 , there is shown multi-compartmental gabion 1 comprising opposed side walls 2 , 3 connected together at spaced intervals along the length of gabion 1 by a plurality of partition walls 4 , 5 , 6 defining, together with side walls 2 , 3 individual compartments 7 , 8 , 9 of multi-compartmental gabion 1 . Individual compartment 8 (and other similar individual compartments) of multi-compartmental gabion 1 is bounded by opposed side wall sections 10 , 11 of the respective opposed side walls 2 , 3 . Partition walls 4 , 5 (and similar partition walls) are pivotally connected to side walls 2 , 3 at hinge points 11 , 11 ′, 12 , 12 ′.
In the embodiments shown in FIGS. 1 and 2 , each side wall section 10 , 11 of multi-compartmental gabion 1 comprises two side wall element panels 13 , 13 ′; 14 , 14 ′, with pivotal connections being provided between neighbouring side wall element panels 13 , 13 ′, and between neighbouring side wall element panels 14 , 14 ′.
The pivotal connections between partition walls 4 , 5 (and other partition walls in the multi-compartmental gabion) and side walls 2 , 3 , and the pivotal connections between neighbouring side wall element panels 13 , 13 ′; 14 , 14 ′, allow multi-compartmental gabion 1 to fold concertina-wise for flat-packing in transportation and storage. In the embodiments shown in FIGS. 1 and 2 , the concertina-wise folding preferably operates so that the pivotal connections between neighbouring side wall element panels 13 , 13 ′; 14 , 14 ′, move inwardly with respect to the longitudinal axis of multi-compartmental gabion 1 so that the width of the flat-packed gabion is at least approximately corresponding to the width of partition walls 4 , 5 , 6 .
The side wall element panels may be provided with texture, ribbing or other irregularities in order to maintain effective strength of the panel whilst minimising its weight, and/or to provide decorative effect.
Referring to FIG. 2 , multi-compartmental gabion 1 is shown filled with a gabion fill material 21 . Fill material 21 may be selected from any suitable available material, as hereinbefore described. Rough earth and stones are shown as the fill material in FIG. 2 . FIG. 2 also shows a cover strip 22 , 22 ′ over the hinged interconnection edges of the gabion.
Referring now to FIG. 3 , there is shown a second embodiment of the multi-compartmental gabion, in which each individual compartment comprises a pair of partition walls 34 , 35 , and a pair of opposed side wall element panels 312 , 313 . Pivotal connections therebetween allow the gabion to fold concertina-wise (first one way, and then the other) for flat packing and storage.
Referring now to FIG. 4 , there is shown a close-up perspective view of the pivotal connection between neighbouring side wall element panels 13 and 13 ′ This pivotal connection may be between two side wall element panels only, or may also include a partition wall. For convenience in the drawing, partition wall 5 has been omitted from the close-up perspective view. However, it will be understood that partition wall 5 may share this particular pivotal connection in a similar fashion. Referring to FIG. 4 , side wall element 13 comprises a substantially closed panel 41 comprising a folded over edge region 42 in which is machined a row of interconnection edge apertures 43 . Prior to folding of folded over edge portion 42 , the corners of side wall element panel 41 at either end of the interconnection edge are removed to facilitate folding. Pivotal connection therebetween is effected by a helical coil 45 which is helically threaded through the interconnection edge apertures of the neighbouring panels. Although not shown in FIG. 4 , loose end 45 of helical coil 44 may be bent round or otherwise prevented from accidentally disengaging with the top most aperture of side wall element 13 , and weakening the pivotal connection by such disengagement.
Referring now to FIG. 5 , there is shown in close-up perspective view the optional openable pivotal connection between neighbouring side wall elements 13 , 13 . In this case, both neighbouring closed panels are provided with helical coil members threaded helically through the interconnection edge apertures thereof. The first hinge member 51 and the second hinge member 52 are thereby provided. Releasable locking member 53 is shown in FIG. 6 connecting the overlapped helical coils.
Referring now to FIGS. 10 to 15 , cross-sections through the gabion are shown where the walls 126 are manufactured of sheet metal. As can be seen, a helical spring 112 is threaded through apertures 114 in the side wall 126 .
In FIG. 10 , a single fold 130 is provided to reinforce the edge of the wall 126 . The aperture 114 passes through both thicknesses 132 of the fold 130 .
In FIG. 11 , a double fold 134 is provided and the aperture 114 passes through all three thicknesses 136 of the fold 134 .
In FIG. 12 , a single fold 130 is provided, but the aperture 114 only passes through a single thickness 132 .
In FIG. 13 , a double fold 134 is provided, but the aperture 114 only passes through a single thickness 136 .
In FIGS. 14 and 15 , a reinforcing strip 138 is stuck to the wall 126 using a layer of adhesive 140 . The aperture can either pass through the reinforcing strip 138 , or the wall 126 , respectively.
In FIGS. 16 , 17 and 18 , the aperture only passes through the wall 126 . Strength/reinforcement advantages can nonetheless be attained so long as the spring 112 is pulled in the direction indicated by arrow A. This arrangement has the further advantage that the aperture 114 need only be drilled or punched through one thickness of material, which reduces manufacturing costs and/or complexity.
FIGS. 16 to 19 show partial cross-sections of the gabion where the wall 126 is manufactured of a plastics material. As can be seen, a thicker, reinforced region 142 is relatively easily formed using a suitable moulding technique. In FIGS. 17 to 19 , a reinforcing wire 144 has been co-moulded with the wall 126 to further reinforce the edge thereof.
A further possible variant of the invention sees reinforcing wires or a reinforcing mesh 146 being integrally mounded with the wall 126 as illustrated in FIG. 17 . This feature means that much thinner wall thicknesses can be provided for a given strength requirement.
Finally, FIG. 20 shows a side view of a wall panel 126 having an edge reinforcement as illustrated in FIG. 6 . As can be seen, the corners of the fold 130 have been cut away 150 to prevent sharp edges 151 (indicated by a dotted line) protruding above the edge 152 of the wall 126 .
As can also be seen in FIG. 16 , the top and bottom edges 153 of the wall 126 have also been folded over to facilitate manual handling of the gabion and to prevent damage to neighbouring objects (not shown) such as a floor surface.
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The invention provides a gabion which may be used to protect military or civilian installations from weapons assault or from elemental forces, such as flood waters, lava flows, avalanches, soil instability, slope erosion and the like, the gabion comprising side walls connected together at spaced intervals by partition walls, the side walls comprising at least one substantially closed side wall element panel, which acts in use of the gabion to prevent a gabion fill material from falling through the side wall, the said action of the substantially closed side wall element panel being effective without the aid of a gabion lining material.
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BACKGROUND OF THE INVENTION
This invention relates to a variable speed hydraulic turbine generator apparatus utilizing an induction generator and a secondary excitation controller connected to the secondary side of the induction generator and more particularly to a control system for variable speed hydraulic turbine generator apparatus which is suitable for realizing running and frequency control at a maximum efficiency point.
One of major objectives of performing speed control for a rotary electric machine is to realize a running of the rotary electric machine at a maximum efficiency point of a turbo-machine by controlling the rotation speed of the rotary electric machine in accordance with a load, such as a pump hydraulic turbine, on the turbo-machine. There are available two major methods for variable speed operation of a hydraulic turbine of a hydraulic turbine generator apparatus.
The first one is the provision of a frequency converter between an AC power line system and a generator. JP-A-48-21045 proposes a method wherein supply of power to the AC power line system can be ensured even when the generator is operated at any desired speeds and the rotation speed is adjusted by regulating a guide value of the hydraulic turbine to realize a running at a maximum efficiency point of the hydraulic turbine.
The second method is to connect the primary side of a wound-rotor type induction machine to the AC power line system and to provide a frequency converter between the secondary side and the AC power line system. This method has hitherto been known as a typical way of controlling the rotation speed in accordance with the output of the generator and is described in, for example, the Electrical Engineering Handbook published by the Institute of Electrical Engineers of Japan in 1967. Control systems for this type of variable speed hydraulic turbine generator apparatus have been proposed as disclosed in, for example, JP-A-52-46428, specification and drawings of Japanese patent application No. 57-182920, and JP-A-55-56499.
A common task shared by the above two types of variable speed hydraulic turbine generator apparatus resides in how the hydraulic turbine output and the generator output are controlled to control the rotation speed. More specifically, the task is directed to how to use, for controlling the outputs of the hydraulic turbine and the generator, a speed different signal (Na-N) resulting from a comparison between an optimum rotation speed command Na calculated from a signal containing an external generator output command signal Po supplied externally to indicate a hydraulic turbine running condition and a rotation speed detection value N. This is because, in an arrangement comprises of a hydraulic turbine and a generator mechanically coupled thereto, it is general that kinetic energy of a fluid flow in the water channel is on the one hand less than kinetic energy of rotation of the mechanical system, i.e., the hydraulic turbine and that loss of the generator is, on the other hand, almost negligible in regulation of the rotation speed, with the result that the difference between the outputs of the hydraulic turbine and generator almost corresponds to an increase or decrease in the kinetic energy of rotation and hence may be used for regulation of the rotation speed of the generator. The external generator output command Po herein referred to means a generator output command other than an internal output command which may be calculated from measured signals representative of voltage, current, frequency, phase and rotation speed of components such as the hydraulic turbine, generator and frequency converter which constitute the variable speed generator apparatus. Specifically, the external generator output command is externally supplied from a central power feed commanding station.
In the aforementioned JP-A-55-56499 proposing a control system for variable speed hydraulic turbine generator apparatus wherein the wound-rotor type induction machine is connected at its secondary side to the AC power line system and the frequency converter is provided between the secondary side and the AC power line system, three kinds of measured signals representative of the speed of drive medium (water flow rate in the case of hydraulic turbine), rotation speed and output of generator stator are employed for controlling the outputs of the generator and hydraulic turbine. This publication however fails to suggest a specified manner of controlling the outputs of the generator and hydraulic turbine. It also fails to suggest how the generator output should respond to the external generator output command Po.
The aforementioned JP-A-52-46428 and specification and drawings of Japanese patent application No. 57-182920 proposing another control system for variable speed hydraulic turbine generator apparatus suggest a control method wherein a rotation speed difference signal is used for controlling the generator output.
BRIEF DESCRIPTION THE DRAWINGS
FIG. 1 is a block diagram of a control system according to a first embodiment of the invention.
FIG. 2 is a block diagram of a rotation speed controller used in the first embodiment.
FIG. 3 illustrates at sections (a) through (g) signal waveforms developing in the first embodiment.
FIG. 4 is a block diagram of a control system according to a second embodiment of the invention.
FIG. 5 illustrates at sections (a) through (g) signal waveforms developing in the second embodiment.
FIG. 6 is a block diagram of a control system according to a third embodiment of the invention.
FIG. 7 illustrates at sections (a) through (e) signal waveforms developing in the third embodiment.
FIG. 8 is a similar waveform diagram but showing signal waveform appearing in the second embodiment.
FIG. 9 is a block diagram of a control system according to a fourth embodiment of the invention.
FIG. 10 illustrates at sections (a) through (g) signal waveforms appearing in the fourth embodiment.
FIG. 11 is a block diagram showing a control system according to a fifth embodiment of the invention.
FIG. 12 is a block diagram of a frequency controller used in the fifth embodiment.
FIGS. 13, 14, 15 and 16 are block diagrams showing control systems according to sixth, seventh, eighth and ninth embodiments of the invention, respectively.
FIG. 17 illustrates at sections (a) through (g) signal waveforms appearing in the ninth embodiment.
FIG. 18 is a graph useful to explain the operation of the ninth embodiment and showing the relation of the hydraulic turbine output to the rotation speed and guide valve opening.
FIG. 19 is a graph showing the relation between the input and output signals of a hysteresis function generator used in the ninth embodiment.
FIG. 20 is a block diagram of a secondary excitation controller used in the ninth embodiment.
FIG. 21 is a block diagram of a rotation speed detector used in the ninth embodiment.
FIG. 22 is a block diagram of a guide valve driver used in the ninth embodiment.
FIG. 23 is a block diagram showing a prior art control system for variable speed hydraulic turbine generator.
FIG. 24 illustrates at sections (a) through (g) signal waveforms develoing in the prior art control system shown in FIG. 23.
FIG. 25 is a block diagram showing another prior art control system.
Referring to FIG. 23, an example of the construction of a prior art control system for variable speed hydraulic turbine generator apparatus will first be described. An induction generator 1 is rotated by a hydraulic turbine 2 directly coupled to its rotor, and its secondary winding 1b is supplied with an Ac excitation current whose phase is regulated by a secondary excitation controller 3 comprised of a frequency converter (cycloconverter) to a predetermined value in accordance with a rotation speed of the induction generator 1, so that the induction generator 1 is operated at variable speeds to produce from its primary winding la AC power at the same frequency as that of voltage on an AC power line system 4. A hydraulic turbine characteristic function generator 5 receives an external generator output command Po and a water head detection signal H which are supplied externally and generates an optimum rotation speed command Na and an optimum guide valve opening command Ya which are required for an operation with maximum efficiency. A slip phase detector 7 detects a slip phase Sp equal to a difference between a phase of voltage on the AC power line system 4 and a rotation phase of the secondary side of induction generator 1 in terms of electrical angle. A rotor of the slip phase detector 7 is wound with a three-phase winding connected in parallel with the primary winding 1a of the induction generator 1 and a stator of the slip phase detector 7 is mounted with Hall converters respectively located at circumferentially different positions spaced by an electrical angle of π/2, so that a signal in phase, as viewed from the secondary side of induction generator 1, with the voltage on the AC power line system 4 is detected by the Hall converters and converted into the slip phase Sp. An induction generator output commander 8 compares an optimum rotation speed command Na delivered out of the hydraulic turbine characteristic function generator 5 with a rotation speed detection signal N from a rotation speed detector 6 to produce an induction generator output command P G . The induction generator output command P G and the slip phase signal Sp from slip phase detector 7 are supplied to the secondary excitation controller 3 which in turn controls the AC excitation current supplied to the secondary winding 1b of induction generator 1 such that an output detection signal P of induction generator 1 detected by an effective power detector 9 equals the induction generator output command P G . As an example, an excitation current controlling method proposed in Japanese Patent Publication No. 57-60645 may specifically be applied. A guide valve driver 10 is responsive to an optimum guide valve opening command Ya from the hydraulic turbine characteristic function generator 5 to regulate the opening of a guide valve 11 so that a hydraulic turbine output PT may be controlled. The secondary excitation controller 3 connects to the AC power line system 4 through a transformer TR 12.
With the control system of FIG. 23, when the external generator output command Po is changed as indicated at section (a) in FIG. 24 with a view of increasing the generator output P stepwise, the optimum rotation speed command Na and the optimum guide valve opening command Ya respond to a stepped increase in the generator output command Po to rise stepwise as indicated at sections (c) and (b) in FIG. 24. Consequently, opening Y of the guide valve 11 is controlled by the guide valve driver 10 so as to gradually proceed to coincidence with the guide valve opening command Ya as indicated at section (d) in FIG. 24, and this change in opening Y of the guide valve 11 causes the hydraulic turbine output PT to change to a value corresponding to the external generator output command Po as indicated at (e) in FIG. 24. On the other hand, in order to increase the rotation speed N of the induction generator 1 as indicated at (f) in FIG. 24 until coincidence with the optimum rotation speed command Na, kinetic energy of the rotary system of the generator apparatus is required to be increased by an amount commensurate with an increase in the rotation speed N. Only way to this end involves either increasing the hydraulic turbine output PT or decreasing the generator output P. However, the hydraulic turbine output PT is determined, as described previously, by the opening Y of guide valve 11 which changes with the optimum guide valve opening command Ya and therefore will not be increased rapidly. Consequently, an increased amount of the kinetic energy is supplied to the rotary system by decreasing the generator output P, with the result that the generator output P desired to be increased is unintentionally decreased transiently as indicated at (g) in FIG. 24, thus adversely affecting the working of the power line system. For prevention of the transient decrease in the generator output P, it is conceivable that within the induction generator output commander 8, the optimum rotation speed command Na from the hydraulic turbine characteristic function generator 5 is initially sent to a component such as a linear delay element capable of suppressing a rapid signal change and an output of the component is then compared with the rotation speed detection signal N from the rotation speed detector 6 to produce the induction generator output command P G . This method advantageously permits part of an increased amount of the turbine output PT to be supplied for increasing the rotation kinetic energy and also permits the remainder to be distributed for increasing the output P of the induction generator 1. But, even with this method, the output P of the induction generator 1 can not be increased before the increase of the hydraulic turbine output PT and disadvantageously, the response speed of the generator apparatus itself is eventually suppressed by the response of the guide valve driver 10. This problem is also encountered when the external generator output command Po is decreased stepwise. Essentially, these problems stem from the fact that only the output of the induction generator 1 is regulated to control the rotation speed N.
The prior art control system has difficulties with the output controlling and rotation speed controlling in the variable speed hydraulic turbine generator apparatus, as has been described so far. Another problem is encountered in controlling the frequency of the AC power line system with the variable speed hydraulic turbine generator apparatus, as will be described below.
The generator apparatus, which employs for variable operation the secondary excitation controller with a frequency converter interconnected between the secondary side of the induction generator and the AC power line system, is characteristic of the fact that the rotation speed does not coincide with the frequency on the AC power line system. From this point of view, Japanese patent application No. 58-199041 proposes a method of controlling the frequency of the AC power line system to a predetermined value. This proposal takes advantage of the fact that while the generator output delivered to the AC power line system must be controlled for controlling the frequency, an output commensurate with a change in the generator output must be supplied from the hydraulic turbine to the generator for the sake of maintaining the rotation speed at an optimum value. An example of the construction in accordance with this proposal is illustrated in FIG. 25 where the same components as those of FIG. 23 are designated by the same reference numerals. Only different components will be described with reference to FIG. 25. A frequency detector 13 detects the frequency of the AC power line system 4, and a frequency controller 14 compares a frequency detection signal f with a frequency set value fo to calculate a generator output command modifying signal ΔPo. Assume now that the generator output command modifying signal ΔPo rises stepwise and the input to the hydraulic turbine characteristic function generator 5 increases stepwise. Under this situation, the output P of the induction generator 1 responds so as to change in quite the same manner as the output P shown at section (g) in FIG. 24. In other words, the output P of the induction generator 1 will not respond to reflect the change of the generator output command modifying signal ΔPo and the intentional frequency controlling disadvantageously leads to a large transient frequency difference.
Returning to FIG. 23, an instance will be considered wherein the induction generator 1 is operated approximately at the synchronous speed. Under this condition, in a cyclo-converter included in the excitation controller 3, the interval for current polarity change is long and during the long interval, current is permitted to conduct through one of anti-parallel connected converter elements of the cyclo-converter, resulting in a significant reduction in output current capacity of the cyclo-converter. The rotation speed range as above is responsible for reduction of the output current capacity of the cyclo-converter and is called a cyclo-converter output forbidden zone. Of course, the capacity of a cyclo-converter designed not to have the output forbidden zone becomes far larger than that of a cyclo-converter designed to have the output forbidden zone.
Accordingly, it has been practice either to sacrifice a generator output range overlapping the cyclo-converter output forbidden zone by using a cyclo-converter of a small capacity which is designed to have the output forbidden zone or to sustain the operation over the entire generator output range by using a cyclo-converter of a large capacity which is designed not to have the output forbidden zone.
SUMMARY OF THE INVENTION
Therefore, a generator apparatus of the type discussed so far which can employ a cyclo-converter of a small capacity but without the output forbidden zone has long been desired.
An object of this invention is to eliminate the prior art drawbacks and to improve stability of the AC power line system by making the generator output smoothly follow the generator output command without decreasing efficiency of power generation.
Another object of this invention is to provide a variable speed hydraulic turbine generator apparatus which can employ a cyclo-converter of a minimal capacity but without the output forbidden zone.
According to this invention, a control system for variable speed hydraulic turbine generator apparatus comprises an induction generator connected at its primary side to an AC power line system; a secondary excitation controller connected to the secondary side of the induction generator and being responsive to a generator output command signal supplied externally to supply to the induction generator an excitation current which causes the induction generator to generate AC power at the same frequency as that on the AC power line system; a hydraulic turbine for rotating the induction generator; a guide valve for regulating the amount of water supplied to the hydraulic turbine; a rotation speed detector for detecting a rotation speed of the induction generator; a rotation speed command calculator for receiving a hydraulic turbine running condition signal inclusive of the external generator output command signal and calculating an optimum rotation speed command; a rotation speed controller for comparing the optimum rotation speed command with a rotation speed signal from the rotation speed detector and producing a guide valve opening control signal in accordance with a difference between the optimum rotation speed command and the rotation speed signal; and a guide valve driver responsive to the guide valve opening control signal to deliver to the guide valve a signal which controls the opening of the guide valve in accordance with the guide valve opening control signal.
The invention will now be described by way of example with reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is illustrated a control system according to a first embodiment of the invention. In FIG. 1, the same components as those of FIG. 23 illustrative of the prior art are designated by the same reference numerals, and only different components, will be described with reference to FIG. 1. A rotation speed command calculator 15 is responsive to a generator output command Po and a water head signal H, both supplied externally, to generate an optimum rotation speed command Na. In a generator apparatus subject to less variations in head, the optimum rotation speed command Na may be produced from only the external generator output command Po without using the water head signal H as input signal. A rotation speed controller 16 compares the optimum rotation speed command Na with a rotation speed signal N detected by a rotation speed detector 6 and produces a guide valve opening command Ya.
FIG. 2 shows an example of the rotation speed controller 16. A comparator 17 produces a rotation speed difference ΔN. The rotation speed difference ΔN is supplied to a proportional element 18 defining K1, where K1 is a gain and an integration element 19 defining K2/S, where K2 is a gain and S is the Laplace operator, and output signals from these elements are added together by an adder 20 to produce the guide valve opening command Ya which is fed to a guide valve driver 10.
The external generator output command Po is also supplied to a secondary excitation controller 3.
With the control system constructed as above, where the generator output command Po is raised stepwise at time t o as indicated at section (a) in FIG. 3 with a view of raising generator output P, for example, stepwise, the generator output P of an induction generator 1 follows a change in the generator output command Po and rises as indicated at (g) in FIG. 3. On the other hand, the optimum rotation speed command Na also increases stepwise as indicated at (c) in FIG. 3 to change the output of the proportional element 18, followed by a stepped change of the guide valve opening command Ya as indicated at (b) in FIG. 3. However, the response speed of opening Y of the guide valve 11 is slower than the speed of response of the generator output P to the generator output command Po. As a result, the hydraulic turbine output PT becomes smaller than the generator output P and the rotation speed N is temporarily decelerated after the rapid change of the generator output command Po. Thereafter, at time t 1 that the generator output P equals the hydraulic turbine output PT, the rotation speed N becomes minimum. Since the speed difference ΔN is positive at time t 1 , the integration element 19 causes the guide valve opening command Ya to continue to increase. Consequently, the guide valve opening Y continues increasing. When the rotation speed N becomes equal to the optimum rotation speed command Na at time t 2 , the guide valve opening Y becomes maximum. Subsequently, the guide valve opening Y and rotation speed N undergo damped oscillation, with the rotation speed N converging to the optimum rotation speed command Na. Referring to FIG. 3, the hydraulic turbine output PT equals the generator output P at times t 3 and t 5 , and the rotation speed N equals the optimum rotation speed command Na at time t 4 .
As will be seen from the above, the rotation speed N can converge to the optimum rotation speed Na by making the generator output P follow the change in the external generator output command Po at a speed faster than the response of the guide valve 11. This is accomplished by initially using up rotation kinetic energy to make the generator output P follow the change in the external generator output command Po to thereby maintain the output P of induction generator 1 at the external generator output command Po while controlling the guide valve 11 such that rotation kinetic energy necessary for regulating the rotation speed N toward the optimum rotation speed command is supplied.
FIG. 4 illustrates a second embodiment of the invention. Only components different from those of FIG. 1 will be described with reference to FIG. 4. A hydraulic turbine characteristic function generator 5 is responsive to the external generator output command Po and water head signal H to generate the optimum guide valve opening command Ya and optimum rotation speed command Na. If variations in head are small, the water head signal H may be omitted. A rotation speed controller 16 having the same construction as that illustrated in FIG. 2 produces a guide valve opening correction signal ΔY which is added at an adder 21 with the optimum guide valve opening command Ya from the hydraulic turbine characteristic function generator 5. A resultant signal is fed to the guide valve driver 10.
With the control system of this embodiment constructed as above, when the generator output command Po is raised stepwise at time t 0 as indicated at (a) in FIG. 5 in order to raise the generator output P, for example, stepwise, the generator output P of the induction generator 1 follows a change in the generator output command Po and rises as indicated at (g) in FIG. 5. On the other hand, the response of opening Y of the guide valve 11 to the optimum guide valve opening command Ya is slower than the response of the generator output P to the generator output command Po. As a result, the hydraulic turbine output PT becomes smaller than the generator output P and the rotation speed N is temporarily decelerated after the rapid change of the generator output command Po. Thereafter, at time t 1 the generator output p equals the hydraulic turbine output PT, the rotation speed N becomes minimum. Since the speed difference ΔN is positive at time t 1 , the guide valve opening correction signal ΔY is also positive and the guide valve opening Y is further increased beyond the optimum guide valve opening command Ya. Consequently, the hydraulic turbine output PT exceeds the generator output P and the rotation speed N begins to increase as indicated at (f) in FIG. 5. The increasing rotation speed N gradually cancels out the difference from the optimum rotation speed command Na and the decreasing guide valve opening correction signal ΔY decreases the hydraulic turbine output pt, thereby suppressing acceleration of the rotation speed N.
In the FIG. 4 embodiment, the speed difference ΔN under the stationary condition is made zero by means of the integration element 19. On the other hand, the difference between the optimum guide valve opening command Ya from the hydraulic turbine characteristic function generator 5 and the guide valve opening Y corresponds to the difference between a hydraulic turbine characteristic stored in the hydraulic turbine characteristic generator 5 and an actual characteristic of the hydraulic turbine 2 and it can be made almost zero by improving the accuracy of a hydraulic turbine characteristic function. Accordingly, it is sufficient that the integration element 19 should generate only the guide valve opening difference (Ya-Y) under the stationary condition. This contrasts the FIG. 4 embodiment with the FIG. 1 embodiment wherein the integration element 19 has to generate the entire guide valve opening command Ya under the stationary condition. In the FIG. 1 embodiment, with the aim of accelerating the response of the guide valve 11, the gain K2 of the integration element 19 is necessarily made larger than a certain value at the cost of appreciably oscillatory responses of the hydraulic turbine output PT as indicated at (e) in FIG. 3 and of the rotation speed N as indicated at (f) in FIG. 3. Contrary to this, in the FIG. 4 embodiment, the response speed can be accelerated even by increasing the gain K1 of the proportional element 18 having damping effect and decreasing the gain K2 of the integration element 19 relatively or correspondingly. Further, as indicated at (e) and (f) in FIG. 5, the hydraulic turbine output PT and the rotation speed N can converge to command values without attended by damping.
FIG. 6 shows a third embodiment of the invention which is a modification of the FIG. 4 embodiment. Only different components will be described with reference to FIG. 6. A comparator 22 produces a difference ΔN between the optimum rotation speed command Na and the rotation speed detection value N. The rotation speed difference ΔN is applied to a generator output modifying commander 23, and an output signal ΔP1 from the commander 23 is added with the external generator output command signal Po at an adder 24, a resultant signal being supplied, as a generator output command signal, to the second excitation controller 3.
The generator output modifying commander 23 has a function as below. Within a range where the absolute value of rotation speed difference ΔN is less than N1, the generator output modifying command signal ΔP1 is kept zero, and when the absolute value of rotation speed difference ΔN exceeds N1, the absolute value of generator output modifying command signal ΔP1 proportional increases as the absolute value of rotation speed difference ΔN increases but can not exceed P1.
In the control system constructed as above, when the generator output command Po is started at time t 0 to increase along a ramp as indicated at (a) in FIG. 7 with a view of increasing the generator output P, for example, along a ramp until it approximates a maximum output of the hydraulic turbine, the response is obtained as will be described below. For the sake of comparison, the response obtained with the FIG. 4 embodiment when the generator output command is increased along a ramp under the same condition will first be explained with reference to FIG. 8. As the generator output command Po increases along a ramp throughout times t 0 to t 3 as indicated at (a) in FIG. 8, the optimum rotation speed command Na remains at a minimum rotation speed determined by a rated voltage of the secondary excitation controller and the like factors until time t 1 as indicated at (c) in FIG. 8. Till then, the optimum guide valve opening command Ya nearly equals the guide valve opening Y as indicated at (b) in FIG. 8. After time t 1 , the optimum rotation speed command Na increases as the generator output command Po increases, to provide the difference ΔN from the rotation speed N by which the guide valve opening Y is rendered to exceed the optimum guide valve opening command Ya fed from the hydraulic turbine characteristic function generator 5, thereby starting supplying part of the hydraulic turbine output as an increment of rotation kinetic energy. At time t 2 , the guide valve opening Y reaches a maximum value and the hydraulic turbine output PT becomes substantially constant as indicated at (d) in FIG. 8. In order to approximate the rotation speed N to the optimum rotation speed command Na the rotation kinetic energy must be increased by increasing the hydraulic turbine output PT beyond the generator output P. However, after time t 3 , the increment of the rotation kinetic energy becomes small in inverse proportion to an increase in ultimate value of the generator output command Po, as indicated at (d) and (e) in FIG. 8, and the rotation speed N becomes less accelerated. As a result, the rotation speed difference ΔN becomes small, thereby prolonging an interval of time terminating in time t 4 that the guide valve opening Y begins to converger to the optimum guide valve opening command Ya, and attainment of a running of the hydraulic turbine with maximum efficiency is prolonged before the rotation speed N converges to the optimum rotation speed command Na. Therefore, in some applications, efficiency degradation is so imminent that it can not be neglected.
Turning to FIG. 7, the rotation speed N and other parameters in the FIG. 6 embodiment respond in guide the same manner as those explained in connection with FIG. 8 until time t 1 . From time t 1 that the optimum rotation speed command begins to increase as indicated at (c) in FIG. 7, the rotation speed difference ΔN starts increasing and at time t 2 , it reaches N1 preset by the generator output modifying commander 23. After time t 2 , the generator output modifying commander 23 generates the generator output modifying command ΔP1 in a direction in which the generator output command Po supplied externally to the secondary excitation controller 3 is cancelled out. Consequently, the generator output P falls below the generator output command Po as indicated at (e) in FIG. 7 and the acceleration of the rotation speed N is increased by an amount corresponding to an increment of the difference between the hydraulic turbine output PT and the generator output P. The guide valve opening Y becomes maximum at time t 3 and the generator output command Po reaches a maximum value at time t 4 . When the rotation speed difference ΔN again decreases to N1 at time t 5 , the generator output modifying command signal ΔP1 becomes zero. At time t 6 , the rotation speed N approximates to the optimum rotation speed command Na, and the guide valve opening Y begins to decrease for converging to the optimum guide valve opening Ya. Therefore, it follows that the generator output P is suppressed throughout times t 2 to t 5 to promote acceleration of the rotation speed N toward the optimum rotation speed command Na. This embodiment is effective for changing the generator output command Po to a great extent and particularly, suited for use as a control system for variable speed hydraulic turbine generator apparatus wherein moment of inertia of the rotary part is large relative to the rated generator output.
FIG. 9 shows a fourth embodiment of the invention which is another modification of the FIG. 4 embodiment. Only different components will be described with reference to FIG. 9. The rotation speed N detected by the rotation speed detector 6 is supplied to a generator output modifying commander 25, an output signal ΔP2 from the generator output modifying commander 25 is added with the external generator output command signal Po at an adder 26, and a resultant signal is supplied as a generator output command signal to the secondary excitation controller 3. The function of the generator output modifying commander 25 shown in FIG. 9 will be explained. When the rotation speed N lies between preset values N2 and N3, the generator output modifying command signal ΔP2 is kept zero and then the rotation speed N falls below the preset value N2, the generator output modifying command signal ΔP2 decreases in proportion to a decrease in the rotation speed N. Conversely, when the rotation speed N goes beyond the preset value N3, the generator output modifying command signal ΔP2 increases in proportion to an increase in the rotation speed N. The absolute value of the generator output modifying command signal ΔP2, however, can not exceed P2. The preset values N2 and N3 define a rotation speed range determined by a rated voltage and a frequency output range of the frequency converter constituting the secondary excitation controller 3 and strength of mechanical parts of the induction generator 1 and hydraulic turbine 2.
With the control system constructed as above, when the generator output command Po is raised stepwise at time t 0 as indicated at (a) in FIG. 10 with a view of increasing the generator output P stepwise under the condition that the rotation speed N approximates the preset value N2, the response is obtained as will be described below. At time t 0 that the generator output command Po rises, the rotation speed N, like the waveform shown in FIG. 5, temporarily decreases as indicated at (f) in FIG. 10 in opposition to a change in the optimum rotation speed command Na. As the rotation speed N falls below the preset value N2, a generator output command originating from the generator output modifying command ΔP2 and supplied to the secondary excitation controller 3 becomes less than the externally supplied generator output command Po. Consequently, the hydraulic turbine output PT coincides with the generator output P at time t 1 which is earlier than time t 2 the hydraulic turbine output PT coincides with the generator output command Po. By adopting this embodiment, the time the rotation speed N becomes minimum shifts from time t 2 for a dashed curve to time t 1 for a solid curve as indicated at (f) in FIG. 10. At the same time, transient overshooting of the rotation speed in the reverse direction can be suppressed considerably. This embodiment is efficient for controlling the rotation speed such that it falls within the preset rotation speed range of the variable speed hydraulic turbine generator apparatus. Obviously, this embodiment may be implemented in combination with the FIG. 6 embodiment.
FIG. 11 illustrate a fifth embodiment of the invention which is still another modification of the FIG. 4 embodiment. Only different components will be described with reference to FIG. 11. A frequency detector 13 detects the frequency on the AC power line system 4, and a frequency controller 27 compares a frequency detection signal f delivered out of the frequency detector 13 with a frequency set value fo to produce a generator output modifying command signal ΔP3. The command signal P3 is added to the external generator output command Po by means of an adder 28, and a resultant signal is supplied to the hydraulic turbine characteristic function generator 5 and the secondary excitation controller 3. FIG. 12 shows an example of the frequency controller 27. A comparator 29 produces a difference Δf between the frequency set value fo and frequency detection signal f. The frequency difference Δf is applied to a proportional element 30 of a gain K 3 and an integration element 31 defining K 4 /S, where K 4 is a gain, and output signals of these elements are added together at an adder 32 and then fed to an limiter 33. The limiter 33 is configured to suppress the absolute value of the generator output modifying command signal ΔP3 to P3 or less.
With this construction, the generator output modifying command signal ΔP3 calculated from the frequency difference Δf can be used for regulating both the hydraulic turbine guide valve driver 10 and secondary excitation controller 3, thus attaining frequency controlling along with stable rotation speed controlling.
FIG. 13 illustrates a sixth embodiment of the invention which is a further modification of the FIG. 4 embodiment. Only different components will be described with reference to FIG. 13. In the field of the variable speed hydraulic turbine generator apparatus, there has not yet been available any specified proposal directed to handling an extremely supplied generator output command which is not confined within a power generation permissible range of the generator apparatus. The embodiment of FIG. 13 makes an approach to this problem. A generator output limit calculator 34 suppresses its output to a preset value P5 when the external generator output command signal Po exceeds the preset value P5 and to a preset value P4 when the command signal Po is below the preset value P4, and a resulting output from the generator output limit calculator 34 is supplied to the secondary excitation controller 3 and the hydraulic turbine characteristic function generator 5.
FIG. 14 illustrates a seventh embodiment of the invention which is a modification of the FIG. 13 embodiment A generator output limit calculator 35, like the aforementioned calculator 34, confines the generator output command Po within a range determined by the preset values P4 and P5. Specifically, in this embodiment, the generator output limit calculator 35 receives the preset values P4 and P5 from a generation power limit function generator 36. The generation power limit function generator 36 receives the water head H to produce an upper limit P5 and a lower limit P4 of generation power output. The upper and lower limits P4 and P5 are determined by a hydraulics characteristic of the hydraulic turbine 2, an output limit of the induction generator 1, and a voltage output limit and an output frequency range of the secondary excitation controller 3. This embodiment permits a variable speed hydraulic turbine generator apparatus subject to large variations in water head to be prevented from being loaded with an overload.
FIG. 15 shows an eighth embodiment of the invention which modifies the FIG. 41 embodiment. Generator output limit calculators 341 and 342 have each the same construction as that of the aforementioned generator output limit calculator 34. The one generator output limit calculator 341 is interposed between an adder 28 for frequency control and the input for generator output command of the hydraulic turbine characteristic generator 5, and the other 342 is interposed between an adder 26 for rotation speed regulation and the input for generator output command of the secondary excitation controller 3. According to this embodiment, even when the commands delivered to the hydraulic turbine and induction generator are modified for frequency control and rotation speed regulation, overloading can be prevented.
As has been described, since in the first to eighth embodiments of the invention the generator output is controlled directly in accordance with the externally supplied generator output command, the generator output can follow the generator output command smoothly to advantageously improve stability of the AC power line system. When the difference between the rotation speed and the optimum rotation speed is large, the generator output can be regulated transiently to thereby sustain the operation without attended by a reduction in power generation efficiency.
Referring now to FIGS. 16 to 22, a ninth embodiment of the invention will be described.
As in the prior art, the hydraulic turbine characteristic generator 5 receives the generator output command Po and water head signal H and produces the optimum rotation speed command Na and optimum guide valve opening command Ya. If the generator output command Po is a command for raising the generator output and the optimum rotation speed command Na following raising of the generator output is N1 which falls within the cycloconverter output forbidden zone, a hysteresis function generator 37 succeeding the hydraulic turbine characteristic function generator 5 produces an output, i.e., a corrected rotation speed command Na 1 which equals N min at a lower limit of the cyclo-converter output forbidden zone as shown in FIG. 19.
At a comparator 42 of the rotation speed controller 16 (See FIG. 21), the rotation speed command Na 1 is compared with an actual rotation speed N detected by the rotation speed detector 6 and a difference ΔN=Na 1 -N is fed to a calculator 46. The calculator 46 is comprised of a proportional element of a gain K 7 , integration elements respectively defining K 8 /S and K 9 /S, where K 8 and K 9 are gains, and an adder 43 and as far as the difference ΔN is present, it produces a correction signal ΔC which corrects the optimum guide valve opening command Ya to a value by which the difference ΔN is made zero. Specifically, the correction signal ΔC is added to the optimum guide valve opening command Ya by means of an adder 44 of the guide valve driver 10 (See FIG. 22), and a corrected guide valve opening command (Ya+ΔC ) delivered out of the adder 44 is applied to an adder 45 connected in series with an integration element defining K 10 /S where K 10 is a gain. The output of the integration element is negatively fed back to the adder 45. The generator output command Po is also fed to a comparator 40 of the secondary excitation controller 3 (See FIG. 20) and compared with an actual generator output signal detected by the effective power detector 9, thus producing a difference ΔP=Po-P which in turn is fed to a power controller 39. The power controller 39 is comprised of a proportional element of a gain K 5 , an integration element defining K 6 /S where K 6 is a gain, and an adder 41 and it produces an output signal applied to a cyclo-converter 38.
With the control system of this embodiment constructed as above, when the generator output command Po is raised stepwise at time t o as indicated at (a) in FIG. 17 with a view of raising the generator output P, for example, stepwise to a range by way of which the rotation speed is urged to fall within the cyclo-converter output forbidden zone, the generator output P of the induction generator 1 follows a change in the generator output command Po and rises, as indicated at (g) in FIG. 17. Then, a negative feedback circuit comprised of the integration element of K 6 /S included in the power controller 39, cyclo-converter 38, induction generator 1, effective power detector 9 and comparator 40 included in the secondary excitation controller 3 gradually decreases the difference ΔP=Po-P, and under the stationary condition, P =Po stands. On the other hand, the opening Y of the guide valve 11 responds to the guide valve opening command Ya more slowly than the generator output P responds to the generator output command Po. Consequently, the hydraulic turbine output PT becomes smaller than the generator output P and after the rapid change of the generator output command Po, the rotation speed N is temporarily decelerated as indicated at (f) in FIG. 17. Thereafter, at time t 1 that the generator output P substantially equals the hydraulic turbine output PT as indicated at (d) in FIG. 17, the rotation speed N stops decreasing. At time t 1 , the actual rotation speed N is smaller than the rotation speed command Na 1 and hence the difference ΔN=Na 1 -N is positive which causes the calculator 46 to produce a positive correction signal ΔC. A guide valve opening command (Ya+ΔC) corrected by this positive correction signal ΔC exceeds the optimum guide valve opening command Ya and then, the hydraulic turbine output PT begins to exceed the generator output P. Accordingly, the rotation speed N increases to approximate the rotation speed command Na 1 and concurrently, the correction signal ΔC also approaches to zero. Ultimately, the guide valve opening Y coincides with the optimum guide valve opening command Ya and the rotation speed N equals the rotation speed command Na 1 . Specifically, a negative feedback circuit comprised of the integration element of K.sub. 8 /S included in the calculator 46, guide valve driver 10 having the adder 44, calculator 46, guide valve 11, hydraulic turbine 2, induction generator 1, rotation speed detector 6 and comparator 42 gradually decreases the difference ΔN=Na 1 -N and under the stationary condition, N=Na 1 stands. Also, under the stationary condition, a difference ΔY=Ya-Y=0 or Ya=Y is established as will be explained below.
(a) The optimum guide valve opening command Ya delivered out of the hysteresis function generator 37 of course corresponds to the generator output command Po.
(b) As described previously, P=Po stands under the stationary condition.
(c) Inertia of all the rotary parts such as runners of the hydraulic turbine 2 and the rotor of induction generator 1 is accelerated or decelerated by the difference between the hydraulic turbine output PT and generator output P and these rotary parts are considered to be a kind of integration element. In addition, as described previously, the negative feedback circuit is formed of the calculator 46, adder 44, guide valve driver 10, guide valve 11, hydraulic turbine 2, generator 1, rotation speed detector 6 and comparator 42. These account for the fact that PT =P stands under the stationary condition.
(d) The guide valve opening Y corresponds to the hydraulic turbine output PT.
When putting the above items (a) to (d) together, the difference ΔY=Ya-Y=0 or Ya=Y stands under the stationary condition.
Conversely, where the optimum rotation speed command Na falls within the cyclo-converter output forbidden zone when the generator output command is decreased, the output of the hysteresis function generator 37, i.e., the corrected rotation speed command Na 1 equals N max at an upper limit of the cyclo-converter output forbidden zone.
As described above, according to the ninth embodiment of the invention, since the capacity of the cyclo-converter can be set under the condition that the generator rotates approximately at the synchronous speed and the cyclo-converter has the output forbidden zone and yet the generator output range equals that obtained with a cyclo-converter without the output forbidden zone, a maximized generator output range can be realized using the cyclo-converter of minimized capacity.
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A control system for variable speed hydraulic turbine generator apparatus comprises an induction generator connected at its primary side to an AC power line system, a secondary excitation controller connected to the secondary side of the induction generator and being responsive to a generator output command signal supplied externally to supply to the induction generator an excitation current which causes the induction generator to generate AC power at the same frequency as that on the AC power line system, a hydraulic turbine for rotating the induction generator, a guide valve for regulating the amount of water supplied to the hydraulic turbine, a rotation speed detector for detecting a rotation speed of the induction generator, a rotation speed command calculator for receiving a hydraulic turbine running condition signal inclusive of the external generator output command signal and calculating an optimum rotation speed command, a rotation speed controller for comparing the optimum rotation speed command with a rotation speed signal from the rotation speed detector and producing a guide valve opening control signal in accordance with a difference between the optimum rotation speed command and the rotation speed signal, and a guide valve driver responsive to the guide valve opening control signal to deliver to the guide valve a signal which controls the opening of the guide valve in accordance with the guide valve opening control signal.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of prior U.S. patent application Ser. No. 10/757,796, entitled “Earset Assembly,” filed on Jan. 13, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to an earset assembly for a hearing aid, a mobile phone, a communication device for a personal computer, a multimedia device, etc. More particularly, the present invention relates to a wired or wireless non-occluding earset assembly.
BACKGROUND OF THE INVENTION
[0003] A sound delivery assembly for hearing aid, communication system or multimedia system is primarily configured to achieve high quality acoustic performance. It is also desired that the structure of the sound delivery assembly maintain in manufacture a designed user comfort in wearing it because he/she wants to use it for an extended time.
[0004] High quality acoustic performance is achieved by high efficiency and high fidelity of the sound delivery system. Efficiency of a sound delivery system is determined by the size of a speaker element and the distance to the entrance of the ear canal from the end of the sound delivery assembly. Fidelity of a sound delivery system is determined by a number of factors including the size of the speaker element and the length of a sound tube to deliver sounds.
[0005] So far, there are two primary types of sound delivery tools. One of them adopts an occluding earset structure such as an earmuff, an occluding earbud, or an occluding earmold. The other type adopts a non-occluding earset structure.
[0006] An ear-occluding structure such as the earmuff type achieves high quality acoustic performance because the size of a speaker element can be relatively large. Other ear-occluding structures such as the earbud and the earmold sound delivery systems also achieve high quality acoustic performance because the sound is delivered into the ear canal at the entrance of the ear canal and because the sound pressure is sealed in by the occlusion, thereby easily producing good bass and high sound level. Thus, small speaker drivers can be used with occluding systems. However, it is not physically comfortable for a user to occlude the ear for an extended period for two reasons: the physical discomfort due to pressure on the tissue required to get a good seal as the jaw and jaw muscles move and change the canal shape, and due to the disturbing and uncomfortable nature of the sound of the user's own voice (bassy and too loud) and audibility of bodily sounds (heart beat, blood flow, chewing sounds, clearing throat, etc.). Another reason for the user's discomfort is that a user has difficulty in hearing sounds other than that delivered by the sound delivery assembly. Lack of hearing the background sounds makes a user feel isolated from his surroundings and uncomfortable. Particularly, when a user uses a mobile phone or communicates with a computer or multimedia, he/she needs to hear the surrounding sounds for safety or as a necessary part of the experience.
[0007] Where the ear is not occluded, a user can hear surrounding sounds in addition to delivered sounds. Conventional non-occluding earsets are coupled with a relatively long sound tube for delivering sounds. They do not achieve high quality acoustic performance because their efficiency and fidelity are not high. Various structure of non-occluding earsets have been designed, however, they are not adjustable for each individual ear anatomy so that some users feel uncomfortable tension to the ear in wearing the earset or the earset provides compromised performance for some users due to the ill fit of the device.
[0008] U.S. Pat. No. 6,009,183 by Taenzer presents an ambidextrous sound delivery system. This sound delivery system uses a tube for delivering sounds. It has an ambidextrous feature provided by rotating the tube at its axis. However, the long tube affects the sound fidelity so that substantial additional form elements need to be included. Additionally, the tube terminates in the ear canal so that the accommodation of different ear sizes has to be done by flexing the tube creating uncomfortable pressure on the canal wall. Further, since the entrance to the ear canal has hair, some users report that an unbearably uncomfortable tickling sensation is produced by the tube.
[0009] U.S. Pat. No. 6,438,245 “Hearing Aid Communications Earpiece” shows an above-the-ear microphone for pickup of the user's own voice. U.S. Pat. No. 6,021,207 “Wireless Open Ear Canal Earpiece” and U.S. Pat. No. 6,181,801 “Wired Open Ear Canal Earpiece” show devices providing sound delivery to the ear canal in a non-occluding manner.
[0010] U.S. Pat. No. 5,659,156 by Mauney presents an earmold for two-way communications devices. This earmold is a non-occluding one designed to securely hold the earmold in the ear and deliver sounds at the entrance of the ear canal. However, this earmold has to be configured to fit each individual and must also be configured to separately fit right and left ears. It is not adjustable for the anatomy of each individual or ear.
[0011] An object of the present invention is to provide a earset assembly having a structure that easily fits to almost all people's either right or left ear and allows a user to wear it with great comfort on the ear for an extended period.
[0012] Another object of the present invention its to provide an earset subassembly which creates and assures good sound performance for almost all ears.
[0013] Another object of the present invention its to provide an earset subassembly which facilitates ease and flexibility in manufacturability of the assembly.
[0014] Another object of the present invention its to provide an earset subassembly which facilitates ease of testing of the assembly during manufacture.
SUMMARY OF THE INVENTION
[0015] An object of the present invention is to provide great comfort in the use of an earset assembly. A wired or wireless earset assembly comprises an earset housing having a curved portion configured to fit to a root of a top of an ear; a speaker driver having an input port, a speaker housing containing the speaker driver, a flexible neck tube having a first extension at a first end of the flexible neck so as to be coupled with at least a part of the curved portion of the earset housing and a second extension at a second end of the flexible tube coupled with the speaker housing, a rotatable cap containing a bud coupled with the speaker housing, circuitry for processing an input signal contained in the earset housing, having an input port and an output port, and a wire connecting the output port of the circuitry and an input port of the speaker driver. The wire is contained in the flexible neck tube. Because the structure of the non-occluding sound delivery assembly of the present invention does not give uncomfortable tension or pressure to the ear, a user can wear the sound delivery assembly with great comfort and high quality acoustic performance for an extended period. In addition, the present invention allows the sound delivery assembly to easily fit to almost all the person's either of right and left ears by an easy procedure. Furthermore, the present invention increases ease of manufacturability because the number of components in the assembly decreases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more embodiments of the present invention and, together with the detailed description, serve to explain the principles and implementations of the invention.
[0017] In the drawings:
[0018] FIG. 1 is side view of an earset assembly in one embodiment of the present invention.
[0019] FIG. 2 is an end view of the device of FIG. 1 .
[0020] FIG. 3 is a view of the opposite side of the device of FIG. 1 .
[0021] FIG. 4 is an end view of the device of FIG. 1 .
[0022] FIG. 5 is an exploded view of the device of FIG. 1 .
[0023] FIG. 6 is a view of the rotatable cap 104 of the device of FIG. 1
[0024] FIG. 7 is a side view of the rotatable cap 104 of the device of FIG. 1
[0025] FIG. 8 is an end view of the rotatable cap 104 of the device of FIG. 1
[0026] FIG. 9 is a bottom view of the rotatable cap 104 of the device of FIG. 1
[0027] FIG. 10 is a cross section view of the rotatable cap 104 of the device of FIG. 1
[0028] FIG. 11 is a cross section view of the rotatable cap 104 connected to the speaker housing 107 .
[0029] FIG. 12 is a front view of the earset assembly of FIG. 1 placed on a right ear.
[0030] FIG. 13 is a front view of the earset assembly of FIG. 1 placed on a left ear.
[0031] FIG. 14 illustrates how a user mounts the assembly to the user's ear.
[0032] FIG. 15 illustrates how a user mounts the assembly to the user's ear.
[0033] FIG. 16 is a front view of another embodiment of a rotatable cap 104 of FIG. 1 .
[0034] FIG. 17 is a side view of another example of rotatable cap 104 of FIG. 1 .
[0035] FIG. 18 is a front view of another example of rotatable cap 104 of FIG. 1 .
[0036] FIG. 19 is a side view of another example of rotatable cap 104 of FIG. 1 .
[0037] FIG. 20 is a front view of another example of rotatable cap 104 of FIG. 1 .
[0038] FIG. 21 is a side view of another example of rotatable cap 104 of FIG. 1 .
[0039] FIG. 21 a is a front view of another example of rotatable cap 104 of FIG. 1 .
[0040] FIG. 21 b is a side view of another example of rotatable cap 104 of FIG. 1 .
[0041] FIG. 22 is a cross-sectional view of an earset assembly according to one embodiment of the present invention.
[0042] FIG. 23 is a perspective view of a wired type earset assembly in another embodiment of the present invention.
[0043] FIG. 24 is a cross-sectional view of the earset assembly of FIG. 23 .
DETAILED DESCRIPTION
[0044] Embodiments of the present invention are described herein in the context of an earset assembly. Those of ordinary skill in the art will realize that the following detailed description of the present invention is illustrative only and is not intended to be in any way limiting. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. Reference will now be made in detail to implementations of the present invention as illustrated in the accompanying drawings. The same reference indicators will be used throughout the drawings and the following detailed description to refer to the same or like parts.
[0045] As shown in FIGS. 1-4 , the earset assembly 90 comprises earset housing 101 , neck member 103 , rotatable cap 104 having bud 105 , and speaker housing 107 for housing a speaker. Earset assembly 90 includes curved portion 102 configured to fit to the top of a user's ear and antenna enclosure portion 109 . Earset housing 101 includes four holes 110 so that a microphone 112 placed near holes 110 can receive sounds. Optionally, antenna enclosure portion 109 may be omitted.
[0046] As shown in FIG. 5 , neck member 103 comprises a neck tube 201 and a curved section 202 . The curved section 202 includes a U-shaped portion 203 coupled to earset housing 101 . The neck tube 201 and curved section 202 form substantially a U-shape or horseshoe shape to be hooked on the ear. Material of neck member 103 is elastic material such as rubber, urethane rubber or silicone rubber or the like. The neck tube 201 may contain a stiffening member 203 a , such as a length of copper wire, to allow the neck tube 201 to be formed by the user to the user's own anatomy, and to allow the neck member 103 to retain that shape, once it is formed. Further, the neck member can have embedded in it, a stiffening element, not shown, to enable the non-formable portions of the neck member 103 to retain their as-molded shapes, while still providing for the comfort of the elastic material against the user's skin. The neck member 103 includes a speaker housing 107 and a microphone housing 208 . A speaker 204 is located in the speaker housing 107 , and microphone 112 is located in the microphone housing 208 . A wireless radio 206 , such as a Bluetooth radio, FM radio, IEEE 802.11 radio or the like, is located in the earset housing 101 .
[0047] FIGS. 6-10 show views of one embodiment of rotatable cap 104 . Rotatable cap 104 comprises body 301 , which is generally cylindrical, rotatably coupled to speaker housing 107 to cover and acoustically seal a speaker 204 , and bud 302 which is generally conical extending from the body 301 . The central axis 302 a of bud 302 is located at an oblique angle to the central axis of generally cylindrical body 301 . Preferably, the angle between the axis 302 a of bud 302 and the axis of body 301 is between 15 degrees and 90 degrees. A generally cylindrical port 306 is formed through the bud 302 , and the port 306 communicates with a cylindrical port 308 formed through the body 301 , and a flange 310 is formed around the periphery of the cylindrical port 308 . By rotating rotatable cap 104 , the distance between the bottom of the curved section 202 of neck member 103 and the opening end of bud 302 is adjusted to fit the distance between the top of the root of the ear and the entrance of the ear canal of each individual. Material of rotatable cap 104 is elastic material. Preferably, material of rotatable cap 104 is rubber, urethane rubber or silicone rubber or the like.
[0048] The bud is preferably made non-occluding by a plurality of notches 310 on its surface, as shown, or by other means such as external longitudinal ridges, lateral piercings, an oval outer cross-sectional shape or the like.
[0049] FIG. 11 shows a cross-sectional view of rotatable cap 104 and speaker housing 107 . Speaker driver 204 is contained in speaker housing 107 . The front face 402 of speaker driver 204 touches a part of the bottom of body 301 of rotatable cap 104 . This allows the elastic material of rotatable cap 103 to form a circular, rotatable seal 403 a to the front face 402 of the speaker driver 204 , preventing the cancellation of sound that would occur if the sound wave from the front of the speaker driver 204 were allowed to mingle with the wave from the back of speaker driver 204 . This cancellation would occur because the wave from the front of the speaker driver 204 is exactly 180 degrees out of phase with the wave from the back of speaker driver 204 .
[0050] There is a contained space between the back of the speaker 204 and the speaker housing 107 , and this space is called “back volume” 403 . According to well known methods in the art, the back volume and speaker vent 406 form an acoustic Helmholz resonator that is tuned to work with the electro-acoustic parameters of speaker driver 204 to allow the assembly to create high fidelity sound to the ear of the user.
[0051] The front sound wave pressure created by the drive of speaker driver 204 is captured by body 301 of rotatable cap 104 and delivered through port 306 toward a user's ear canal. Here it should be understood that the sound tube for delivering sounds created by speaker, consisting of the port 306 formed through the bud 302 , is short and speaker driver 204 is located in the speaker housing 107 . Since the length of the sound tube is relatively short the earset assembly achieves high efficiency and high fidelity despite a relatively small speaker driver. Also, due to high efficiency and high fidelity, the power consumption of the earset sound assembly decreases. Accordingly, a user can continue to use the earset sound assembly for a longer period without replacing a battery with a new one or recharging a battery. On the other hand, the speaker is relatively large compared to the restricted size of an ear canal located speaker, such as are used in In-The-Canal (ITC) and Completely-In-The-Canal (CIC) hearing aids, allowing for improved bass response fidelity and efficiency as compared to those designs.
[0052] FIGS. 12 and 13 are a front view of the earset assembly of FIG. 1 placed on a right ear 500 and a left ear 501 , respectively. It should be noted that the axis of the speaker is oriented substantially perpendicular to the axis of the ear canal 504 of the user with the front face 402 of the speaker directed forward, in the direction the user is facing.
[0053] A user can wear the earset assembly of the present embodiment according to the following steps, illustrated in FIGS. 14 and 15 . First, a user rotates the rotatable cap 104 so as to direct bud 302 toward the ear on which the user wants to wear the assembly. The user puts bud 302 at entrance 502 of ear 500 (or 501 ), and then places earset housing 101 above ear 500 (or 501 ) as seen in FIG. 14 . Then, the user rotates earset housing 101 rearward behind the auricle so as to securely hook the assembly on the ear, as shown in FIG. 15 . If the bud 302 is not directed toward the user's ear entrance 502 , the user can remove the device and adjust the angle of rotatable cap 104 to make the assembly secure, yet comfortable. This adjustment only needs to be made once for a new user. It should be noted that the ports 110 are located symmetrically on each side of the device to allow for use of the device on either ear.
[0054] Further, neck tube 201 is adjustable as described above by forming the neck tube 201 into any comfortable shape, for example by forming the neck tube 201 in a lateral curve to increase or decrease the distance of the end of bud 104 from the entrance of the ear 502 . Such adjustment is retained by the stiffening member 203 a , even when the device is off the ear.
[0055] The structure of the earset assembly of the present invention allows a user to wear the earset assembly on either of right and left ear, placing the ear bud very close to the entrance of the ear 502 and securely hooking the earset assembly on the ear according to the above described procedure. Because neck member 103 is primarily elastic material such as rubber, urethane rubber or silicone rubber, which is flexible and adjustable to fit the individual user, a user does not feel uncomfortable tension and a user does not feel irritated in wearing the earset assembly. Consequently, the user can use the earset assembly with great comfort for an extended period.
[0056] Moreover, it should be understood that the rotatable cap 104 can be rotated to any angle to fit a wide variety of users. This is best understood with reference to FIGS. 12 and 13 . As shown in FIG. 12 the distance between the top of the user's ear and the entrance 502 to ear canal is relatively short, so the rotatable cap is located with the axis of port 306 oriented at an angle upward from the horizontal. On the other hand, as shown in FIG. 13 the distance between the top of the user's ear and the entrance 502 to ear canal is relatively long, so the rotatable cap is located with the axis of port 306 oriented at an angle downward from the horizontal.
[0057] FIGS. 16 and 17 show a top view and a side view of another example of rotatable cap 104 , respectively. Bud 701 extending from the surface of body 702 has a cylindrical shape. The diameter of bud 701 is selected to fit opening end 703 of bud 701 to an entrance of the ear canal.
[0058] FIGS. 18 and 19 show a top view and a side view of another example of rotatable cap 104 , respectively. Bud 801 is extended from the side surface of body 802 , and directs in a direction parallel to front face 402 of speaker driver 401 .
[0059] FIGS. 20 and 21 show a top view and a side view of another example of rotatable cap 104 , respectively. A bud comprises cylinder 901 extended from body 903 and mushroom shaped part 902 coupled with the ear end of cylinder 901 . The bud directs in an oblique direction to the plane parallel to the bottom of body 903 so as to just enter the opening of the ear canal. Preferably, the angle between the axis of the bud and the axis of generally cylindrical body 903 is between 15 degrees and 90 degrees. The mushroom shaped part is of relatively thin and resilient material and includes a plurality of port piercings 904 . The port piercings 904 prevent occlusion by preventing a complete seal of the mushroom shaped part 902 with the inside of the ear canal. When the mushroom shaped part is inserted into the ear canal it deforms slightly and tends to be captured and not easily fall out or be jarred loose. Therefore this design is useful for sport models of the device.
[0060] FIGS. 21 a and 21 b show a top view and a side view of another example of rotatable cap 104 , respectively. In this embodiment the bud includes three sound ports 906 . When viewed in FIG. 21 a the vertical dimension “a” of the end of the bud can be seen to be longer than its horizontal dimension “b”. Accordingly when the bud is inserted in the ear canal the long axis contacts the ear canal while the short axis does not, so that the bud is prevented from being occluding.
[0061] FIG. 22 shows a cross-sectional view of an earset assembly in one embodiment of the present invention. As shown in FIG. 22 , the earset assembly comprises antenna 1001 , circuitry 1002 for processing a signal received by antenna 1001 , and wire 1003 contained in neck member 103 which connects between output port 1004 of circuitry 1002 and input port 1005 of speaker driver 401 , and battery 1006 . Circuitry 1002 and battery 1006 are contained in earset housing 101 . Battery 1006 supplies the electrical power to speaker driver 401 and circuitry 1002 . Battery 1006 may be rechargeable so that the assembly may comprise a port for recharging battery 1006 . Alternatively, an external power source may supply the electrical power to speaker driver 401 and circuitry 1002 through a cable so that battery 1006 need not be contained in earset housing 101 . Antenna 1001 is contained in antenna enclosure portion 109 . Alternatively, antenna 1001 may be covered by another cover or uncovered. A signal received by antenna 1001 is processed by circuitry 1002 , and then transmitted to speaker driver 401 through wire 1003 in neck member 103 . Speaker driver 401 transduces the transmitted electrical signal to a sound, and then the sound is delivered to an ear of the user through a hollow in bud 105 .
[0062] An earset assembly further comprises microphone 1010 as shown in FIG. 22 . Preferably, microphone 1010 is placed near the end of curved portion in earset housing 101 , that is the bottom of U-shape configured by the coupling of earset housing 101 and neck member 103 . Earset housing 101 has one or more holes called microphone sound ports near microphone 1010 . A sound received by microphone 1010 via the microphone sound ports is transduced to an electrical signal. The electrical signal is processed by a circuitry 1007 contained in earset housing 101 , and communicated with an external communication device or multimedia device through antenna 1001 .
[0063] In accordance with another embodiment of the present invention, FIG. 23 shows a perspective view of a wired type earset assembly. As shown in FIG. 23 , the earset assembly comprises housing 1101 having curved portion 1102 configured to fit to the top of an ear, flexible tube 1103 , rotatable cap 1104 having bud 1105 , and speaker housing 1107 coupled with rotatable cap 1104 . The flexible tube 1103 and curved portion 1102 are substantially U-shaped to be hooked on the ear. FIG. 24 shows a cross-sectional view of the earset assembly of FIG. 23 . As shown in FIG. 24 , the earset assembly further comprises circuitry 1301 coupling with external signal source 1302 such as communication device and multimedia device through a cable 1303 , wire 1304 contained in flexible tube 1203 which connects between output port 1305 of circuitry 1301 and input port 1306 of speaker driver 1307 . Circuitry 1301 processes a signal transmitted through cable 1303 and then processed signal is further transmitted to speaker driver 1307 through wire 1308 in flexible tube 1203 . Electrical power is supplied to circuitry 1301 through cable 1303 and also supplied to speaker driver 1307 . Speaker driver 1307 transduces the transmitted electrical signal to a sound, and then the sound is delivered to an ear of the user through a hollow in bud 1205 .
[0064] An earset assembly further comprises microphone 1310 as shown in FIG. 24 . Preferably, microphone 1310 is placed near the end of curved portion in housing 1201 , that is the bottom of the U-shape configured by the coupling of housing 1201 and flexible tube 1203 . Housing 1201 has one or more holes called microphone sound ports near microphone 1310 . A sound received by microphone 1310 via the microphone port(s) is transduced to an electrical signal. The electrical signal is processed by a circuitry 1311 contained in housing 1201 , and communicated with external communication device or multimedia device 1302 .
[0065] It should be understood that the design of neck member 103 is an important feature. As designed, all the critical electro-acoustic and ergonomic (human fit) elements of the device are captured in this one neck member sub-assembly. Accordingly, the neck member sub-assembly controls the delivered sound frequency response, loudness, loudness/distortion trade-off, mic pickup directionality, mic sensitivity, mic SNR, top-of-ear comfort, ear variation adjustability (one size fits all), ear occlusion, microphone wind noise rejection, and even the product's as-worn appearance (Hair, the ear and head coverings usually “camouflage” the back of the instrument, i.e. the earset housing 101 when worn so the neck member sub-assembly becomes the most visible element of the earset).
[0066] Thus, the neck member 103 sub-assembly is designed so that it can be pre-built and pre-tested, thereby controlling the quality of the product. The remainder of the device, which is housed in earset housing 101 , consists of highly reliable and consistent parts (i.e. the radio, battery and housings), so later assembly of these parts to the neck member 103 sub-assembly is routine. Yet, all product differentiation can readily be done in the earset housing 101 . For example, the Bluetooth radio can be changed to 802.11 radio (for VoIP applications), or to low-power FM radio for low cost applications, without affecting the customer's product perception (It looks and works the same to them). As another example, the battery can be changed from Lilon to NiCd to LiP to NiMH without any change to the perceived product or its audio performance. Yet another example, housing colors, logo printing, shape and size, can all be changed while the acoustics and ergonomics do not change. Thus, how the product feels and acts remains captured in the neck member 103 sub-assembly. Despite this product flexibility, it is unnecessary to redesign and qualify another electro-acoustic solution every time it is desired to make a product change.
[0067] Furthermore, the special neck member 103 simplifies the testability of the device. The neck member 103 sub-assembly can be tested for acoustic performance by installing the speaker and microphone in the neck member 103 and then connecting the tester signal leads to the speaker and microphone leads. After testing is completed satisfactorily, the neck member 103 is affixed to the earset housing 101 with its included components.
[0068] Another important point to note about the neck member 103 is that it is single part that houses both a speaker and a microphone without feedback between them. Usually, such an assembly is undesirable, since audio frequency mechanical vibrations created by the speaker travel directly to the microphone creating feedback “echo”, in other words the listener at the other end of the communication hears his own voice returning to him/her with a two-way delay. This can be very disturbing and prevent easy communication. However, the neck member 103 overcomes this since the use of elastomeric material allows this single sub-assembly to avoid the feedback problem.
[0069] While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art having the benefit of this disclosure that many more modifications than mentioned above are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.
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A wired or wireless earset assembly comprises an earset housing having a curved portion configured to fit to the top of an ear, a speaker driver contained in a speaker housing, a flexible tube having a first extension so as to be coupled with at least a part of the curved portion of the earset housing and a second extension coupled with the speaker housing, a rotatable cap containing a bud coupled with the speaker driver, a sound delivery port in the bud, a circuitry for processing an input signal in the case, and a wire in the flexible tube connecting the circuitry and the speaker driver. The structure of the assembly allows a user to wear it with great comfort and high quality acoustic performance for an extended period, enables the assembly to fit to both right and left ears by a simple rotation of the cap, and increases ease of manufacturability.
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This is a continuation of application Ser. No. 318,563, filed Mar. 3, 1989 and now abandoned.
TECHNICAL FIELD
The present invention relates to fiber processing equipment utilized in the wood pulp and paper industries. More particularly, the present invention relates to a rotor disc for a refiner and its method of formation.
BACKGROUND OF THE INVENTION
Paper can be manufactured from a variety of materials. Rags, for example, are used for the highest quality paper. Lower quality paper can be made from seed fibers, jute, flax, grass and other plants. The largest amount of paper today, however, is made from wood pulp.
Wood pulp manufacture typically begins with cutting trees, trimming the cut trees into logs and de-barking the logs to provide the raw wood material. The logs are sliced and the slices broken into chips. The chips are screened or torn to obtain a plurality of chips of a given size. This is often accomplished by delivering the wood chips to a refiner wherein the chips are torn to provide a raw fibrous pulp containing fibers of a desired length and size. The raw pulp is oftentimes washed and bleached to remove impurities. The purified, but yet raw, pulp is then delivered to a second refiner or a series of refiners that beat the pulp to a desired degree. One skilled in the art will appreciate that the refining process affects the length of the fibers, their plasticity and their capacity for bonding together in the papermaking machine. The quality of the finished product is determined more at the time of refining than at any other time in the paper production process. At the conclusion of the refining process, the pulp "stock" is suitable for introduction into a papermaking machine.
Different types of refiners are known. Some refiners are provided with cone-shaped beater rolls in a similarly shaped housing. Other refiners are provided with substantially round discs. Disc refiners typically include a mass chamber having an inlet for the incoming unrefined pulp material and an outlet for the refined pulp. Some disc refiners provide one rotating and one stationary disc, whereas others provide two rotating discs. The discs face one another and, through rotation of one or both discs, frictionally engage the stock to refine the pulp. U.S. Pat. No. 3,984,057, for example, describes a refiner with three coaxial discs; the outer discs are stationary and the intermediate disc is rotated by a power-driven shaft.
The pulp-engaging face of any refining disc is conventionally provided with a plurality of spaced blades, each of a predetermined thickness, height, and angular position. Dams are conventionally provided within the spaces so as to better process the stock. The arrangement of the blades and dams is, in part, dictated by the type of wood to be processed (i.e. hard, soft or otherwise) as well as by the desired parameters for the resulting end product, be it pulp or wood stock. It is therefore to be understood that, in operation of a refiner, a mixture of wood chips and water is delivered to the mass chamber and directed between at least two discs, engaged by the blades and dams thereof and, by friction, torn or ground into a pulp.
The manufacturing process employed for producing a refining disc is both slow and complex. This is particularly so for an intermediate rotor disc, because it has two refining faces. One method of manufacturing a refining disc is to cast the disc (and blade pattern) as one solid piece. Typical materials for this method are carbon steel, iron or stainless steel. Regardless of material, the blades and dams must be machined or tooled in order to assure precise alignment, angular relationship and proper blade/dam configuration. A related method calls for the production of a frame consisting of two or more concentric rings interconnected by spaced, radially extending rods. The blades and dams are fixed, usually by welding, to the frame. Alternatively, a plurality of steel plates may first be fixed to the frame, and then the blade and dams may be fixed to the plates. Of course, for a double face disc the process is done twice. These methods have several disadvantages, many of which are explained in the commonly owned U.S. Pat. No. 3,614,826. Any foundry method of manufacture is a lengthy process. This particular foundry process is labor intensive, requiring skilled workmanship. Further, a refining disc made from cast iron or the like is very heavy. The sheer mass of the disc increases the refiner's operating costs and makes replacement difficult, causing long periods of down time. Specifically, the excessive weight of the disc wears on the motor utilized to rotate the disc. In addition, the steel casting process results in plates and blades that are porous and brittle.
Those skilled in the art will appreciate that the cutting action or refining efficiency of a refiner depends, in large part, on the number or blades; the more blades per given area, the stronger and more efficient the tearing action of the disc. Thus, another disadvantage with these prior art methods is that it is relatively impossible to cast a refiner disc with tall and/or thin blades spaced closely together or in complicated patterns. This results in poor stock distribution and processing. The foundry method also results in a loss of about 70% of the material used in the refining discs due to the wear on the blades.
Another method of manufacturing refiner discs was developed in response to these disadvantages. Specifically, refiner discs have been manufactured by welding stainless or carbon steel blades onto a base in the pattern or arrangement desired. To manufacture a two-sided rotor disc, blades are welded to both sides of the base. Specifically, the blades are individually welded along their bottom edges so as to be fixedly secured to the base. The completed disc, whether one-sided or two-sided, is secured within the refiner in the conventional manner.
The welding process is a lengthy process, requiring skilled workmanship. While not as heavy as cast iron refining discs, the discs manufactured according to the welding method are relatively heavy, which significantly contributes to the refiner's operating costs. The heat generated by the welding process softens the blades, resulting in a decrease in the useful life of the refining disc. Further, the blade-by-blade welding process is expensive in terms of materials, time and manpower.
Accordingly, there is a need for an improved rotor disc for a refiner that is less expensive to manufacture in terms of labor, time and materials costs; more efficient in terms of cutting strength, pulp stock distribution and fiber treatment, conserves energy and other refiner operating costs, and offers an increase in useful performance lifetime. Moreover, the preferred refiner disc would be relatively lightweight and easily installed.
SUMMARY OF THE INVENTION
The present invention solves the above-described problems in the prior art by providing a welded rotor disc that preserves the original hardness of the blade elements and significantly reduces the weight of the disc. As a result, the life and operating efficiency of the rotor disc area increased. The method of the present invention reduces manufacturing cost in terms of time, labor and materials.
Generally described, the present invention comprises a plurality of refining blades alternately positioned between a plurality of spacers. The blades and spacers are fixedly secured one to the other in a predetermined arrangement of a certain number to provide an annular segment or blade sector. A plurality of blade sectors are fixedly secured one to another to provide a completed refiner disc. Of course, the spacers may be provided with dams to enhance the refining capability of the disc.
It is to be understood that the preferred blades of the present invention are of a height substantially greater than, and preferably twice that of conventional blades. Thus, it will be appreciated that a first teaching of the present invention is the elimination of the base member to which conventional blades have heretofore been secured. As a result, the weight of the disc is substantially reduced, providing corresponding benefits in refiner operating costs.
According to the method of the present invention, the blades and spacers are secured one to another by a continuous weld about the inner and outer circumference of a disc. Thus, it will be further appreciated that a second teaching of the present invention is the elimination of the manufacturing step of individually welding along the base edges of each blade length. Rather, the method of the present invention comprises the step of welding continuously about the outer and inner circumferences of a plurality of blades and blade sectors to form the completed disc. This method provides a significant reduction in manufacturing costs in terms of time, labor and materials. Moreover, because the length of each blade is not subjected to the welding process, the blades of the completed double-faced rotor disc retain their original hardness, resulting in a greater disc life expectancy and increased tearing efficiency.
Accordingly, it is an object of the present invention to provide an improved refining disc for use in refiners of pulp or other types of fibrous stock used in paper making and related industries.
It is another object of the present invention to provide an improved refining disc whose manufacture is simplified in order to conserve time, labor and materials.
It is another object of the present invention to provide an improved refining disc the use of which results in better stock distribution and fiber treatment by the refiner.
It is another object of the present invention to provide an improved refining disc, the use of which conserves energy and other operating costs.
It is another object of the present invention to provide an improved refining disc that provides a longer useful performance lifetime.
It is another object of the present invention to provide an improved refining disc which is lighter in weight than previous refining discs.
It is another object of the present invention to provide an improved refining disc wherein the blade elements maintain their original degree of hardness.
It is another object of the present invention to provide an improved refining disc which is readily installed or replaced, thereby resulting in less downtime of a refiner.
It is another object of the present invention to provide an improved refining disc that enjoys the benefits of a welded manufacturing process, but overcomes the shortcomings thereof.
It is another object of the present invention to provide an improved double-faced rotor refining disc without use of a base plate or like member.
It is another object of the present invention to provide an improved method of manufacturing a double-faced rotor disc for a refiner.
It is another object of the present invention to provide an improved method manufacturing a double-faced rotor disc by eliminating the manufacturing step of welding along the bottom or base length of each blade.
These and other objects, features and advantages of the present invention may be more clearly understood and appreciated from a review of the following detailed description of the preferred embodiment and by reference to the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan front view of the preferred embodiment of a refining disc manufactured in accordance with the present invention.
FIG. 2 is a front plan view of an annular segment of the refining disc shown in FIG. 1.
FIG. 3 is an exploded perspective view of the alternately arranged blades and spacers of the annular segment shown in FIG. 2.
FIG. 4 is a perspective view of two blades with spacers integrally formed on one side of each blade, thereby showing a second preferred embodiment of the present invention.
FIG. 5 is a top partial view of an annular segment formed by the alignment of blades and spacers shown in FIG. 4.
FIG. 6 is a perspective view of a blade and a spacer, the blade having two spacers integrally formed on both sides thereof, thereby showing a third preferred embodiment of the present invention.
FIG. 7 is a top partial view of an annular segment formed by the alignment of blades and spacers shown in FIG. 6.
FIG. 8 is an end view of the annular segment of FIG. 2, showing the welding cord which interconnects the blades and spacers at a top circumference thereof.
FIG. 9 is a front plan view of an annular segment whose blades and spacers are welded one to the other by continuous weld cords at an inner circumference and an outer circumference.
FIG. 10 is a front plan view of a preferred embodiment showing the welding of two annular segments in accordance with the present invention.
FIG. 11 is a front plan view of an annular segment whose blades and spacers are held together by transverse rods, one of which is shown in cut away, thereby showing yet another preferred embodiment of the present invention.
FIGS. 12A-F illustrates side views of six different central element configurations.
DETAILED DESCRIPTION
Referring now to the drawings, in which like numerals indicate like elements throughout the several figures, FIG. 1 illustrates a refining disc 20 composed of annular segments 22a-h arranged around a central element 50. The refining disc 20 of the preferred embodiment of the present invention is of conventional size and shape as commonly used in conjunction with refiners for processing the wood pulp stock. The refining disc 20 defines a first pulp engaging face 24. It is to be understood that the disc 20 also defines a second correspondingly configured pulp engaging face (not shown) on the opposite side thereof. The control element 50 is attached to the refining disc 20 in any suitable manner. FIG. 12 shows alternatively configured central elements 50, which are discussed in greater detail hereinbelow.
FIG. 2 illustrates a front view of the annular segment 22a constructed in accordance with the preferred embodiment of the present invention. Those skilled in the art will appreciate that, but for an alternative alignment of blade elements, annular blade segment 22a is substantially identical in construction and the method of formation, to blade segments 22b-h. Thus, only blade segment 22a is described in detail.
The annular segment 22a is composed of interconnected and alternately arranged blades 27 and spacers 30. FIG. 3 illustrates the alternately arranged blades 27 and spacers 30 of one embodiment of the present invention. Each of the blades 27 are generally rectangular in shape, providing a narrow end 28 which is peaked so as to form a convenient ridge 29 for welding as described in detail below. The blades 27 may be made of any suitably rigid material. A preferred material is stainless steel. The blades 27 are each of a height of a convention disc. Thus, the blades 27 substantially equivalent to that are roughly twice the height of a conventional refining blade.
The spacers 30 are also generally rectangular in shape and are necessarily as long as the blades 27, but not necessarily as wide or as high. A spacer 30 is placed between two blades 27 so as to form a channel 31 to allow for the passage of the stock. In this embodiment, the spacers 30 are provided with integral dam members 32 for better processing of the stock. Dams 32 are well known in the art and, accordingly, need not be disclosed in greater detail.
Preferred materials for the construction of the spacers include steel, wood and plastic, or any other suitable rigid material. Alternative forms of the blades 27 may be provided. For example, FIG. 4 shows blades 27a with integrally formed spacers 30a. The advantage of such a construction is that the disc assembly process is shortened by virtue of the omission of any step for securing a separate spacer to a blade. FIG. 5 shows the positioning of the blades 27a for welding in accordance with the present invention as described in detail below. Similarly, FIG. 6 shows a blade 27b with integrally formed spacers 30b and 30c that project from opposite sides of the blade. The embodiment of FIG. 5 further shows a blade 27a formed without any spacers for use with the blades 27b. FIG. 7 shows the positioning of the blades 27b and 27c for welding in accordance with the present invention as described in detail below.
An common teaching of each disclosed embodiment of blade and spacer configuration and alignment is that the blade is approximately twice the height of a conventional blade, thereby providing the standard height of a refining disc while omitting the use of any mounting plate or base member typically used when manufacturing a welded double face rotor disc. It will be further appreciated that so long as the blades and spacers are symmetrically formed, the configuration on one face of a double-faced rotor disc will mirror that of the other face. This is, of course, of no limitation on the present invention since one of ordinary skill in the art could readily configure one face differently from the other.
FIG. 8 shows the weld cord of the preferred embodiment of FIG. 2. More particularly, a weld cord 40 is made only of the ends 28 of the blades 27 and the spacers 30. In this manner, the blades 27 and spacers 30 are secured one to the other to form the annular segment 22a or blade sector. A like weld cord 41 is made at the opposite end of the blades 27 and spacers 30 so as to fixedly secure the elements at each end. Thus, as shown in FIG. 2, the inner circumference of the annular segment 22a is secured with a weld cord 40 and the outer circumference of the annular segment 22a is secured with a weld cord 41. This arrangement is further shown in FIG. 9, which illustrates that the weld cords 40 and 41 are continuous about the lengths of their respective circumferences. FIG. 11 further shows the welding of the two annular segments 22a and 22b, thereby demonstrating that regardless of blade alignment, the welds 40 and 41 remain continuous about the inner and outer circumferences of the refining disc 20.
Welding is the preferred means of securing the blades 27 and spacers 30. However, one skilled in the art will appreciate that yet other means may be employed. Turning of FIG. 10, transverse rods 60 may be utilized to connect the blades 27 and spacers 30. In such a case, each of the blades 27 and spacers 30 are drilled to provide holes 61 of sufficient diameter to receive the rods 60. The rods 60 define a leading end 63 and trailing end 64. the trailing end is fitted with an integrally formed head. The leading end is preferably threaded for receipt of a nut or like reining member. The rod 60 is passed through the holes 61 until the leading edge projects slightly from the blade segment 22 and the trailing edge is flush against the blade segment. A nut or like member (not shown) is secured to the leading edge of the rod 60 to secure the blades 27 and spacers 30 one to the other. Of course, as shown in FIG. 10, a plurality of rods 60 could be utilized. Moreover, rods 60 could be used in conjunction with the weld cords 40 and 41.
Once the disc 20 is so formed, the central element 50 is secured within and to the inner circumference of the disc. A plurality of configurations may be employed, depending essentially on the configuration of the shaft of the refiner upon which the disc is being mounted. For example, a ring-like structure with radial ears projecting into a central opening (FIG. 12a); a ring with holes (FIG. 12b); a ring with a single spoke including a central hole for fixing about the shaft (FIG. 12c); a ring with a plurality of spokes that converge at a central hole (FIGS. 12d and f); and a fan blade-like configuration (FIG. 12e). Thus, regardless of configuration, the actual element comprises a hub by which the refining disc 20 is secured to a shaft for rotation.
The present invention thus includes an improved method of manufacturing a double-faced rotor disc for a refiner, whereby a plurality of blades 27 and spacers 30 are secured on to the other to form a blade sector. A first preferred method comprises the step of welding continuously about the inner and outer circumferences of the blade sector 22a. A second preferred method comprises the steps of drilling holes in the blades 27 and spacers 30, then inserting rods 60 in the holes and securing the blades and spacers about the rods with conventional fasteners such as nuts, wingnuts and any like device.
It will be appreciated that, by virtue of its construction, the present invention eliminates the need for any base member or mounting plate as a component element of a double-faced rotor disc. It will be further appreciated that the method of the present invention provides for continuous welding about the inner and outer circumferences of the disc, thereby eliminating the need for welding along the bottom length of each individual blade.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention is not to be construed as limited to the particular forms disclosed, because these are regarded as illustrative rather than restrictive. Moreover, variations and changes may be made by those skilled in the art without departing from the spirit of the invention as set forth by the following claims.
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The present invention discloses an improved rotor disc for a refiner and its method of formation. The invention comprises a plurality of blade members spaced apart by a spacer between each adjacent blade member. Dams may be provided on the spacer. In forming the preferred disc, the plurality of blades and spacers are secured one to the other to form a blade segment. A plurality of blade segments are affixed one to the other to, in turn, form the disc. The invention is characterized by an absence of any mounting plate or base member. The method of the invention is characterized by a continuous weld along either of the inner circumference or the outer circumference of the disc.
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FIELD OF THE INVENTION
This invention concerns a method for repairing a broken weft thread on weaving machines, in particular for repairing thread breaks which occur between the yarn supply package in use and the device, itself common technology, for forming a particular thread accumulation necessary for inserting a weft thread into the shed.
The method is particularly applicable to a weaving loom which uses a rotating package frame preferably of the type where the supply packages are presented one after the other to the insertion mechanism by a conveyor belt.
BACKGROUND OF THE INVENTION
In conventional weaving machines, a disadvantage exists in that thread breaks which occur between the yarn supply and the yarn accumulator must be repaired manually, and in that the accumulator must then be rethreaded manually. Furthermore, manual rethreading has generally been required when the yarn supply, for example a yarn package, becomes empty.
In connection with the latter disadvantage, devices exist which ensure a continuous supply of thread by tying together two yarn packages and automatically switching from one to the other, as disclosed in U.S. Pat. No. 4,450,876. However, this type of device still suffers from the disadvantage that repair and rethreading after a thread break must be done manually.
SUMMARY OF THE INVENTION
The method according to the invention includes the steps of continually providing yarn supply packages; using a thread clip to hold the thread end of at least the supply package following the yarn supply package in use; monitoring the weft thread for breaks between the supply package in use and the device for forming the above-mentioned thread accumulation; and when a break is detected, gripping the thread end of the following supply package which is not in use and tying it to the weft section of broken thread which is still connected to the thread accumulating device.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to explain the characteristics of the invention, the following preferred embodiments are described, without being limitative in any way, with reference to the accompanying drawings, where:
FIGS. 1 to 3 are schematic diagrams illustrating the method according to the invention;
FIG. 4 shows a variant of the step shown in FIG. 3;
FIGS. 5 to 9, 10 to 12, 13 to 14, and 16 respectively show four variants of the invention.
FIG. 15 is a schematic diagram showing control means for carrying out the method of FIGS. 1 to 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a weft insertion mechanism which, as is known, includes a package frame 1, a device 2 on which a particular thread accumulation 3 can be formed, and a weft insertion device 4 for inserting the weft thread 5 into the shed 6 on the weaving machine, where this thread 5, as is known, is beaten up between the warp threads by a reed 7.
The package frame 1 is of the type where in addition to the supply package in use 8A, at least one second supply package 8B is held in readiness to be used as soon as the previous package is empty or is no longer connected to the device 2 as the result of a thread break. In this embodiment, this is achieved by using a package frame 1 consisting of a conveyor belt 9, such that as shown schematically by the arrow 10 the empty supply packages can be evacuated automatically, while a full supply package is presented automatically. The device 2 used to form a weft accumulation 3 can consist of e.g. a prewinder which itself is common technology.
Clearly, on an airjet weaving machine the insertion device 4 will consist of a main injector or similar, while on a gripper machine it will be formed by grippers.
Also in FIG. 1, use is made of: a number of thread clips 11A to 11D which in this case are mounted on the conveyor belt 9; a thread eye 12 through which the weft thread 5 is led from the package frame 1 to the device 2 for forming 8 a thread accumulation 3; a detection device 13; and a threading device 14 or suchlike. The detection device 13 monitors the thread 5 for breaks, either by detecting the absence of the thread or by detecting that the thread is not moving.
The method according to the present invention consists of gripping the thread end 15 of at least the supply package 8B following the supply package in use 8A, by means of a thread clip 11B. In the embodiment shown in FIG. 1, the thread end 15 of each supply package 8 is brought into the corresponding thread clip 11 during installation of the package on conveyor belt 9.
Here it should be noted that either mechanical or pneumatic thread clips (thread catchers) 11A-11D can be used. Pneumatic thread catchers, consisting of e.g. suction nozzles, offer the advantage that the thread is always held kept stretched between the thread catcher and the supply package, even if the distance between the thread catcher and the supply package changes as a result of rotation of the conveyor belt 9 of the package frame 1.
If a thread break 16 occurs, as shown in FIG. 1, this is detected by the detector 13. As a result of this detection, the threading device 14 is actuated e.g., in the manner shown in Belgian Pat. No. 1,000,368, and U.S. Pat. No. 4,054,159 and 4,756,341, such that said threading device moves through the thread eye 12 and grips the thread end 15 of the next supply package 8B, as shown in FIG. 2. The clip 14A of the threading device 14 can be either mechanical or pneumatic, e.g. in the form of a suction nozzle. The threading device 14 is then drawn back, thus threading the detector 13 and the thread eye 12, after which the thread end 15 is joined to the weft section 17, preferably by means of a welded splice 18, as shown in FIG. 3. The join can be made by devices which themselves are common technology, for example a tying-in device or a splicer, represented in the figures by reference numeral 19. A known knotting device is shown, for example, in U.S. Pat. No. 4,423,586.
The free end 20 formed on the supply package 8A previously in use can be brought back into the thread clip 11A in various ways.
As shown in FIG. 3 this is done by means of a suction nozzle 21 which scans the outer surface of the corresponding supply package 8A, catches the thread end 20 and then brings it into the thread clip 11A.
As shown in FIG. 15, the conveyor belt 9 can be driven by means of a motor 53. This motor is controlled by means of a control unit 54 which in turn is coupled to detector 13. Upon detecting a thread break, motor 53 is switched on to move the conveyor over a distance which is equal to the distance between the two packages. The displacement can be controlled by means of a proximity switch 55 or the like. An exact displacement can also be obtained by using a stepper motor.
As shown in FIG. 4, the supply package 8A is first brought back into the position where new supply packages are normally mounted on the conveyor belt 9, in order for the thread end 20 to be led into the thread clip 11A by the suction nozzle 22. Clearly, in this case when a new supply package is mounted the suction nozzle 22 also has the function of finding its thread end 15 and leading said thread end into the corresponding thread clip.
In the embodiment shown in FIGS. 5 to 9, instead of the above-mentioned thread clips 11 a single pneumatic thread catcher or suction nozzle 23 is used. By means of this suction nozzle 23 the thread end 15 of the next new supply package 8B is found and caught, whereupon said suction nozzle 23 is brought to a particular point P, as shown in FIG. 6. When the detector 13 detects a thread break 16, the package frame 1 is actuated such that said package 8B is brought into the same position as the package previously in use 8A, so that, as shown in FIG. 7, the thread end 15 is situated in front of the thread eye 12 and the detector 13. As shown in FIG. 8, it is then simple for the thread end 15 to be drawn through the detector 13 and the thread eye 12 by means of the threading device 14 and then connected to the the weft section 17, as shown in FIG. 9.
The embodiment shown in FIGS. 10 to 12 uses a fixed thread clip 24, in which the thread end 15 of each new package 8B is placed, and an auxiliary device 25 with a fork 26 which moves, e.g., by a pneumatic or hydraulic cylinder, so as to bring the thread end 15 of the supply package 8B into line with the thread eye 12 and the detector 13. Clearly in this case after the broken thread 5 has been repaired the package frame 1 is turned so that, as shown in FIG. 12, the supply package 8B is brought into the position shown for supply package 8A.
In another variant of the invention, the thread end 15 of the supply package 8B following the supply package in use 8A is caught by a suction nozzle 23, in exactly the same way as shown in FIGS. 5 and 6, after which when a thread break 16 is detected, the suction nozzle 23 is moved so that the thread end 15 is brought into the vicinity of the thread end 12 and/or the detector 13. The position obtained in this way is shown in FIG. 13. Then, as shown in FIG. 14 the thread from the supply package 8B is drawn through the thread eye 12 by means of the threading device 14.
In another variant, not shown in the figures, the suction nozzle 23 is presented to the thread eye 12, whereupon the suction is cut off and compressed air supplied, so that the thread end 15 is blown through the thread eye 12. Then either the threading device 14 brings the thread end 15 to the device 19, or thread end 15 is blown directly into the vicinity of the device 19. This can be accomplished, as shown in FIG. 16, by providing a valve system 50 which can be switched into at least two positions, respectively connecting the nozzle 23 with a suction source 51 or with compressed air supplying means 52.
In yet another variant not shown in the figures, instead of the fork 26 shown in FIG. 10 a suction nozzle is used, e.g. suction nozzle 23, where the auxiliary device 25 with suction nozzle 23 can be moved as in the embodiments shown in FIGS. 5 and 13, i.e. in order to bring the thread to a particular point P, after which when a thread break occurs the bar with the suction nozzle 23 mounted on it extends until it come in front of the detector 13 and the thread eye 12, whereupon the thread can be drawn through.
If the weft section 17 is no longer located at the point at which it is to he connected to the thread end 15, it can be fetched by means of e.g. the method described in Belgian patent application No. 8700566 made by the present applicant.
The present invention is in no way limited to the embodiments described by way of example .and shown in the figures; on the contrary, such a method according to the invention can be implemented in all sorts of variants while still remaining within the scope of the invention.
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A method for repairing a weft thread on a weaving machine, in particular for repairing thread breaks between a yarn supply package and an accumulator, includes the step of providing at least two yarn supply packages, a second package automatically replacing the one in use when the one in use becomes empty. Additional steps include using a thread clip to hold a thread end of the second supply package, monitoring the weft thread for breaks between the supply package in use and the accumulator, and when a thread break is detected, gripping the thread end of the second supply package and joining it to the broken weft section which is connected to the accumulator. An apparatus is provided which includes means for carrying out each of the above-described steps.
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LATIN NAME OF THE GENUS AND SPECIES
[0001] The mandarin cultivar of this invention is botanically identified as Citrus reticulata.
VARIETY DENOMINATION
[0002] The variety denomination is ‘DaisySL’.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a new and distinctive mandarin cultivar designated ‘DaisySL’, which was developed at Riverside, Calif., and derived from an irradiated bud of ‘Daisy’ mandarin. ‘Daisy’ mandarin was produced in Indio, Calif. in 1963 by J. R. Furr from a conventional hybridization of 2n ‘Fortune’×2n ‘Fremont’×mandarin. ‘Fortune’ mandarin was itself produced from a conventional hybridization of 2n ‘Clementine’×2n ‘Dancy’ mandarin made by J. R. Furr in Indio, Calif. in 1954 and released in 1964. ‘Fremont’ mandarin was obtained from a conventional hybridization of 2n ‘Clementine’ mandarin×2n ‘Ponkan’ mandarin made by P. C. Reece in Orlando, Fla. in 1948 and later fruited, selected and released by J. R. Furr in Indio, Calif. in 1964.
[0004] Irradiation of budwood from registered ‘Daisy’ trees in Lindcove, Calif., was accomplished in June, 1997 at Riverside using 50 Gray units of gamma irradiation from a Cobalt-60 irradiation source. Buds from this irradiation were propagated onto various rootstocks in the greenhouse at Riverside where they were grown to field-plantable-sized trees. These trees were planted in June 1998 at Riverside. Fruit production and evaluation began in 2001. One selection from this irradiated population (propagated on Carrizo citrange rootstock) distinguished itself from the others in having very low seed counts in comparison to the original ‘Daisy’ cultivar, and with the excellent fruit quality and normal fruit production characteristics of the ‘Daisy’ parent. After two seasons of fruiting this selection, designated as ‘Daisy IR 1’, was selected for further trials and in January 2003 buds were taken and propagated onto Carrizo and C35 citrange rootstock. Budwood was also sent in April 2003 for evaluation of disease status and elimination of viruses and other pathogens as needed to establish trial plantings. ‘DaisySL’ was known throughout experimental evaluation as Daisy IR1-(for DAISY IRradiated selection #1). Twenty trees were planted at Riverside in June 2003. Fruit production on these 20 trees commenced in 2006. In June 2004 two trees of ‘DaisySL’, which had been produced from budwood that had tested and certified as tristeza-free, were sent Lindcove, Calif. where they were planted in the citrus breeding block. In June 2004 seventy-two trees, produced in Lindcove, Calif. were planted (twelve trees each) at six sites, Arvin, Irvine, Lindcove, Oasis, Santa Paula and Woodlake, Calif. All trials were propagated equally on Carrizo and C35 citrange rootstocks. Fruit production of these propagated trees commenced in 2006 (a few trees at each site) and 2007 (all trees at all sites). The properties of ‘DaisySL’ were found to be true to type and transmissible by asexual reproduction in comparing these plantings with the original ‘DaisySL’ selection.
BRIEF SUMMARY OF THE INVENTION
[0005] ‘DaisySL’ is a mid-season maturing diploid mandarin that combines medium-large sized fruit of excellent quality and production with very low seed content even in mixed plantings. It would likely be successful in the mid-season marketing window that currently has very few low-seeded, high quality cultivars.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The Figures depict various characteristics of ‘DaisySL’.
[0007] FIG. 1 shows an eight-year-old ‘mother’ tree of ‘DaisySL’ on Carrizo citrange rootstock.
[0008] FIG. 2 shows a three-year-old ‘DaisySL’ tree on Carrizo citrange rootstock at Santa Paula, Calif. (first crop).
[0009] FIG. 3 shows a bud-union of nine-year-old ‘DaisySL’ on Carrizo citrange rootstock.
[0010] FIG. 4 shows the fruit of ‘DaisySL’ taken at Riverside in February.
[0011] FIG. 5 shows fruit clusters of ‘DaisySL’ taken at Santa Paula in February.
[0012] FIG. 6 shows leaves of ‘DaisySL’
[0013] FIG. 7 shows open and closed flowers of ‘DaisySL’ mandarin
DETAILED DESCRIPTION OF THE INVENTION
[0014] ‘DaisySL’ is a mandarin selection developed at the University of California Riverside from an irradiated bud of the diploid mandarin cultivar ‘Daisy’, a mid-season maturing variety. ‘DaisySL’ distinguishes itself by being very low seeded (2.2 seeds/fruit) in all situations of cross-pollination, differing from ‘Daisy’ which will set from 16-25 seeds/fruit in cross-pollinated situations. Evaluation of ‘DaisySL’ mandarin began on the original tree at Riverside in 2001 and has continued annually until the present. In Riverside, Calif. ‘DaisySL’ fruit matures in winter (early-December). ‘DaisySL’ holds its fruit quality characteristics through February. Fruit size is moderately large (68 mm) averaging 135 grams per fruit. Fruit are slightly obconate in shape with a very deep orange rind color and an extremely smooth rind texture. Flesh color is very deep orange and finely-textured, fruit are juicy, with a rich, sweet and very distinctive flavor when mature. Fruit are only moderately easy to peel. Tree growth habit is spreading with excellent production commencing in the third year after planting. Alternate bearing can be a problem in trees that are not culturally managed to reduce this tendency.
[0015] Cultural practices ‘DaisySL’ mandarin can be grown according to accepted cultural practices for most mandarin varieties including planting densities of 150-250 trees per acre (375-625 trees/ha), normal fertilization and pest control practices, and the use of standard rootstocks for mandarins. Pruning may enhance production and health of the tree if applied after the second year of full fruit production. Other rootstocks adapted to more marginal growing conditions of salinity, high pH or very heavy soils may be useful in those conditions.
Comparison with existing mandarins:
[0017] Mid to late season maturing mandarin cultivars in production include ‘Daisy’ mandarin (the original cultivar from which ‘DaisySL’ was derived), ‘W. Murcott’ (Afourer), ‘Fortune’ mandarin, Ortanique mandarin, ‘Temple’ tangor, ‘Dancy’ mandarin ‘Minneola’ tangelo, and the mid-season Clementina selections ‘Hernandina’ and ‘Nour’. All of these cultivars will be seedy if grown in the presence of a pollenizer. Some, including the Clementina selections, ‘Fortune’, ‘Ortanique’ and ‘Page’ mandarins will have few seeds if no pollenizer is present. Recently released mid to late season cultivars that are very low-seeded include ‘Tango’ mandarin, ‘Gold Nugget’ mandarin, ‘TDE2’ mandarin hybrid (Shasta Gold®) ‘TDE3’ mandarin hybrid (Tahoe Gold®), and ‘TDE4’ mandarin hybrid (Yosemite Gold®). ‘DaisySL’ differs from these cultivars in being earlier maturing, having fruit with a smoother rind texture, and a lesser ability to maintain fruit on the tree or in storage for an extended period. Trees of ‘DaisySL’ show similar alternate bearing characteristics to these cultivars. Additional differences (summarized in Table 6) distinguish it from each of these cultivars.
[0018] ‘DaisySL’ mandarin exhibits low seed numbers (<2.5 seeds per fruit) under all conditions of cross-pollination. Additionally, preliminary evaluations indicate that pollen from ‘DaisySL’ has low germination rates in culture (˜10-20%) and appears not likely to cause high seed numbers in other mandarins, specifically ‘Tango’, ‘W. Murcott’ and Clementines. A comparison of ‘DaisySL’ with other low-seeded mid and late-season mandarins is provided in Table 6 below. ‘DaisySL’ is distinctive and superior in having outstanding flavor, an exceptionally smooth rind, reduced alternate bearing, and larger fruit size preferred in some markets, although it retains the tendency of its parent ‘Daisy’ for fruit to split at levels approaching 20% in bad years.
Trees, foliage, and flowers:
[0020] Tree size, growth and fruit production characteristics and fruit quality characteristics have been compared in these evaluations to ‘Daisy’ mandarin from the same field block. Six-year-old ‘DaisySL’ trees in trials at Riverside, and four-year-old trees at the other six sites have been evaluated for from two to four years of fruiting (see Tables 1 and 2). Tree size and growth characteristics of ‘DaisySL’ have been consistent with ‘Daisy’ throughout the evaluations. Growth of both the ‘Daisy’ and the ‘DaisySL’ selection has been quite spreading (characterized as ‘leggy’) in the first several years of growth followed by a tendency to grow into a more spherical, slightly drooping shape in ensuing years. The nine-year-old ‘DaisySL’ tree at Riverside on Carrizo citrange rootstock is 3.3 m high and 3.7 m wide with a normal upright growth habit yielding a canopy volume of 23.65 m 3 . In comparison nine-year-old ‘Daisy’ control trees have averaged 3.2 m tall and 3.6 m wide yielding a canopy volume of 21.7 m 3 on Carrizo citrange rootstock. Scion circumference for ‘DaisySL’ on Carrizo rootstock was 38.5 cm with the rootstock circumference 54.7 cm. Scion circumference for the nine-year old ‘Daisy’ trees averaged 36.9 cm on Carrizo rootstock and 38.2 cm on C35 rootstock. In the younger multi-location trials five-year-old ‘DaisySL’ trees on Carrizo rootstock have averaged 2.8 m in height and 3.0 m in diameter with canopy volumes of 8.48 m 3 and trees on C35 rootstock averaged 2.9 m in height and 2.7 m in diameter with canopy volumes of 7.48 m 3 . Leaves of ‘DaisySL’ are moderately large for a mandarin (86.1 mm in length×47.9 mm in width), ovate in shape and concave in cross-section, with an acute apex with weak emargination and a convex base and are dark-green in color (adaxial—RHS Green 139A, abaxial—RHS Green 137C). Petioles are medium in length (9.5 mm) and normally lack wings. The selection lacks thorns. Flowers of ‘DaisySL’ are hermaphroditic with greenish-white petals and yellowish anthers and are borne in clusters. Pollen viability for ‘DaisySL’ is moderately low (10-20% germination vs. ˜75% germination for ‘Daisy’), and pollen production is reduced (30-40% that of ‘Daisy’) in comparison to ‘Daisy’.
[0000]
TABLE 1
Tree, leaf, flower and seed characteristics (for nine-year-old tree) of
‘DaisySL’ mandarin
1.
Tree height
3.7 m
2.
Crown diameter
3.8 m
3.
Crown shape
Spreading, open
4.
Trunk circumference
38.5 cm
(on Carrizo rootstock)
5.
Bud-union characteristics
Slightly benched
(citranges)
6.
Rootstock-scion compatibility
Excellent (with citranges)
7.
Tree vigor
Moderately vigorous
8.
Bark color
RHS Grey-Brown 199B
9.
Leaf shape
Ovate
10.
Leaf cross-section
Concave
11.
Leaf blade length
86.1 mm
12.
Leaf blade width
47.9 mm
13.
Leaf apex
Acute with weak emargination
14.
Leaf base
Convex
15.
Leaf margins
Slightly crenate
16.
Leaf abaxial color
RHS Green 137C
17.
Leaf adaxial color
RHS Green 139A
18.
Petiole length
9.5 mm ± 1.1
19.
Petiole width
1.5 mm
20.
Petiole wings
Absent
21.
Petiole color
RHS Green 137C
22.
Thorniness
Not present
23.
Inflorescence type
Clustered
24.
Flowering habit
Flowers once per year
25.
Flower size
13.0 mm (medium)
26.
Flower structure
Complete
27.
Petal color
RHS White 155C
28.
Anther color
RHS Yellow 13B
29.
Pollen viability*
Low (10-20%)
(*measured as in-vitro germination)
Fruiting, fruit and production characteristics:
[0022] Fruit of ‘DaisySL’ are slightly obconate in shape with no neck. The fruit has a slightly convex basal end (moderately depressed) with a truncate (slightly depressed) distal end, and a distinctive areola and non-persistent style. The fruit is large-sized for a mandarin (classed as Jumbo by State of California standards and size 21 for industry packing standards) averaging 68.0 mm in diameter and 60.1 mm in height with a very smooth, deep orange rind color (RHS Red-Orange N30C) and slightly conspicuous, slightly raised oil glands. The rind is moderately adherent at maturity and relatively thin averaging 3.0 mm in thickness. This rind thinness is implicated in the tendency of ‘DaisySL’ and its parent ‘Daisy’ to experience a moderately high level of splitting of fruit, sometimes as high as 20% of the total crop. The fruit interior has a fine flesh texture with 10-11 segments and a semi-solid axis of medium size at maturity. The fruit are juicy, averaging approximately 47% juice and 135 g in weight. Fruit from trees on Carrizo and C35 citrange rootstocks average 11.9-12.8% soluble solids and 1.03-1.28% acid in early December at six trial locations in California increasing to 14.2-15.8% soluble solids and 0.78-0.92% acid in early February. The fruit average 2.2 seeds per fruit in the presence of cross-pollination at all locations. Seeds, when present, are polyembryonic, yellow-white in color (Yellow-White 158B) with greyed-yellow (Greyed-Yellow 160C) colyledons and a greyed-yellow (Greyed-Yellow 163B) inner seed coat.
[0023] Full fruit production of ‘DaisySL’ begins in the third year after planting similar to ‘Daisy’. A few fruit will set in the second year after planting but not at commercially acceptable levels. Fruit production on four-year-old trees averaged 27-48 kg at four fruiting trial sites. The original tree at Riverside was similar in fruit production in the fourth year and in years 7, 8 and 9 yielded 77, 32 and 72 kg of fruit respectively indicating that in the earlier years of production the variety has somewhat of a tendency to alternate bear, similar to ‘Daisy’.
[0000]
TABLE 2
Fruit characteristics of ‘DaisySL’ mandarin at maturity
1.
Fruit shape
Slightly obconate
2.
Fruit diameter
68.0 mm ± 4.2
3.
Fruit height
60.1 mm ± 2.9
4.
Fruit: shape of basal end
Slightly convex
5.
Fruit: shape of distal end
Truncate (slightly depressed)
6.
Fruit: distal end areola
Present (18 mm ± 1.2 mm in diameter)
7.
Fruit neck
Not present
8.
Style
Not persistent
9.
Rind texture
Smooth
10.
Oil glands
Slightly conspicuous, slightly raised
11.
Rind Color
RHS Orange-Red N30C
12.
Rind thickness
3.0 mm
13.
Albedo thickness
1.5 mm
14.
Albedo color
RHS Yellow Orange 23C
15.
Rind adherence
Moderately strong
16.
Rind separation
Very slight
17.
Flesh (pulp) color
RHS Orange-Red N30D
18.
Flesh (pulp) texture
Moderately fine
19.
Number of segments
10-11
20.
Axis: structure
Semi-solid
21.
Axis: size
Medium
22.
Navel presence
Not present
23.
# Seeds/fruit (mean)
2.2 (cross-pollinated conditions)
24.
Seed embryony
Polyembryonic
25.
Seed coat color
RHS Yellow-White 158B
26.
Seed cotyledon color
RHS Greyed-Yellow 160C
27.
Seed inner coat color
RHS Greyed-Yellow 163B
28.
Fruit weight
135.4 g
29.
% Juice a
46.8%
30.
% Soluble solids (at maturity)
14.6%
31.
% Acid (at maturity)
0.98%
32.
Season of maturity
Mid-season (early Dec.-January)
33.
Fruit holding ability
1-2 months
on tree past maturity
34.
Fruit quality after storage
Good
(5.6° C., 30 days)
a weight of juice extracted with a reamer as a percentage of fruit weight
[0000]
TABLE 3
Crop yields for ‘DaisySL’ and ‘Daisy’
(control trees) at three trial sites over
two years, 2006/2007 and 2007/2008.
2006/
2006/
2007/
2007/
7
7
8
8
Tree
Mean
Yield
Mean
Yield
Age
Yield
Range
Yield
Range
#
2008
Root-
(kg/
(kg/
(kg/
(kg/
Site
Selection
Trees
(yrs)
stock
tree)
tree)
tree)
tree)
River-
‘DaisySL’
10
6.0
Car-
32.8
24.3-
53.8
43.3-
side
rizo
44.9
65.4
River-
‘DaisySL’
10
6.0
C35
37.6
27.8-
54.9
47.0-
side
48.9
61.4
River-
‘DaisySL’
1
9.0
Car-
77.1
77.1
32.1
32.1
side
(mother)
rizo
River-
‘Daisy’
2
9.0
Car-
70.6
67.5-
39.4
35.2-
side
control
rizo
73.6
43.6
Santa
‘DaisySL’
5
4.0
Car-
26.4
19.8-
42.6
34.6-
Paula
rizo
38.4
55.7
Santa
‘DaisySL’
5
4.0
C35
28.9
22.6-
44.0
37.1-
Paula
34.9
56.4
Santa
‘Daisy’
2
4.0
Car-
26.4
24.9-
47.9
45.1-
Paula
control
rizo
27.9
50.7
Irvine
‘DaisySL’
9
4.0
Car-
31.4
24.5-
45.9
38.9-
rizo
39.7
54.8
Irvine
‘DaisySL’
10
4.0
C35
33.6
27.4-
47.6
33.1-
40.0
57.6
Irvine
‘Daisy’
2
4.0
Car-
28.9
27.0-
50.1
44.0-
control
rizo
30.8
56.2
[0000]
TABLE 4
Seed counts (average number of seeds per fruit) for
‘DaisySL’ and ‘Daisy’ (control trees) at four trial
sites over two years, 2006/2007 and 2007/2008.
2006/7
2007/8
%
Tree
Mean
Mean
Fruit
Age
Seeds/
Seeds/
with
(yrs)
Root-
Fruit
Fruit
0-2
Site
Selection
2008
stock
(range)
(range)
seeds
Riverside
‘DaisySL’
6.0
Carrizo
2.41
1.41
81.3
(1.88-3.30)
(0.88-2.30)
Riverside
‘DaisySL’
6.0
C35
2.19
1.39
83.8
(1.50-2.88)
(1.02-2.09)
Riverside
‘DaisySL’
9.0
Carrizo
2.26
1.86
78.9
(mother)
Riverside
‘Daisy’
9.0
Carrizo
18.9
17.2
3.2
control
Santa Paula
‘DaisySL’
4.0
Carrizo
1.21
1.09
89.7
(0.78-2.31)
(0.69-1.97)
Santa Paula
‘DaisySL’
4.0
C35
1.49
1.26
86.5
(1.06-2.72)
(0.90-2.22)
Santa Paula
‘Daisy’
4.0
Carrizo
15.3
14.8
5.1
control
Irvine
‘DaisySL’
4.0
Carrizo
2.16
1.61
79.9
(1.88-2.76)
(1.15-2.32)
Irvine
‘DaisySL’
4.0
C35
2.13
1.43
81.4
(1.51-2.87)
(0.96-2.19)
Irvine
‘Daisy’
4.0
Carrizo
17.4
14.9
6.1
control
Lindcove
‘DaisySL’
4.0
Carrizo
2.22
1.44
86.5
(1.35-3.02)
(0.77-2.11)
Lindcove
‘DaisySL’
4.0
C35
2.33
1.36
88.4
(1.45-2.95)
(0.88-1.97)
Lindcove
‘Daisy’
15
Carrizo
17.1
16.3
3.1
control
[0000]
TABLE 5
Mean and standard deviation (S.D.) of
soluble solids, acid and solids/acid ratio for
DaisySL at four trial sites, 2007/8 crop year.
Soluble
Soluble
Solids
Solids
%
%
%
Acid
Site
Date
Carrizo
S.D.
C35
S.D.
Carrizo
S.D.
River-
Dec. 6,
12.8
0.29
12.6
0.48
1.28
0.18
side
2007
River-
Jan. 9,
14.2
0.38
14.0
0.39
1.00
0.12
side
2008
River-
Feb. 6,
15.8
0.43
15.6
0.34
0.88
0.10
side
2005
Santa
Dec. 5,
11.9
0.39
12.0
0.26
0.97
0.19
Paula
2007
Santa
Jan. 11,
13.1
0.19
13.7
0.39
0.90
0.09
Paula
2008
Santa
Feb. 8,
14.7
0.33
14.2
0.44
0.80
0.16
Paula
2008
Irvine
Dec. 7,
12.1
0.66
11.9
0.49
1.03
0.14
2007
Irvine
Jan. 7,
13.9
0.38
12.8
0.55
0.89
0.13
2008
Irvine
Feb. 6,
15.3
0.44
13.5
0.26
0.78
0.08
2008
Lind-
Dec. 12,
12.1
0.22
12.0
NA
1.33
0.24
cove
2007
Lind-
Jan. 15,
13.0
0.26
13.3
0.52
1.00
0.11
cove
2008
Lind-
Feb. 12,
15.8
0.33
15.5
0.41
0.90
0.07
cove
2008
%
S/A
S/A
Acid
Ratio
Ratio
Site
Date
C35
S.D.
Carrizo
C35
River-
Dec. 6,
1.22
0.11
10.0
9.8
side
2007
River-
Jan. 9,
0.95
0.10
14.2
14.7
side
2008
River-
Feb. 6,
0.92
0.06
17.9
17.0
side
2005
Santa
Dec. 5,
0.89
0.07
13.5
14.9
Paula
2007
Santa
Jan. 11,
0.84
0.07
14.7
16.3
Paula
2008
Santa
Feb. 8,
0.81
0.06
17.3
17.5
Paula
2008
Irvine
Dec. 7,
1.10
0.12
11.7
10.8
2007
Irvine
Jan. 7,
0.90
0.14
14.5
14.2
2008
Irvine
Feb. 6,
0.77
0.11
17.8
17.5
2008
Lind-
Dec. 12,
1.28
0.19
9.1
9.4
cove
2007
Lind-
Jan. 15,
1.02
0.06
13.0
13.0
cove
2008
Lind-
Feb. 12,
0.88
0.08
17.6
17.6
cove
2008
[0000]
TABLE 6
Comparison of ‘DaisySL’ with other
late season, low-seeded mandarins.
Data for Riverside, California.
Gold
Trait
‘DaisySL’
TDE2
TDE3
TDE4
Nugget
Tango
Matu-
Early
Febru-
January-
Febru-
Febru-
Febru-
rity
Decem-
ary
February
ary
ary-
ary-
ber-
March
March
early
January
Seeds
2.2
0.02
0.29
0.32
<0.1
0.22
per
fruit
RHS
Orange-
Orange-
Orange-
Orange-
Orange
Orange
rind
Red
Red
Red
Red
25A
N25A
color
N30C
N3OD
N30C
N30C
Rind
very
slightly
papillate
smooth
bumpy
smooth
texture
smooth
pitted
Fruit
135
185
134
175
108
90
weight
(g)
Fruit
0.88
0.78
0.85
0.78
0.88
0.81
height/
width
Alter-
medium
medium
medium-
medium-
high
medium
nate
high
high
bear-
ing
[0024] Fruit storage trials included storage of washed but not waxed fruit at 5.6° C. for up to 60 days with fruit samples taken every 14 days for analysis. Data indicate that the storage characteristics of ‘DaisySL’ are fair with some rind deterioration (rind drying) and some significant indication of fungal disease problems in 23% of the fruit. There was no significant deterioration in juice quality or taste over a 30 day storage period in those fruit without fungal pathogens, but with more significant rind deterioration if kept to 60 days. Overall Daisy can only be considered to be fair in storage ability due primarily to the somewhat susceptible nature of the rind to pathogen organisms. Fungicide treatment and waxing might decrease decay and rind deterioration during storage.
[0025] No susceptibilities to plant or fruit diseases or to pests beyond those normally associated with citrus species have been observed.
|
‘DaisySL’ is a mid-season maturing diploid mandarin that combines medium-large sized fruit of excellent quality and production with very low seed content even in mixed plantings. It would likely be successful in the mid-season marketing window that currently has very few low-seeded, high quality cultivars.
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|
CROSS REFERENCE OF RELATED APPLICATION
This is a Continuation application that claims the benefit of priority under 35 U.S.C. §119 to a non-provisional application, application Ser. No. 11/645,547, filed Dec. 27, 2006 now U.S. Pat. No. 8,154,586.
FIELD OF THE INVENTION
The invention involves digital film technique, to be specific, a sort of optics technique together with computer graph technique, recorded in digital or some other regular ways, so as to generate a device system that can really restore 3D effects by projecting image on curved screen.
BACKGROUND OF THE INVENTION
3D movie brings forward a lifelike experience. As stated by the pioneering 3D movies principle, when people watch with eyes, distance and 3D effect are engendered by eye angel, thus when two eyes aim at same object, the visual angle is different. The closer the object, the more different the view filed of two eyes, vice versa, the less; and it is almost paralleled looking into far distance. 3D movie principle namely two cameras shoot at the same time simulating human eyes, projecting to the same screen in synchronization, therefore 3d effect is produced with different views of the two eyes separated by polarized glasses.
The principle to make 3d movie by adopting curved screen: a few parameters need to be explained concerning optical characters of human eyes: horizontal coverage of human eye is around 150°, vertical coverage is around 55°. The best viewing angle is: around 10° up and down the viewing field, 10° for horizontal direction. The distance of the two pupils is 55-74 mm. Viewing angle around 55° is similar with human eyes. Perspective effect of projected image at this angle conforms with that of human eyes, real and natural. FIGS. 1 & 2 are viewing field and viewing angle diagram of human eyes. Eyes will move around with head when looking around, as shown on FIGS. 3 & 4 . The existing 3D movie production technique normally simulates spherical or curved surface with multiple planes, wherein the produced image is not seamless, smooth or continuous and can only be applicable to such simple geometrical models as sphere and conicoid. If applicable to 3d model, the parallax can not turn to be smooth and continuous. The curved surface can also be simulated with the optical ray tracing method under present technique. But the rendering cost is very high.
SUMMARY OF THE INVENTION
The purpose of the invention is to put forward a kind of curved film projection system to improve the existing technique.
Technical solution the invention adopts aims to create a sort of curved film projection system, comprising
a rendering surface,
a projection screen,
a real scene rendering model of image system,
a rendering model of projection system that renders the projection the image rendered by the rendering model of image system on the rendering surface, and
a projecting device that projects the image finally rendered by the rendering model of projection system onto the projection screen through optical lens.
The said projection screen is regarded as the first surface or part of the first surface. The said rendering surface is regarded as the second surface or part of the second surface. The first surface is behind the said second surface, watching from observer's eyes to projection screen. The viewing direction and angle from observer's eyes to the rendering surface is consistent with that to the projection screen. The viewing direction and angle from observer's eyes to the rendering surface is consistent with that to the screen; the said image system rendering model can be reversible with the said projection system model. The said rendered real scene by projection system rendering model, projected to the second surface and then to the projection screen through projecting device, exactly restore the distorted image produced by the image system rendering model.
The rendering models of both image system and projection system respectively comprise cameras and projectors, the view directions of which are consistent, two centers coincide, but the optical paths are reversible.
The curved film projection system is characterized that the image system rendering model comprises up-and-down M-layer digital cameras and each layer contains N cameras.
In the preferred embodiment, the said M is 3, the said N is 7, the said image system rendering model contains 21 single digital cameras. The angle of the horizontal view field of each digital camera is 25.7142857°, and the angle of vertical view field is 60°. The viewing direction of all digital cameras follow the same direction as that of the divided viewing field. Horizontal viewing direction of each camera is 12.85710, 38.5714°, 64.2857° 90°, 115.7143°, 141.4286° and 167.1429° respectively.
In another alternate embodiment, the said M is 3, the said N is 3, the said image system rendering model contains 9 single digital cameras. The angle of horizontal view field of each camera is 60°. The angle of vertical view field is 60°. Viewing direction of all digital cameras follow the direction of divided viewing field. The horizontal viewing direction of each single digital camera in each layer is 30°, 90° and 150° respectively.
The projection system rendering model comprises upper and lower M-layer digital cameras, each layer of which contains N single digital projectors.
In a preferred embodiment, the said M is 3, the said N is 7, the said projection system rendering model contains 21 single digital cameras. The angle of horizontal view field of each projection system rendering model is 25.7142857°, and the angle of vertical view field is 60°. The viewing directions of all digital projectors are the same as divided viewing field. Horizontal viewing direction of each projector in each layer is 12.8571°, 38.5714°, 64.2857°, 90°, 115.7143°, 141.4286° and 167.1429° respectively.
In another alternate embodiment, the said M is 3, the said N is 3, and the said projection system rendering model contains 9 cameras. The angle of horizontal view field of each projector is 60°. The angle of vertical view filed is also 60°. Viewing direction of all digital projectors are the same as that of divided viewing field. The horizontal viewing direction of each digital projector in each layer is 30°, 90° and 150° respectively.
The said first surface of the curved film projection system is a curved surface, a plane surface, or a combination of plane and curved surface. The said second surface is sphere or conicoid.
Set a spherical surface, take the vertical section of the sphere, which is round in shape, the said vertical axis of the section is OZ, divide horizontal viewing field 0-180° of the section into n parts, indicate the n viewing directions with radial ° A 1 - 0 An, divide the said semicircle diameter evenly into n parts with section points as PO, P 1 , P 2 . . . Pn−1 and Pn, draw n lines as L 1 , L 2 , L 3 . . . Ln−1 and Ln paralleled to OZ axis cross the said n section points, then followed with in turn M 1 , intersection point of ° A 1 and L 1 , M 2 , intersection point of 0 A 2 and L 2 , M 3 , intersection point of 0 A 3 and L 3 . . . Mn−1, intersection point of 0 An−1 and Ln−1,
Mn, intersection point of 0 An and Ln, connect MO, Mi, M 2 . . . Mn−1 and Mn to get a curve K, rotate curve K 360° around OZ axis to get curved surface B, the said second surface is curved surface B.
The invention adopts a technical solution of curved film projection method which is characterized in following steps:
A1) the rendering model of image system rendering the real scene. A2) the rendering model of projection system rendering the projection of image rendered by the image system rendering model on the rendering surface. A3) the projecting device projecting the finally rendered image of the rendering model of projection system onto the projection screen via the optical lens.
The rendering as mentioned in above A2) adopts orthogonal rendering.
The application of curved film projection system avails as follows: the adoption of spherical rendering model based on optical path reversibility principle vividly restores ubiety of space project; the image turns to be totally seamless, smooth and continuous that can exactly restore spherical surface and conicoid; the parallax could be made smooth and continuous under 3D mode by application of curved surface that either can be or not be described in mathematic model, which bring the audience a lifelike experience. The rendering cost could be decreased considerably accordingly by introducing a simplified digital optical lens model into this curved film projection system.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will become apparent form the following detailed description of the invention when read with the accompanying drawings in which:
FIG. 1 is a side view of viewing field and visual angle of human eyes;
FIG. 2 is a plane view of viewing filed and visual angel of human eyes;
FIG. 3 is a schematic diagram of the scene viewed when human eyes look up and down;
FIG. 4 is a schematic diagram of the scene viewed when human eyes look left and right;
FIG. 5 is a schematic diagram of 0-180° continuous integral of viewing field 0-180°
FIG. 6 is a diorama mapped plane on spherical surface from ahead
FIG. 7 is a diorama mapped side elevation on spherical surface from ahead
FIG. 8 is a mapped perspective on spherical surface from ahead
FIG. 9 is a side elevation of simplified digital model for spherical screen calculation;
FIG. 10 is a plane view of simplified digital model for spherical screen calculation;
FIG. 11 is a perspective of simplified digital model for spherical screen calculation;
FIG. 12 is a side elevation of optical path of spherical screen;
FIG. 13 is a plane view of optical path of spherical screen;
FIG. 14 is a schematic diagram of optical lens model used for spherical screen system;
FIG. 15 is a schematic diagram of spherical screen, optical lens and image system;
FIG. 16 is a schematic diagram of anchor point of spherical surface;
FIG. 17 is a schematic diagram of spherical surface imaging through optical lens;
FIG. 18 is a schematic diagram of spherical surface imaging through common digital lens;
FIG. 19 is an imaging comparison diagram of through optical lens and common digital lens;
FIG. 20 is a schematic diagram of reversibility principle of optical paths;
FIG. 21 is a plane view of computer rendering overall model
FIG. 22 is a side elevation of computer rendering overall model
FIG. 23 is a perspective of overall model rendering;
FIG. 24 is a systematic overview of computer rendering image system;
FIG. 25 is a schematic diagram of one of the 7 cells when spherical surface intersected along meridian
FIG. 26 is a schematic diagram of three cases when spherical surface intersected along meridian;
FIG. 27 is a schematic diagram of rendering image of spherical surface u unit in computer;
FIG. 28 is a schematic diagram of rendering image of spherical surface m unit in computer;
FIG. 29 is a schematic diagram of rendering image of spherical surface d unit in computer;
FIG. 30 is a systematic overview of computer rendering projection system;
FIG. 31 is a diagram of projected range onto spherical surface of u unit;
FIG. 32 is a diagram of projected range onto spherical surface of m unit;
FIG. 33 is a diagram of projected range onto spherical surface of d unit;
FIG. 34 is a schematic diagram of hemispherical orthogonal rendering;
FIG. 35 is the mathematical model of digital optical lens;
FIG. 36 is the rendering model of digital optical lens;
DETAILED DESCRIPTION OF THE INVENTION
By adopting optical paths reversibility, to realize restoration of space object ubiety through spherical rendering model, the produced image of the invention turns to be totally seamless, smooth and continuous, which is applicable to spherical surface, conicoid, or curved surface that can either be described or not in mathematic model. The parallax can be made smooth and continuous in 3D mode. Curved surface can also be simulated with calculation of optical ray tracing method, which is costly, comparatively simplified model is substantially savable.
Suppose human eyes at the same level, set a simple analogue as shown on FIG. 5 to simulate the view range when human eyes look around. As indicated, if C is supposed to be a source point, line out in some direction an infinitesimal solid angel dco, corresponding to ds, a section of the spherical surface, the spherical radius as r, then the following relation is brought up: dco=ds/r 2 , the solid of entire space co=4n sterad, is the continuous integral of human eye viewing field. In order to represent the real screen ahead of eyes, suppose all real objects has a projection on spherical surface with eyes as the center of the circle, when image recorded at eyes position, then projected to the same spherical surface, a real scene can be experienced when looking from the center of the sphere as shown on FIGS. 6 , 7 and 8 . As indicated on FIGS. 6 and 7 , if such space objects as offing, ship, plane and bridge have a projection on the spherical surface with eye as the center of the circle, a real scene can be felt at the correct location from the projection. The basic principle of the invention is to record the scene viewed from audience eyes location, view field and viewing angle, and then project to one section of spherical surface with eyes as center of the circle. Audience can feel the viewed scene restored when watching from effective position. The projected image may be actually shot, but the simulation limited by equipment conditions (such as hoist, bracket, gliding rail or any other walking equipments), what can be caught are only browed scenes or flying scenes; restricted with browse equipments or flight safety, many extreme shrilling pictures cannot be caught. So this is an option for low cost production.
Computerized production is also viable, whose carrier can be film, video tape, disk, hardware or other digital removable disk storage device. To ensure the image correctness projected onto the screen, the characteristic of projector optical lens should be got acquainted. It is extraordinarily costly to realize the rendering by setting up lens analogue and material character in computer as every extra wide angle lens has very complicated characteristics of analogue and material character. Otherwise the image is very limited if projection is done with actually shot image.
The preferred embodiment of the invention is to record the scene viewed from audience eyes' location, viewing field and viewing angle, and then project to one section of spherical surface with eyes as center of the circle. When watching from effective position, audience can feel the viewed scene restored. Optical paths of spherical screen model is as shown on FIGS. 12 & 13 , the indicated camera lens should be provided with extra wide angle ranging 0-160°, characterized with viewing field continuously and evenly distributed. The projector lens should be especially designed optical type, with extra wide angle lens made by any manufacturer in the world, similar with the model as indicated on FIG. 14 , both are center system of spherical surfaces.
FIG. 15 gives the detailed description on relation of spherical screen, optical lens, imaging surface, definite object and object on imaging surface. It goes in two steps: firstly, without spherical screen, real image N′N is produced image of edifice M′M on imaging surface transiting optical lens; secondly, laying a spherical surface in front of optical lens, an image PT will be produced when real image N′N is projected onto the spherical surface. When observer watches image PT in front of the lens, he could sense the true building M′M, this is because the height of viewing field direction, viewing angle and observing point are certified to be highly uniform, as well the perspective relation is certified to be correct. Some data can be obtained through analysis on the experimental shot real image, which are taken as design reference of digital optical lens.
Mark an anchor point on spherical surface as shown on FIG. 15 . Define the anchor point in this way: divide longitude and parallel into n parts, the intersection points of the divided parts as shown on FIG. 16 are the marked anchor points. Shoot the real image of the spherical surface formed on the imaging surface with the system shown on FIG. 15 . As shown on FIG. 17 , the one in use is extra wide angle optical lens 163° and 17 mm, many marked anchor points are clearly indicated. If the shot real image is projected back onto the screen, they will be correspondingly superposed with the marked anchor points one by one. Set common digital camera with same parameter as extra wide angle optical lens, namely 163°, set model in computer as shown on FIG. 15 , spherical surface production and marked anchor point as shown on FIG. 16 , when common digital camera takes place of optical lens and imaging surface as shown on FIG. 15 , the image produced hereby from the rendering as shown on FIG. 18 , is obviously different from that by optical lens. The imaging character of special optical lens as analyzed on FIG. 17 shows that it is impossible for any practically applied special extra wide angle lens to reach 180°, because 180° represent infinity viewpoint in horizontal or vertical direction and fails to be imageable on imaging surface. But X 1 , X 2 , MO, Y 1 and Y 2 on FIG. 17 can infinitely reach the infinity in horizontal, front and vertical direction, that is X 1 -M 0 -X 2 represent an infinite line along horizontal direction, Y 1 -M 0 -Y 2 is an infinite line along vertical direction.
As indicated on FIG. 17 , the rendered image on imaging surface of marked anchor point on spherical surface is evenly distributed on a circular surface, the center of the circle, the center of the sphere and the center of special optical lens are completed superposed, which predicates that the viewing field of front hemisphere, with center of lens as origin, is evenly divided, approaching schemed perfect image. If certain object located within the hemisphere in front of lens, and kept a certain distance from lens center line, its image may obtain an image about its same size on imaging surface, free of picture distortion.
The imaging character of common digital extra wide angle lens as shown on FIG. 18 : the closer to the viewing field direction perpendicular to lens center line, the more distorted of the image. Its deficiency is that the object has a smaller effective imaging area near lens center line. As the important viewing area, the small area fails to support sufficient image resolution.
FIG. 19 is the imaging contrast by adopting optical lens and common digital lens. Image produced through common lens will lead to picture distortion. One purpose of this invention is to create a simplified digital lens model provided with the same optical character as special optical lens, therefore calculated amount is accordingly reduced, rendering cost is lowered down as well. The detailed solution will be mentioned in the following introduction.
As indicated on FIG. 9 , as human eyes are at the same level, camera with field angle 60° can realize true reflection of human eye perspective. Thus view field ranging 0-180° up and down is divided into 3 parts, each of which is 60°. The effect when human eyes look around the scene can be simply simulated with 3 cameras with field angle 60. Due to pupillary distance 55 mm-74 mm, when looking around scene ranging 0-180°, continuous parallax variation will be engendered, that is, the viewing scene is slightly different from each eye. Jump of viewed image through human eyes projected by camera is uncomfortable. Therefore in consideration of the best viewing field, taking larger value at 20° position, the horizontal continuous viewing field ranging 0-180° is simulated in 7 viewing directions, the minimum quantity of view field continuity as shown on FIG. 10 . The consecutive viewing direction in front of audience ranging 0-180° is simulated in 7 horizontal and 3 vertical viewing directions, totally 3×7=21 directions, so that image jump cannot be felt, in the mean time viewing field integral model is greatly simplified, as shown on FIG. 11 .
The said digital lens model of invention is not common type, but an algorithm model composition of many computer graphs, which is more like a rendering image algorithm. The final imaging effect is almost the same with imaging effect of the specified extra wide angle optical lens mentioned in the invention. The said digital lens model in the graphics software can be represented as two rendering model. The first model is to simulate image of hemispherical scene ranging 0-180° in front of human eye; the second model is to correspondingly project images series shot by the first one to a special calculated curved surface. The imaged obtained when the curved surface is perpendicularly rendered is almost similar to that projected by special optical lens.
The following is emphasized on elaboration of digital lens model of the invention: first goes with reversibility of optical paths. As shown on FIG. 20 , either three centers and center lines of human eyes, camera and projector are superposed. When two radials sent by object M′M in front of human eyes are shot and then projected by projector with same angle, putting a screen on optical paths at this time, an image m′m cast onto the screen by projector, which superposes with M′M observed from human eyes. If it is plane image, human eyes will verdict the object distance through perspective. When it comes to 3d image, human eyes will position the object precisely, which is so called reversibility of optical paths.
The most important part of the invention is two rendering models described above. As indicated on FIGS. 21 , 22 and 23 , the systematic general diagram includes two rendering models, image system rendering model and projection system rendering model. Either image system or projection system, each includes three layers cameras or projectors, each layer has 7 cameras or projectors, that is to say, the whole rendering model comprises 21 cameras and 21 projectors, each of which is identical in viewing field direction and every center of which superposes at center of hemispherical surface. Camera unit and projector unit can be taken as two units same in parameter, but completely reversible in beam radiation. Camera and projector together complete light energy transfer in reciprocal way by receiving and projecting radial. Their parameters are as follows: horizontal view field angle: 180°-=−7=25.7142857°; vertical view field angle: 60°; the three layers is indicated with u, m, d; horizontal 7 directions are indicated with 01 , 02 , 03 , 04 , 05 , 06 and 07 , camera is C, projector is P, they relates as follows:
Upper
Camera
CuO1
Cu02
Cu03
Cu04
Cu05
Cu06
Cu07
layer
No.
Projector
Pu01
Pu02
Pu03
Pu04
Pu05
Pu06
Pu07
No.
Middle
Camera
Cm01
Cm02
Cm03.
Cm04
Cm05
Cm06
Cm07
layer
No.
Projector
Pm01
Pm02
Pm03
Pm04
Pm05
Pm06
Pm07
No.
Lower
Camera
Cd01
Cd02
Cd03
Cd04
Cd05
Cd06
Cd07
layer
No.
Projector
Pd01
Pd02
Pd03
Pd04
Pd05
Pd06
Pd07
No.
Projector with 01 postfix in the three layers is defined as Group 01 , those with 02 is defined as Group 02 . . . 7 groups altogether from 01 - 07 . Vertical view field of layer u, m and d is as shown on FIG. 22 : u is +60, m is 0°, d is −60°. Horizontal viewing field direction of group 01 - 07 are as shown on FIG. 21 :
Group
01
02
03
04
05
06
07
Horizontal
12.8571°
38.5714°
64.2857°
90°
115.7143°
141.4286°
167.1429°
viewing
field
direction
FIG. 23 is general perspective drawing of computer rendering model. The image system rendering model and projection system rendering model will be expounded separately. What image system rendering model do is to simulate hemispherical area scene when human eyes look around in the front ranging 0-180°, rendering the viewed image in 21 viewing field directions, continuity simulating of viewing field variation. FIG. 24 indicates general diagram of computer rendering image system.
FIG. 25 indicates one of the 7 units intersected along longitude direction with center of the sphere as the center, mainly one unit of intersected view field in vertical direction, which is composed of 3 cameras. FIG. 26 indicates three types of intersection along parallel direction, vertical 180° area is divided into parts of u, m and d, vertical view field angle of each is 60°, 25.7142857° in horizontal.
FIGS. 27 , 28 and 29 indicates image of upper, middle and lower part of spherical surface rendered by digital camera, amongst of which the shadowed part is the effective rendered coverage, 0 point is viewing field center. As computer graphics software can only rendering plane image, only the mapping of the sphere onto the plane surface can be rendered. The rendered image is very similar with that viewed by human eyes. The vertical viewing field angle is 60°, 25.7142857° in horizontal. The proportion of image width and height:width:height=25.7142857:60=0.428571:1
Ratio of height and width in computer graphics software is indicated with resolution. So rendering image resolution of u, m and d should be 429×1000 or its multiple, for instance: n (429×1000), n as multiple coefficient. Computer rendering image system can produce as much as 21 images (7 images in each of upper, middle and lower layers) by simulating viewed effect of human eyes. The all produced image satisfying n 429×1000), one-to-one corresponding to projector.
What projection system rendering model to do is to project rendered images produced by image system onto spherical surface one-to-one correspondingly, and optical paths reversibility should be assured, that is, the image should be seamed in perfection by projection system onto spherical surface.
FIG. 30 is general diagram of projection system rendering model, as indicated projection unit are one-to-one corresponding to imaging units of image system. u, m and d image rendered by image system as shown on FIGS. 31 , 32 and 33 , are projected to the corresponding area on curved surface through projection system. To ensure the reversibility of optical paths, projection unit of projection system should be provided with following optical characters: vertical view field angle=60
horizontal view field angle=25.7142857°, only under this condition, can the projection units of projection system be regarded reversible with imaging unit of image system, and this reversibility is the key point of the invention. The cited optical character is just a preferred embodiment.
FIG. 34 indicated the orthogonal rendered image of a hemisphere in computer graphics software, which is a synthetic image rendered by 21 digital camera lenses. Obviously the picture is deformed, the middle stretched, two sides compressed, as shown on FIG. 17 , which is different from the symmetrical graphics obtained through optical lens. What the invention to solve is to restore image, which enable the image rendered through digital lens to be the same as that through optical lens. The invention fabricate a curved surface, on which image of spherical surface is perfectly projected, the obtained image in the curved surface being orthogonal rendered is the same as that through optical lens.
FIG. 35 indicates how to make the curved surface in computer graphics software. Divide viewing field horizontal range 0-180° into n parts, indicated with ° A 1 - 0 An, as shown on FIG. 35 . Divide spherical diameter evenly into n parts as PO, P 1 , P 2 . . . Pn−1, Pn, make n parallels paralleled to OZ axis as L 1 , L 2 , L 3 . . . Ln−1, Ln, which represent orthogonal view field distribution. Determine in turn intersection point M 1 between OA′ and L 1 , M 2 between 0 A 2 and L 2 , M 3 between 0 A 3 and L 3 . . . Mn−1 between 0 An−1 and Ln−1, Mn between 0 An and Ln, join M 0 , M 1 , M 2 . . . Mn−1 and Mn, to get a curved line, as shown on FIG. 35 , which is called curve K.
Curve K is not a focal conic due to without focus. Intersection point M 0 , M 1 , M 2 . . . Mn−1, Mn, made when curve K intersected by n radials namely OAO, 0 A 1 , 0 A 2 . . . 0 An−1, 0 An sent from 0 point, is actually projection of n radials by dividing 0-180° horizontal view field. When projection MO, M 1 , M 2 . . . Mn−1, Mn is orthogonally cast onto semicircle diameter, point mapping is acquired as P 0 , P 1 , P 2 . . . Pn−1, Pn, which divide the diameter into n parts. Therefore horizontal 0-180° viewing field can be divided onto a horizontal line. Rotate curve K around OZ axis as shown on FIG. 35 , a curved surface B, namely rendering surface will be engendered, as shown on FIG. 36 . The curved surface is characterized as follows: when projection system project radial onto the surface, if orthogonally rendered, an image will be obtained similar with the one when hemispherical surface is rendered through specified optical lens, that is to say, optical paths reciprocal conversion is completely realized.
FIG. 36 indicates the final rendering model through digital optical lens. Camera resolution is set to be 4096×3592 at orthogonal rendering. The calculation of which is relative to projecting equipment of 70 mm and 10 apertures, which is the preferred embodiment of the invention.
In consideration of further cost reduction, part numbers of horizontal viewing field can be small, to the minimum 3 parts, another optional embodiment of the invention: by adoption of 3 viewing field directions either in horizontal or vertical, that is 3×3=9 viewing field direction, to simulate continuous viewing field direction ranging 0-180° in front of audience. The image system rendering model corresponding of the embodiment includes three layers of cameras, each layer of which include 3 cameras. The projection system rendering model is one to one correspond with the image system rendering modem. The projection system rendering model also includes three layers of projectors, each layer of which include 3 projectors. The viewing direction of both projectors and cameras are consistent, centers completely superposed, optical paths reversible. Horizontal view field of 01 - 03 are as follows:
Group
01
02
03
Horizontal viewing field direction
30°
90°
150°
The simplified method above will produce some image jump, but which is acceptable basically and lower the rendering cost.
The inner side of spherical screen adopts special metal reflecting material, internal surface is evenly sprayed to ensure even reflection.
The technique and equipment concerning this invention can be widely applied to film industry, which can either be recorded in simulation mode or digital ways, as well, they are applicable to 3D production.
The invention involves many other embodiments, rendering surface as part of curved surface B, projection screen as part of spherical surface, view field angle of rendering surface and projection screen are consistent.
As for image system rendering model composed of common digital lens, the rendered image turn to be distorted, the engendered distortion is restored by keeping rendering surface unchanged (as curved surface B, or part of curved surface B), the projection screen is at the rear side of rendering surface viewing field direction, viewing field direction and angle of rendering surface is consistent with that of projection screen. Subjected to the above said conditions, the invention can be applied in some other ways, for example, projection screen can be hemispherical surface or part of it, rendering surface is part of curved surface B. Projection screen can be plane, combination of plane and curved surface, random curved surface or part of it; rendering surface can also be spherical surface, conicoid or part of it.
No matter it is image system or projection system, arrangement as follows are also available: up-down M layer cameras or projectors, each layer contains N cameras or projectors, that is to say, the whole rendering model may include M><N cameras and M×N projectors, M and N can be any positive integer.
|
The invention involves a sort of curved film projection system, including a rendering surface, a projection screen, a real scene rendering model of image system, a rendering model of projection system that renders the projection the image rendered by the rendering model of image system on the rendering surface, and projecting devices that projects the image finally rendered by the rendering model of projection system onto the projection screen through optical lens. The viewing direction and angle from observer's eyes to the rendering surface is consistent with that to the projection screen: The image system rendering model can be reversible on optical path with the projection system rendering model. The curved film projection system not only reduces the rendering cost, but also produces lifelike experience for audience.
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BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention relates to pressure control techniques which control the pressure in a low pressure processing chamber such as a plasma processing chamber and more particularly to a pressure control technique which enables high speed control regardless of plasma dissociation or change in the effective flow rate.
[0003] (2) Description of the Related Art
[0004] FIG. 2 illustrates a device which controls the pressure in a low pressure processing chamber. As shown in FIG. 2 , a throttle valve 3 is located between a low pressure processing chamber 1 and an exhaust device 2 . In this control device, the reading of a pressure gauge 4 connected with the low pressure processing chamber 1 through an arithmetic and control unit 13 is fed back and reflected in the opening degree of the throttle valve 3 so that the pressure in the low pressure processing chamber is automatically controlled (see Japanese Patent Application Laid-Open Publication No. H10-11152).
[0005] There are various known methods of feeding back the reading of a pressure gauge for the valve opening degree and the most commonly used method is PID control. Usually in a typical PID control method, valve opening operation amount ΔVV is calculated for each control cycle in accordance with a PID control calculation formula (Formula 1 below) to control the opening degree of the valve.
[Formula 1]
[0006] Δ VV 32 VV n+1 −VV=Gi ( P n −P 0 )+ G p ( P n −P n−1 )+ G d (P n −2 P n−1 +P n−2 ) (1)
Here,
[0000]
ΔVV: Valve opening operation amount (%)
VVn+1: Next valve opening operation degree (%)
VVn: Current valve opening degree (%)
Pn: Current pressure (Pa)
Pn−1: Previous pressure (Pa)
Pn−2: Pressure before previous pressure (Pa)
P 0 : Target pressure (Pa)
Gi: Integral gain (fixed)
Gp: Proportional gain (fixed)
Gd: Differential gain (fixed)
[0017] In the above PID control method in which the valve opening operation amount ΔVV is calculated for each control cycle to control the valve opening degree, control is stable under a condition that the gain values in the PID control calculation formula are optimal. However, it may take long time to reach a target pressure. In addition, it may take extremely long time to reach the target pressure if there is a large difference from the optimal condition in terms of gas type, gas flow rate, gas dissociation state or target pressure level.
[0018] In other words, the above control method takes long control time and requires gain optimization for each condition. Besides, hunting often occurs with a butterfly throttle valve which shows a very nonlinear relation between valve opening and exhaust speed.
SUMMARY OF THE INVENTION
[0019] The present invention has been made in view of the above problem and provides a control technique which quickly adjusts the low pressure processing chamber to a desired pressure regardless of gas type, gas flow rate or target pressure simply by optimizing constants.
[0020] In order to address the problem, the present invention provides a pressure control device for a low pressure processing chamber which has the following constitution.
[0021] The device includes: a low pressure processing chamber; gas supply means which supplies processing gas to the low pressure processing chamber; plasma generating means which supplies electromagnetic energy to the processing gas supplied to the low pressure processing chamber and generates plasma; exhaust means which exhausts gas in the low pressure processing chamber; gas pressure measuring means which measures gas pressure in the low pressure processing chamber; exhaust speed adjusting means which adjusts exhaust speed of gas to be exhausted by the exhaust means; and an arithmetic and control unit which makes control calculation to calculate an exhaust speed to make the gas pressure measured by the pressure measuring means equal to a target value, and controls the exhaust speed adjusting means according to the calculation result.
[0022] Therefore, according to the present invention, the low pressure processing chamber can be quickly adjusted to a desired pressure regardless of gas type, gas flow rate or target pressure simply by optimizing constants.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention will be more particularly described with reference to the accompanying drawings, in which:
[0024] FIG. 1 illustrates an example of a microwave plasma processing apparatus which adopts a pressure control method according to the present invention;
[0025] FIG. 2 illustrates a conventional device for controlling the pressure in a low pressure processing chamber;
[0026] FIG. 3 is a graph showing the relation between exhaust speed and valve opening;
[0027] FIG. 4 is a graph showing pressure response in the conventional control method;
[0028] FIG. 5 is a table of constants which are used in a first embodiment;
[0029] FIG. 6 is a graph showing pressure response in the control method according to the first embodiment;
[0030] FIG. 7 is a graph showing pressure response in the conventional control method;
[0031] FIG. 8 is a graph showing pressure response in the control method according to the first embodiment;
[0032] FIG. 9 is a graph showing pressure response in the conventional control method;
[0033] FIG. 10 is a graph showing pressure response in the control method according to the first embodiment;
[0034] FIG. 11 is a graph showing pressure response in the conventional control method;
[0035] FIG. 12 is a graph showing pressure response in the control method according to the first embodiment;
[0036] FIG. 13 is a graph showing pressure response in the conventional control method;
[0037] FIG. 14 is a graph showing pressure response in the control method according to the first embodiment;
[0038] FIG. 15 is a graph showing pressure response in the conventional control method;
[0039] FIG. 16 is a graph showing pressure response in the control method according to the first embodiment;
[0040] FIG. 17 is a table of constants which are used in Comparative Example 1;
[0041] FIG. 18 is a graph showing pressure response in the control method of Comparative Example 1;
[0042] FIG. 19 is a table of constants which are used in Comparative Example 2;
[0043] FIG. 20 is a graph showing pressure response in the control method of Comparative Example 2;
[0044] FIG. 21 is a graph showing pressure response in the control method of Comparative Example 2;
[0045] FIG. 22 is a table of constants which are used in Comparative Example 3;
[0046] FIG. 23 is a graph showing pressure response in the control method of Comparative Example 3;
[0047] FIG. 24 is a graph showing pressure response in the control method of Comparative Example 3;
[0048] FIG. 25 is a table of constants which are used in a second embodiment;
[0049] FIG. 26 is a graph showing pressure response in the control method according to the second embodiment;
[0050] FIG. 27 is a graph showing pressure response in the control method according to the second embodiment;
[0051] FIG. 28 is a table of constants (revised) which are used in the second embodiment;
[0052] FIG. 29 is a graph showing pressure response (revised) in the control method according to the second embodiment;
[0053] FIG. 30 is a graph showing pressure response (revised) in the control method according to the second embodiment;
[0054] FIG. 31 is a table showing conditions for three steps according to a third embodiment;
[0055] FIG. 32A shows the structure of a sample at the first step in an etching process, FIG. 32B shows the second step in the process and 32 C shows the third step in the process;
[0056] FIG. 33 illustrates the structure of an etched sample;
[0057] FIG. 34 is a graph showing changes in effective gas flow rate and pressure in the conventional control method;
[0058] FIG. 35 is a graph showing etch rates for polysilicon and silicon oxide film which vary with pressure; and
[0059] FIG. 36 is a graph showing change in pressure in the control method according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0060] Next, the preferred embodiments of the present invention will be described in detail referring to the accompanying drawings. First, the present inventors have developed PID control calculation formulas in order to provide a control technique which quickly adjusts the low pressure processing chamber to a desired pressure regardless of gas type, gas flow rate or target pressure. The characteristics of the control method using the formulas are as follows.
(1) Integral gain Gi is not constant but is a function which has a positive correlation with exhaust speed Sn calculated from the valve opening degree in each control cycle and also a negative correlation with target pressure value P 0 and varies from one control cycle to another. In other words, when the valve opening is larger and the target pressure value is smaller, the integral gain is larger, and conversely when the valve opening is smaller and the target pressure value is larger, the integral gain is smaller. (2) Proportional gain Gp is not constant but is a function which has a negative correlation with target pressure value P 0 . In other words, when the target pressure value is smaller, the proportional gain is larger, and conversely when the target pressure value is larger, the proportional gain is smaller. (3) According to the result of calculation using the integral gain Gi and proportional gain Gp, the valve opening is not directly adjusted but the valve opening is adjusted so as to attain the calculated exhaust speed operation amount.
[0064] The correlation between exhaust speed and valve opening can be determined by measurements using standard gas in advance. Therefore, it is not necessary to make measurements for each gas type and each gas flow rate in advance.
[0065] The integral gain Gi and proportional gain Gp which satisfy the above condition can be calculated in accordance with Formulas 2 and 3:
[0000]
[Formula 2]
G
i
=
a
1
+
a
2
S
n
b
1
+
b
2
P
0
(
2
)
[Formula 3]
G
p
=
1
c
1
+
c
2
P
0
(
3
)
[0066] The opening degree of the exhaust valve, ΔVV, is determined in accordance with Formulas 4 and 5 using the above integral gain Gi and proportional gain Gp and a differential gain.
[Formula 4]
[0067] Δ S=S n+1 −S n =Gi ( P n −P 0 )+ G ( P n −P n−1 )+ G d ( P n −2 P n+1 +P n−2 ) (4)
[Formula 5]
[0068] Δ VV=F ( S n+1 )− VV n (5)
Here,
[0000]
ΔVV: Valve opening operation amount (%)
ΔS: Exhaust speed operation amount (L/s)
VVn+1: Next valve opening operation degree (%)
VVn: Current valve opening degree (%)
Sn+1: Next exhaust speed (L/s)
Sn: Current exhaust speed (L/s)
Pn: Current pressure (Pa)
Pn−1: Previous pressure (Pa)
P 0 : Target pressure (Pa)
Gi: Integral gain (varies from one control cycle to another) Gp: Proportional gain (varies from one control cycle to another) Gd: Differential gain (constant) F(s): Function of exhaust speed and valve opening as measured using standard gas in advance a 1 , b 1 , c 1 : 0 or a positive constant (fixed) a 2 , b 2 , c 2 : a positive constant (fixed)
[0084] Exhaust speed operation amount ΔS was calculated in accordance with the above formulas and valve opening operation amount ΔVV was calculated based on the calculated ΔS, and the valve was operated according to the calculated ΔVV. The result shows that the following effect is achieved by using the above formulas.
[0085] By setting appropriate values for the constants “an”, “bn”, “cn” in Formulas 2 and 3, the effective flow rate is calculated from the pressure and exhaust speed in each control cycle and it is automatically fed back and reflected in gain values so that control is optimized. Therefore, quick and stable control is done regardless of gas flow rate or target pressure. Furthermore, according to the result of calculation (ΔS) using control calculation formulas, the valve opening is not directly adjusted but the valve opening is adjusted so as to attain the above calculated exhaust speed operation amount (ΔS). Consequently, even if the function of the opening degree of a throttle valve and exhaust speed, F(S), is very nonlinear, control can be performed stably with less hunting.
[0086] Also, optimal control can be achieved regardless of throttle valve structure by optimizing the constants “an”, “bn”, “cn” in Formulas 2 and 3 for a specific gas type, a specific gas flow rate and a specific target pressure and pre-calculating the function of exhaust characteristics F(S). Besides, even when the gas type, gas flow rate, gas dissociation state or target pressure changes, optimal control can be achieved.
[0087] Next, the information about optimal control which has been thus obtained will be given in detail.
First Embodiment
[0088] FIG. 1 illustrates an example of a microwave plasma processing apparatus which adopts a pressure control method according to the present invention.
[0089] In this apparatus, plasma 8 is generated by introducing a microwave generated by a magnetron 5 through a wave guide 6 and a quartz window 7 into a low pressure processing chamber 1 . Processing gas introduced through a gas inlet 9 is dissociated by the plasma 8 and a sample 11 placed on a sample holder 10 is processed using radicals generated by dissociation. The low pressure processing chamber 1 has a capacity of 59 liters.
[0090] The plasma processing apparatus includes a butterfly throttle valve 3 as an exhaust speed adjusting means between the low pressure processing chamber 1 and an exhaust device 2 so that the pressure in the low pressure processing chamber is automatically controlled by feeding back the difference between the reading of a pressure gauge 4 connected with the low pressure processing chamber 1 and the target pressure to let it reflected in the opening degree of the throttle valve 3 through an arithmetic and control unit 13 . The operation speed of the throttle valve 3 is 25% per second (it takes four seconds for valve operation from the fully closed state to the fully open state).
[0091] The relation between the opening of the valve 3 and the processing chamber pressure was measured using O 2 gas, as the processing gas, supplied at a flow rate of 150 sccm. FIG. 3 shows the relation between exhaust speed and valve opening as calculated from the measured processing chamber pressure. In the pressure control device according to the present invention, the result indicated in FIG. 3 is used as function F in Formula 5 above.
[0092] Next, consideration will be given to automatic pressure control in control cycles of 300 ms using the pressure control device as shown in FIG. 1 . Prior to discussing the PID control method in this embodiment, an explanation is given below of the result of a test conducted on the common conventional PID control method (in the conventional method, valve opening operation amount ΔVV is calculated for each control cycle in accordance with the PID control calculation formula (Formula 1) to control the valve opening). In the test on the conventional control method, O 2 gas was supplied at 150 sccm as the processing gas and automatic pressure control was performed so as to reach target pressure 0.5 Pa once in the absence of plasma discharge; then at time t=0s the pressure response with higher target pressures 1.0 Pa, 2.0 Pa, and 3.0 Pa was investigated. For gain values in the PID control calculation formulas, optimized values for each condition were used. FIG. 4 shows the result of control by the conventional control method. As shown in FIG. 4 , it took 7-12 seconds to reach the target pressures.
[0093] Next, the control method according to the present invention (in which PID control calculations are made in accordance with Formulas 2-5 to calculate the exhaust speed and the calculation result is fed back to the exhaust speed adjusting means) was carried out. The constants “an”, “bn”, “cn” used for the control calculations are shown in FIG. 5 . FIG. 6 shows the result of control by this control method.
[0094] As apparent from FIG. 6 , the target pressures were reached in one or two seconds in the control method according to this embodiment. A test was conducted to investigate the pressure response in decreasing the target pressure from 1.0, 2.0 and 3.0 Pa to 0.5 Pa. FIGS. 7 and 8 show pressure response in the conventional control method and the control method according to this embodiment, respectively. While it takes 5-7 seconds to reach target pressure 0.5 Pa in the conventional method as shown in FIG. 7 , it takes 2 seconds to reach 0.5 Pa in the control method according to this embodiment as shown in FIG. 8 .
[0095] This suggests that according to this embodiment, quicker control can be done regardless of target pressure by optimizing constants “an”, “bn”, and “cn”.
[0096] Then, the target pressure was increased from 0.5 Pa to 2.0 Pa under the condition that O 2 gas as processing gas was supplied at a flow rate of 150 sccm and plasma discharge was generated. Tests were conducted on pressure response in the conventional control method and the control method according to this embodiment at different microwave power levels. In the conventional control method, gain values optimized under the condition of O 2 gas supply at a flow rate of 150 sccm in the absence of plasma discharge were used. For constants “an”, “bn”, and “cn” in the control method according to this embodiment, the values shown in FIG. 5 were used. FIGS. 9 and 10 respectively show the results of these tests.
[0097] As the microwave power is larger, dissociation progresses and one O 2 gas molecule turns into two O radicals and thus the number of moles becomes larger and the effective flow rate increases. Therefore, in the conventional control method, if gain values obtained without plasma are used, it takes longer time to reach the target pressures and with 1000 W microwave power, target pressure 2 Pa is not reached in 15 seconds, as shown in FIG. 9 .
[0098] On the other hand, in the control method according to this embodiment, the effective flow rate is calculated for each control cycle and automatically fed back and reflected in gain values. Consequently, pressure 2 Pa is reached in about two seconds, whether the microwave power is 0, 500 or 1000 W, as shown in FIG. 10 . FIGS. 11 and 12 respectively show the results of tests which were conducted using the conventional control method and the control method according to this embodiment where the target pressure was decreased from 2.0 Pa to 0.5 Pa.
[0099] In the conventional control method, as shown in FIG. 11 , when the microwave power is larger, it takes longer time to reach target pressure 0.5 Pa (up to 13 seconds or so). By contrast, in the control method according to this embodiment, pressure response is the same at any microwave power level as shown in FIG. 12 and target pressure 0.5 Pa is reached in about 2 seconds.
[0100] This demonstrates that the control method according to this embodiment permits quick control with optimized constants “an”, “bn”, and “cn”, regardless of plasma dissociation or effective flow rate.
[0101] Then, the target pressure was increased from 0.5 Pa to 2.0 Pa under the condition that SF 6 gas as processing gas was supplied at a flow rate of 150 sccm and there was no plasma discharge. Tests were conducted on pressure response in the conventional control method and the control method according to this embodiment. In the conventional control method, gain values optimized under the condition of O 2 gas supply at a flow rate of 150 sccm in the absence of plasma discharge were used. For constants “an”, “bn”, and “cn” in this embodiment, the values shown in FIG. 5 were used. FIGS. 13 and 14 respectively show the results of these tests.
[0102] Since SF 6 gas is harder to exhaust than O 2 gas, the effective exhaust speed decreases about 60 percent. Consequently SF 6 gas requires longer time to reach the target pressure than O 2 gas, and as shown in FIG. 13 , target pressure 2 Pa is not reached in 15 seconds. By contrast, in the control method according to this embodiment, the difference in demonstrated characteristics between SF 6 gas and O 2 gas is small and 2 Pa is reached in about 2 seconds as shown in FIG. 14 .
[0103] FIGS. 15 and 16 respectively show the results of tests on pressure response in the conventional control method and the control method according to this embodiment where the target pressure was decreased from 2.0 Pa to 0.5 Pa. In the conventional control method, SF 6 gas requires longer time to reach 0.5 Pa than O 2 gas, and as shown in FIG. 15 , it takes up to 10 seconds or so. By contrast, in the control method according to this embodiment, the difference in pressure response between the gases is smaller and 0.5 Pa is reached in about 2 seconds as shown in FIG. 16 .
[0104] This demonstrates that the control method according to this embodiment permits quick control with optimized constants “an”, “bn”, and “cn”, regardless of gas type.
[0105] As explained above, the control method according to this embodiment permits robust quick pressure control which does not depend on gas pressure, gas flow rate, gas type and gas dissociation state. In the above examples of pressure control, the flow rate was constant; however, this embodiment achieves a similar effect even in pressure control at the time of gas change which involves a large change in the flow rate or in maintaining the pressure constant when the gas flow rate is changed.
[0106] In this embodiment, integral gain Gi and proportional gain Gp are calculated in accordance with Formulas 2 and 3 respectively and the valve opening operation amount is calculated in accordance with Formulas 4 and 5. However, a similar effect can be achieved irrespective of the above formulas if the following conditions are satisfied: (a) integral gain Gi is a function which has a positive correlation with exhaust speed Sn and also has a negative correlation with current pressure Pn and target pressure value P 0 ; (b) proportional gain Gp is a function which has a negative correlation with current pressure Pn and target pressure P 0 ; and (c) the valve opening is adjusted so that the value obtained by the PID control calculation formulas is the exhaust speed operation amount. Although differential gain Gd is 0 in this embodiment, a similar effect can be achieved using a differential gain value other than 0 as far as the value is appropriate.
COMPARATIVE EXAMPLE 1
[0107] One feature of the first embodiment is that the valve opening is not directly adjusted according to the value obtained from the PID control calculation formulas but the valve opening is adjusted so that the value obtained by the above calculation formulas is the exhaust speed operation amount. The advantage of this feature is discussed below.
[0108] First, a pressure control test was conducted using Formulas 2 and 3 which express integral gain Gi and proportional gain Gp and using PID control calculation formula, Formula 1, which directly expresses the valve opening operation amount.
[0109] In the test, O 2 gas as processing gas was supplied at a flow rate of 150 sccm and the target pressure was increased from 0.5 Pa to 2.0 Pa in the presence of plasma discharge. Like the first embodiment, pressure response at different microwave power levels was investigated. For constants “an”, “bn”, and “cn”, the values optimized without plasma as shown in FIG. 17 were used. FIG. 18 shows the test result.
[0110] As shown in FIG. 18 , while control is stable with smaller microwave power (0 W, 500 W), hunting occurs around 2 Pa with larger microwave power (1000 W). The inventors researched the cause for this and found that since the effective flow rate increases with larger microwave power, the valve opening in the steady 2 Pa state increased from 8.4% at 0 W microwave power to 15% at 1000 W. Referring to FIG. 3 which shows the relation between valve opening and exhaust speed, the exhaust speed changes with a change of the valve opening (1%) as follows: 15 L/s at 8.4% valve opening or so and 25 L/s at 15% or so. Hence, it is thought that hunting occurred because the exhaust speed was too high at 1000 W even with the same valve opening operation amount.
[0111] On the other hand, in the first embodiment, the value obtained from the PID control formulas using Formulas 4 and 5 is the exhaust speed operation amount. This may be the reason why control is done stably without hunting as shown in FIG. 10 even when a valve with very nonlinear exhaust characteristics is used, or when gas is dissociated.
[0112] Although the first embodiment uses the PID control calculation formula and Formulas 4 and 5 as the transform expressions from the PID control calculation formula for the valve opening operation amount, any PID control calculation formula may be used to achieve a similar effect if the valve opening can be adjusted so that the formula expresses the exhaust speed operation amount. Although the first embodiment uses a butterfly throttle valve which provides a nonlinear relation F(s) between valve opening and exhaust speed, a pendulum type throttle valve which demonstrates relatively linear exhaust characteristics may be used to achieve a similar effect.
COMPARATIVE EXAMPLE 2
[0113] Another feature of the first embodiment is that integral gain Gi and proportional gain Gp are functions which have a negative correlation with target pressure P 0 in Formulas 2 and 3. The advantage of this feature is discussed below.
[0114] First, in order to eliminate the correlation of integral gain Gi and proportional gain Gp with target pressure P 0 , a pressure control performance test was carried out where b 2 and c 2 in Formulas 2 and 3 were 0.
[0115] In the test, O 2 gas as processing gas was supplied at a flow rate of 150 sccm and the target pressure was increased from 0.5 Pa to 1.0, 2.0 and 3.0 Pa in the absence of plasma discharge and pressure response was investigated. For constants other than bc and c 2 , namely “an”, “bn”, and “cn”, the values optimized for target pressure increase from 0.5 pa to 2.0 Pa as shown in FIG. 19 were used. FIG. 20 shows the test result.
[0116] Under the optimized condition for 2.0 Pa target pressure, the pressure rises almost as quickly as in the case shown in FIG. 6 where b 2 and c 2 are not 0. On the other hand, under the non-optimized condition for 1.0 Pa target pressure, the pressure does not rise quickly, and under the non-optimized condition for 3.0 target pressure, hunting occurs in the initial phase of pressure rise.
[0117] Using the same constants, a test was conducted to investigate the pressure response in decreasing the target pressure from 1.0, 2.0 and 3.0 Pa to 0.5 Pa. FIG. 21 shows the test result. It is known from this that it takes longer time to reach 0.5 Pa target pressure than in the case shown in FIG. 8 where constants b 2 and c 2 are not 0.
[0118] This suggests that quick control is possible in the first embodiment even under different pressure conditions because integral gain Gi and proportional gain Gp have a negative correlation with target pressure P 0 . Although the values of integral gain Gi and proportional gain Gp are given by Formulas 2 and 3 respectively in the first embodiment, as far as integral gain Gi and proportional gain Gp are functions which have a negative correlation with target pressure P 0 , they may be given in another way to achieve a similar effect.
COMPARATIVE EXAMPLE 3
[0119] Another feature of the first embodiment is that integral gain Gi is a function which has a positive correlation with exhaust speed Sn in Formula 2. The advantage of this feature is discussed below.
[0120] First, in order to eliminate the correlation between integral gain Gi and exhaust speed Sn, a pressure control performance test was carried out where a 2 in Formula 2 was 0.
[0121] In the test, O 2 gas as processing gas was supplied at a flow rate of 150 sccm and the target pressure was increased from 0.5 Pa to 1.0, 2.0 and 3.0 Pa in the absence of plasma discharge and pressure response was investigated. For constants other than a 2 , namely “an”, “bn”, and “cn”, the values optimized for target pressure increase from 0.5 Pa to 2.0 Pa as shown in FIG. 22 were used. FIG. 23 shows the test result. Under the optimized condition for 2.0 Pa, the pressure rises almost as quickly as in the case shown in FIG. 6 where a 2 is not 0. On the other hand, under the non-optimized condition for 1.0 Pa target pressure, the pressure does not rise quickly. Also using the same constants, a test was conducted to investigate the pressure response in decreasing the target pressure from 1.0, 2.0 and 3.0 Pa to 0.5 Pa. FIG. 24 shows the test result. It is known from this that it takes longer time to reach 0.5 Pa target pressure than in the case shown in FIG. 8 where a 2 is not 0.
[0122] This suggests that quick control is possible in the first embodiment even under different pressure conditions because integral gain Gi has a positive correlation with exhaust speed Sn.
[0123] Although the value of integral gain Gi is given by Formula 2 in the first embodiment, as far as integral gain Gi is a function which has a positive correlation with exhaust speed Sn, any other function may be used to achieve a similar effect. In the test, the values optimized for pressure increase from 0.5 Pa to 2.0 Pa as shown in FIG. 25 were used for constants “an”, “bn”, and “cn”.
Second Embodiment
[0124] A pressure control test was conducted on the pressure control device shown in FIG. 1 in which the length of the pipe 12 connecting the processing chamber and the pressure gauge was increased from 5 mm to 1 mm. As a result of the increase in the length of the pipe 12 , time lag in transmission of the actual pressure in the processing chamber to the pressure gauge increased from 25 ms to 500 ms.
[0125] In the test, O 2 gas as processing gas was supplied at a flow rate of 150 sccm and the target pressure was increased from 0.5 Pa to 1.0, 2.0 and 3.0 Pa in the absence of plasma discharge and pressure response was investigated. Formulas 2 and 3 were used for integral gain Gi and proportional gain Gp, and the values optimized for target pressure increase from 0.5 pa to 2.0 Pa as shown in FIG. 25 were used for constants “an”, “bn”, and “cn”.
[0126] FIG. 26 shows the test result. The time required for control increased from 1-2 seconds (in the first embodiment) to 4-6 seconds. This is because of a lag between the reading of the pressure gauge and the actual pressure in the processing chamber by increasing the length of the pipe 12 .
[0127] An attempt to further improve response in this situation would result in a further overshoot. Using the constants shown in FIG. 25 , a test was conducted on the pressure response in decreasing the target pressure from 1.0, 2.0 and 3.0 Pa to 0.5 Pa. As shown in FIG. 27 , response is relatively good in decrease from 1.0 Pa but an extreme undershoot occurs in decrease from 2.0 Pa or 3.0 Pa.
[0128] In order to solve this problem, the inventors have developed Formulas 6 and 7 in which pressure value Pn for each control cycle is added to the denominators of Formulas 2 and 3 which respectively express integral gain Gi and proportional gain Gp in the present invention.
[0000]
[Formula 6]
G
i
=
a
1
+
a
2
S
n
b
1
+
b
2
P
0
+
b
3
P
n
(
6
)
[Formula 7]
G
p
=
1
c
1
+
c
2
P
0
+
c
3
P
n
(
7
)
[0129] Here, a 3 , b 3 , c 3 : positive constants (fixed values) In the test, Formulas 6 and 7 were used to express integral gain Gi and proportional gain Gp respectively and O 2 gas as processing gas was supplied at a flow rate of 150 sccm and the target pressure was increased from 0.5 Pa to 1.0, 2.0 and 3.0 Pa in the absence of plasma discharge and pressure response was investigated. The values optimized for target pressure increase from 0.5 Pa to 2.0 Pa as shown in FIG. 28 were used for constants “an”, “bn”, and “cn”. FIG. 29 shows the test result. The time required to reach the target pressure decreased about 1 second.
[0130] Using the constants shown in FIG. 28 , a test was conducted on the pressure response in decreasing the target pressure from 1.0, 2.0 and 3.0 Pa to 0.5 Pa. FIG. 30 shows the test result. Here, an undershoot like the one shown in FIG. 27 is not seen and target pressure 0.5 Pa is reached in 2-3 seconds.
[0131] This suggests that robustness against time lags is improved by using Formulas 6 and 7, in which pressure value Pn for each control cycle is added to the denominators of Formulas 2 and 3, in the calculation of integral gain Gi and proportional gain Gp.
[0132] Although the values of integral gain Gi and proportional gain Gp were given by Formulas 6 and 7 respectively in this embodiment, as far as integral gain Gi and proportional gain Gp are functions which have a negative correlation with both target pressure P 0 and pressure value Pn for each control cycle, they may be given in another way to achieve a similar effect.
Third Embodiment
[0133] Using the pressure control device shown in FIG. 1 , three steps whose conditions are shown in FIG. 31 were carried out to etch a sample whose structure is shown in FIG. 32A . In this etching process, polysilicon 61 , silicon oxide film 62 , and polysilicon 63 are etched along a resist pattern mask 60 , and silicon oxide film 64 is left on silicon 65 as the substrate.
[0134] At the first step, the polysilicon 61 and the silicon oxide film 62 are etched. At the second step, the polysilicon 63 is etched until the silicon oxide film 64 is exposed. At this time, the polysilicon 63 is tapered by etching as illustrated in FIG. 32B . At the third step, the tapered portion (pattern bottom) is removed by etching. During this etching work, a high pressure gas condition which slows down the silicon oxide film etching speed is used in order to prevent the silicon oxide film 64 from being etched.
[0135] By taking these three steps, the sample is expected to become a rectangular shape of the polysilicon from which said tapered portion is removed, as illustrated in FIG. 32C . In this embodiment, for the purpose of throughput improvement, the three steps are carried out continuously without a waiting time between steps.
[0136] Regarding how a sample having the structure as shown in FIG. 32A is shaped by processing, comparison was made between the pressure control method according to the present invention and the conventional pressure control method.
[0137] When the control method according to the present invention was used, the silicon oxide film 64 remained almost intact across its thickness as illustrated in FIG. 32C . On the other hand, when the conventional control method was used, part of the silicon oxide film 64 at the pattern bottom was lost and the substrate silicon 65 was partially etched as shown in FIG. 33 . In addition, a residue 66 was seen on the silicon oxide surface.
[0138] Next, the reason for the partial loss of the silicon oxide film 64 at the pattern bottom was investigated. FIG. 34 shows how the effective gas flow rate and the pressure change when the conventional method is used.
[0139] As indicated in FIG. 34 , in the conventional control method, the speed of pressure rise after the start of Step 3 was slow and while the pressure was below 2 Pa, the wafer (sample) was processed.
[0140] FIG. 35 shows etch rates for the polysilicon and silicon oxide film in pressure change from 0.4 Pa to 2 pa under the gas condition for Step 3 . It is apparent from FIG. 35 that while the silicon oxide film etch rate is very low at 2 Pa, it is higher at lower pressure levels, or as high as 40 nm/min or so around 0.5 Pa, suggesting a very low etch selectivity of the silicon to silicon oxide.
[0141] Therefore, it may be considered that the silicon oxide film 64 was thin and part of the silicon oxide film 64 was etched in the period from the start of Step 3 until 2 Pa was reached.
[0142] Besides, at Step 2 , the sudden decline in the flow rate could not be followed up by pressure control and the pressure remained as low as 0.3 Pa or less. Since the polysilicon etch rate was as low as 60 nm/min or less in the low pressure range below 0.3 Pa, etching of the polysilicon hardly progressed. It may be considered that polysilicon residue 66 was generated for this reason.
[0143] FIG. 36 shows the result of a test on pressure change in the control method according to the present invention. As shown in FIG. 36 , the time required to reach 2 Pa after the start of Step 3 is decreased to 1 second. Furthermore, virtually no pressure drop is seen just after the start of Step 2 . It may be considered that for these reasons the processed sample has a good shape as shown in FIG. 32C .
[0144] Consequently in the control method according to the present invention, even if the steps are continuously carried out, etching can be properly done and throughput can be improved.
[0145] As explained so far, according to the preferred embodiments of the present invention, an exhaust speed which makes the pressure in the processing chamber equal to the target pressure is calculated by PID control calculation; and feedback control of exhaust speed adjusting means (throttle valve) is performed to match the valve opening degree to the calculated exhaust speed. In the PID control calculation, the integral gain and proportional gain have a negative correlation with the target pressure value and the integral gain has a positive correlation with exhaust speed. Hence, irrespective of the throttle valve's exhaust characteristics (nonlinear relation between exhaust speed and valve opening), the pressure in the processing chamber can be quickly brought to the desired pressure level. Even when gas type, gas flow rate or target pressure is altered, optimization of the gains is not needed. Therefore, quick, flexible pressure control can be performed.
|
A control device which quickly adjusts a low pressure processing chamber to a desired pressure regardless of gas type, gas flow rate or target pressure simply by optimizing constants. The device includes: a low pressure processing chamber; gas supply means which supplies processing gas to the low pressure processing chamber; plasma generating means which supplies electromagnetic energy to the processing gas supplied to the low pressure processing chamber and generates plasma; exhaust means which exhausts gas in the low pressure processing chamber; gas pressure measuring means which measures gas pressure in the low pressure processing chamber; exhaust speed adjusting means which adjusts exhaust speed of gas to be exhausted by the exhaust means; and an arithmetic and control unit which makes control calculation to calculate an exhaust speed to make the gas pressure measured by the pressure measuring means equal to a target value, and controls the exhaust speed adjusting means according to the calculation result.
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BACKGROUND
[0001] The present application relates generally to the field of fluid-based energy conversion and more specifically to fluidkinetic energy conversion in both uni- and bi-directional currents.
[0002] Historically, conventional methods of converting water flow into useable energy have been done through large dams and systems of generators. While the electricity generated from these sources is reliable, altering the natural flow of rivers has an extremely negative impact on the environment. Although devices have been used in converting flowing water into useable energy for centuries, there has been a recent push for more environmentally friendly solutions to produce power and provide energy. Much progress has been made in recent years improving upon designs that convert kinetic energy from tides and rivers into an energy source available to the public.
[0003] These fluidkinetic devices have significant advantages over solar and wind powered devices. Tides and rivers offer a much more reliable, predictable and consistent source of renewable energy, if captured correctly. Previous designs and proposals are far from ideal. Many tide conversion systems involve extreme environmental alterations. For example, the earliest tidal power station, the Rance Tidal Power Station, involves a half mile dam on the estuary restricting the natural flow of ocean and requiring a nine square mile tidal basin.
[0004] Most fluidkinetic designs are also extremely complex and are expensive to build, transport, install, and maintain. The Francis turbine, for instance, is one of the most widely used designs in the world. However, its impressive efficiency comes from a rather complex design that includes moving turbine blades. Obviously, as moving parts are added, fluidkinetic energy conversion designs quickly become more complex and more expensive.
[0005] Efforts have recently been made to provide devices that are able to efficiently extract electricity from the kinetic energy of naturally flowing bodies of water. These designs have allowed for smaller scale production and opened the possibility for many previously uneconomical generation sites. Many of these models are optimized for rivers and other inland water energy extraction, making them inefficient and/or unsuitable for use in tides.
[0006] Designing a device that will work well in the ocean poses several unique challenges. Unlike inland energy capturing devices, an efficient and effective tidal device requires a bi-directional design of either the turbines, the generating system, or a combination of both.
[0007] Several innovations have been made to allow for the capture of both the inbound and ebb flow of ocean tides. For example there have been designs where a conventional hydro turbine is mounted on a pivot on the floor of the ocean, or some other stationary object. Devices such as this are periodically rotated 180 degrees to face the changing direction of the current. While these types of devices are able to capture the majority of available flow, they are not yet commercially practical. Devices with more moving parts require more maintenance and will cost more to manufacture and operate than simple fixed devices.
[0008] Therefore a need exists for a simple, reliable, economical solution for extracting kinetic energy from flowing bodies of water. The present invention provides a simple and cost-effective device for converting fluidkinetic energy into useable energy, such as electricity.
SUMMARY
[0009] One embodiment of the present invention described below includes two turbines rotating in opposite directions and places them substantially in series in the same housing or enclosure. As shown, the turbines are offset, having one turbine positioned towards one end of the enclosure and one towards the opposite end. The enclosure inlets may include a fluid flow divider unit, or divider, which concentrates the fluid entering the device into two parallel passageways, each of which may have a width of approximately one third of the total width of the device. The divider unit may be connected to an internal wall which isolates the passageways. A number of configurations are possible for the divider. For example, in one embodiment, immediately in advance of the rear turbine, the internal wall may angle to the right to make room for the rear turbine. The wall may then continue and connect to the divider unit at the other end of the device. One advantage of some embodiments is that, because of the simplicity of the design, the rear half of the device may be a mirror image of the front half. This enables stationary bi-directional generation without additional moving parts or complex rotational devices or schemes.
[0010] An electrical generating unit may be connected to the turbines in any number of ways. For example, a generator may be placed on top of the device to allow for easy installation and access for maintenance if necessary. To allow for both turbines to contribute to the rotation of the generating unit, gears, belts, or other rotational motion converters may be mounted to the shafts of the turbines that extrude from the top of the enclosure. This enables a lighter device and efficient gearing for the generator.
[0011] In some embodiments, a cowl may be attached at one or both ends of the enclosure. The cowl, among other things, captures more fluid than the device would otherwise capture and increases the pressure and velocity of the fluid entering the device. The inclusion of the cowl may also enable higher device efficiency and more energy produced per unit. In some embodiments, a cowl may be attached at both ends to allow for the stationary unit to capture both the ebb and inward flows of the tide and have the benefit of a larger area of fluid captured by the device in either direction.
[0012] The mounting apparatus for the device may preferably be very flexible to allow for installation in a broader range of energy or electricity producing sites. In some embodiments, the mounting apparatus may be grid like, allowing for the grid to be added on after initial installation or to be sized down after initial environmental evaluations. In some embodiments, the mounting apparatus may be configured so several grids are able to be connected together. This apparatus may also allow for smaller individual units to be part of a larger grid. This means that large, expensive single units are not required, but many smaller units may comprise a single grid that would otherwise be occupied by a large single unit.
[0013] These smaller units allow, among other things, easy access to extract and repair or replace specific units without shutting down the entire production site. A monitoring system may also be installed to monitor each individual unit's power output allowing for easy diagnosis and maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows the interior of an embodiment of the fluidkinetic energy conversion enclosure.
[0015] FIG. 2 shows the fluid inlet of an embodiment of the fluidkinetic energy conversion enclosure.
[0016] FIG. 3 shows the interior of another embodiment of the fluidkinetic energy conversion enclosure.
[0017] FIG. 4 shows a skewed profile view of an embodiment of the fluidkinetic energy conversion enclosure.
[0018] FIG. 5 shows a profile view of an embodiment of the fluidkinetic energy conversion enclosure complete with a generator casing.
[0019] FIG. 6 a shows a skewed view of an embodiment of an array of fluidkinetic energy conversion enclosures.
[0020] FIG. 6 b shows a skewed view of an embodiment of a two-dimensional array, or grid, of fluidkinetic conversion enclosures.
[0021] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0022] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that various changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense.
[0023] FIG. 1 shows one embodiment of the fluidkinetic energy converter. Fluidkinetic energy converter apparatus enclosure 100 , is shown from above. This view shows the enclosure subdivided into two passageways 103 and 104 , each passageway creating fluid communication between fluid inlet 130 and fluid outlet 140 . As is demonstrated in this figure by way of multiple parallel arrows approaching inlet 130 , this embodiment is designed to accept fluid at inlet 130 . As the fluid enters inlet 130 , it encounters an interior structure or fluid flow divider 105 . The purpose of the divider 105 at the inlet is to focus and concentrate the fluid flow into a given flow path in a subsection of the passageway. This can be accomplished by dividers of numerous variety of shapes and sizes, one of which may be as shown in this embodiment as an elongated isosceles triangle shape for divider 105 .
[0024] Looking first at the fluid flow paths in passageway 103 of FIG. 1 , the fluid, after being redirected by divider 105 , comes into contact with the working portion 101 a of turbine 101 . It can be seen that one of the purposes of divider 105 is to divert fluid away from the returning portion 101 b of turbine 101 that, if impacted by the fluid, would hinder its ability to freely rotate about its axis of rotation. As the fluid comes into contact with turbine 101 in this configuration, it induces rotation in a counter-clockwise orientation. Were diverter 105 not in place, the fluid flow would impact not only the working portion 101 a of turbine 101 , but it would also impact the returning portion 101 b . The fluid in contact with the working portion 101 a of 101 would attempt to induce counter-clockwise rotation while the fluid in contact with the returning portion 101 b of 101 would attempt to induce clockwise rotation. The combined forces would largely cancel each other out and lead to a highly inefficient turbine arrangement. Therefore, the divider 105 may be preferentially positioned to be such as to focus the fluid flow on a working portion 101 a of turbine 101 . Generally speaking, the minimum width of the passageways 103 and 104 and the radius of the respective turbines 101 and 102 may be optimized to accommodate the anticipated fluid flow.
[0025] Returning to FIG. 1 , after fluid passes by turbine 101 , it continues through passageway 103 and exits the enclosure at fluid outlet 140 . Fluid flow through passageway 104 works in the same manner as discussed for passageway 103 . One difference in passageway 104 is that turbine 102 may be offset and located further back from the inlet 130 . In this embodiment, this offset arrangement allows for two turbines, 101 and 102 , to be aligned substantially in series, meaning that they are in the fluid flow path in a sequential or one-after-the-other, as opposed to parallel, arrangement, and therefore decrease the overall width of the enclosure unit. Similar embodiments could potentially allow for more than two turbines being arranged in series all while maintaining a relatively modest overall enclosure width. Likewise, a vertical, or top-and-bottom, and other arrangements of turbines 101 and 102 can also be configured. Another difference with passageway 104 and turbine 102 as shown is that fluid passing through passageway 104 induces turbine 102 to rotate in the opposite rotational direction as turbine 101 . Of course, gearing, or other converters, can be implemented to drive a generator 110 (shown connected to turbines 101 and 102 by solid lines representing the wide range of connection possibilities) in a single direction of rotation. FIG. 2 shows the embodiment of FIG. 1 from in front of the fluid inlet 230 . FIG. 2 also includes a cowl 220 which may be included on some embodiments to catch and redirect a larger volume of fluid into passageways 203 and 204 and through the enclosure 200 . Other fluid capture devices may also be used. Gears 211 and 212 may be attached to the rotational axes of turbines 101 and 102 (not shown). Other motion translators may also be used. Generator attachment 215 may also be located adjacent to gears 211 and 212 . As fluid induces rotation of turbines 101 and 102 , gears 211 and 212 also rotate. The gears 211 and 212 may be attached to a generator 210 (shown connected to gears 211 and 212 through solid lines representing the wide range of connection possibilities) that translates the gear rotation into electricity or other useful work output.
[0026] FIG. 3 is another embodiment of the fluidkinetic energy conversion enclosure 300 . In this embodiment, the passageways 303 and 304 are configured with dividers 305 and 306 to enable the turbines to accept bi-directional fluid flow. In this embodiment, either end of enclosure 300 serves as an inlet or outlet. Each opening 330 and 340 may be configured to divert and focus fluid onto working portions of turbines 301 and 302 . This embodiment may be advantageously located, for instance, in a tidal environment where the currents ebb and flow.
[0027] For example, as current enters opening 330 , it meets divider 305 and is focused into passageways 303 and 304 , respectively. As shown, the fluid in passageway 303 induces counter-clockwise rotation of turbine 301 , and then continues through passageway 303 eventually exiting the enclosure through opening 340 . Also as shown, the fluid in passageway 304 travels through the passageway and induces clockwise rotation of turbine 302 before exiting the enclosure at opening 340 . Then, when the tide reverses direction, fluid enters the enclosure through opening 340 , meets divider 306 , and is focused into passageways 303 and 304 . For this flow direction, the fluid in passageway 304 induces counter-clockwise rotation of the turbine 302 and then continues through the passageway 304 and exits the enclosure through opening 330 . The fluid continues in passageway 303 , travels the length of the passageway, induces clockwise rotation of turbine 301 and then exits the enclosure at opening 330 . In a tidal environment, the constant ebb and flow of the ocean currents would constantly induce turbine rotation that would be translated into energy, such as electricity, through a generator unit. Again, suitable gearing or other motion translators can be implemented to drive an electrical generator or other output.
[0028] FIG. 4 shows a skewed profile view of the tidal embodiment of FIG. 3 . As in the preceding embodiment, this one includes cowl 420 . In a tidal operation it may be advantageous to include a second cowl 421 . The current embodiment may implement gears 411 and 412 or other similar rotational motor converter in much the same fashion as the embodiment in FIG. 2 . Also seen in FIG. 4 are the generator attachment 415 and the divider 405 .
[0029] FIG. 5 shows a profile view of a dual cowl, 520 and 521 , embodiment. This figure also shows the addition of a generator cover 525 which encloses the motion translators (e.g., gears 411 and 412 ) and the generator unit. Other protective covers may also be implemented.
[0030] FIG. 6 a shows a skewed profile view of an array of generator apparatuses, 600 a , 600 b, 600 c, . . . 600 n, according to one possible embodiment. As understood by those of ordinary skill in the art, other one, two, and three dimensional array or grid arrangements, such as the grid in FIG. 6 b , are also possible.
[0031] FIG. 6 b shows a possible two dimensional or grid embodiment created by stacking multiple one dimensional arrays, 600 a - n,x , 600 a - n,y , and 600 a - n,z , of generator apparatuses upon each other.
[0032] Although this invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of this invention. Accordingly, the scope of the present invention is defined only by reference to the appended claims and equivalents thereof.
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A fluidkinetic energy converter includes a passageway-filled enclosure. Turbines are mounted in the passageways and fluid flow may be concentrated on subparts of the turbines by inner fluid flow deflectors or dividers. The energy converter enclosure can include dividers at both inlets and outlets in order to be adaptable for either river or tidal environments. Notably, apart from the turbines and energy generating components, the enclosure may be implemented such as to have no moving parts, thereby reducing complexity, cost, and weight.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The applicants hereby claim foreign priority benefits under U.S.C. § 119 of Japanese Patent Application No. 2004-115815 filed on Apr. 9, 2004, and the content of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an exhaust gas purification device for an engine, and more particularly to an engine exhaust gas purification device comprising a filter for trapping particulate matter contained in the exhaust gas, and an EGR (exhaust gas recirculation) valve for recirculating the exhaust gas to an intake side.
[0004] 2. Description of the Related Art
[0005] Restrictions on the exhaust gas of diesel engines become stricter year by year, and hence the discharge amount of particulate matter (PM) contained in the exhaust gas must be suppressed. A continuous regeneration diesel particulate filter (DPF) exists as a device for removing PM from exhaust gas.
[0006] As shown in FIG. 2 , in a continuous regeneration DPF, a filter c for trapping the PM in the exhaust gas is provided in an exhaust passage b of an engine a. The PM trapped in the filter c is burned continuously according to the temperature of the exhaust gas, and thus the filter c self-regenerates. However, when the exhaust gas temperature is low, for example under low speed, low load conditions, the PM trapped in the filter c cannot be burned by the temperature of the exhaust gas, and hence regeneration is not possible. As a result, the PM continues to accumulate in the filter c, causing the filter c to become clogged and the exhaust pressure to rise.
[0007] To solve this problem, a technique of using a catalyst-carrying filter c′ as the filter c such that the unburned components of the fuel are supplied to this catalyst-carrying filter c′ is known. According to this technique, the catalyst-carrying filter c′ is activated to rise in temperature by the unburned fuel components, and hence the catalyst-carrying filter c′ can be regenerated forcibly even when the exhaust gas temperature is comparatively low, for example under low speed, low load conditions.
[0008] Supply of the unburned fuel components to the catalyst-carrying filter c′ has been achieved by the present inventor and so on through multi-injection and post-injection from an injector d into the cylinder. Multi-injection involves performing one or more sub-injections following a main injection while the flame generated by the main injection continues to burn. Post-injection involves performing one or more sub-injections following the main injection after the flame generated by the main injection has died out.
[0009] If an EGR valve e is opened to implement exhaust gas recirculation during forcible regeneration of the catalyst-carrying filter c′ through such multi-injection and post-injection, the unburned fuel components produced by the multi-injection and post-injection are recirculated to the intake side from the exhaust side through an EGR passage f. As a result, the unburned components turn into a tar-like substance and stick to an intake manifold g and the like. In the worst case, this may lead to blockages. Hence, a system in which the EGR valve e is closed and the exhaust gas is not recirculated during forcible regeneration of the catalyst-carrying filter c′ has been considered.
[0010] However, it was discovered that with such a system, although unburned components can indeed be prevented from adhering to and accumulating in the intake manifold g by closing the EGR valve e, exhaust gas remains in the EGR passage f, an EGR cooler h, and so on, which are disposed further upstream in the flow direction of the EGR gas than the closed EGR valve e, and hence the unburned components turn into a tar-like substance and accumulate in these parts h, f.
[0011] Note that Japanese Patent Application Laid-open Publication S58-51235 (Patent Document 1) and Japanese Patent Application Laid-open Publication H3-67014 (Patent Document 2) are known as related prior art documents. However, in the device disclosed in Patent Document 1, the filter c is self-regenerated by controlling an intake throttle valve i provided in an intake passage h to close, and in the device disclosed in Patent Document 2, in addition to the control described in Patent Document 1, self-regeneration of the filter c is improved in efficiency by opening the EGR valve e to reduce the amount of new intake air, thereby increasing the temperature of the exhaust gas passing through the filter c. Hence the technological premise of these documents differs from that of the system described above, in which self-regeneration is performed by raising the temperature of the catalyst-carrying filter c′ through multi-injection and post-injection.
SUMMARY OF THE INVENTION
[0012] An object of the present invention is to provide an engine exhaust gas purification device which prevents unburned fuel components from accumulating in an EGR passage by scavenging the EGR passage as needed.
[0013] A first invention designed to achieve this object is an engine exhaust gas purification device comprising a filter provided in an exhaust passage of an engine, for trapping particulate matter contained in exhaust gas, a catalyst provided on the upstream side of the filter and/or on the surface of the filter, for regenerating the filter, an EGR valve provided in an EGR passage linking the intake side and exhaust side of the engine, an injector for injecting fuel into a cylinder of the engine, and control means for controlling the injector and EGR valve. During regeneration of the filter, the control means close the EGR valve when fuel injection from the injector is controlled to supply unburned fuel components to the catalyst, and open the EGR valve when no fuel is injected from the injector upon a request for speed reduction or the like.
[0014] According to this invention, if fuel ceases to be injected from the injector due to a speed reduction request or the like issued while fuel injection from the injector is being controlled such that unburned fuel components are supplied to the catalyst to regenerate the filter, the EGR valve, which has been closed up to this point, is opened. As a result, the EGR passage is scavenged by air that is not mixed with fuel, and hence residual unburned components in the EGR passage are scavenged by this air in an appropriate manner.
[0015] During regeneration of the filter, the control means may control an intake throttle valve provided in an intake passage of the engine to close. In so doing, the amount of new intake air is reduced during regeneration of the filter, and hence reductions in the temperature of the exhaust gas are suppressed, reductions in the temperature of the catalyst and/or the filter are suppressed, and a consequent deterioration in the regeneration capability of the filter is prevented.
[0016] A second invention is an engine exhaust gas purification device comprising an intake throttle valve provided in an intake passage of an engine, a filter provided in an exhaust passage of the engine, for trapping particulate matter contained in exhaust gas, a catalyst provided on the upstream side of the filter and/or on the surface of the filter, for regenerating the filter, an EGR valve provided in an EGR passage linking the intake side and exhaust side of the engine, an injector for injecting fuel into a cylinder of the engine, and control means for controlling the injector, the EGR valve, and the intake throttle valve. During regeneration of the filter, the control means basically supply unburned fuel components to the catalyst by controlling fuel injection from the injector, and when no fuel is injected from the injector during exceptions such as a request for speed reduction, the control means control the intake throttle valve to close, and control the EGR valve to open.
[0017] According to this invention, if fuel ceases to be injected from the injector due to a speed reduction request or the like issued while fuel injection from the injector is being controlled such that unburned fuel components are supplied to the catalyst to regenerate the filter, the intake throttle valve is controlled to close, thereby reducing the amount of new intake air such that reductions in the temperature of the catalyst and/or the filter are suppressed. Furthermore, the EGR valve is controlled to open at the same time as the intake throttle valve is controlled to close, and hence negative pressure inside the cylinder, which is generated when the intake throttle valve is controlled to close, is reduced by controlling the EGR valve to open. As a result, oil loss via the piston rings and oil loss via the guides can be suppressed. Moreover, by controlling the EGR valve to open, residual unburned components in the EGR passage are scavenged by air.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a system diagram of an engine exhaust gas purification device according to a preferred embodiment of the present invention.
[0019] FIG. 2 is a system diagram of a conventional example of an engine exhaust gas purification device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] A preferred embodiment of the present invention will be described below in detail on the basis of the attached drawings.
[0021] As shown in FIG. 1 , an injector 2 (in the illustrated example, an injector of a common rail-type fuel injection system) is attached to a cylinder head of a diesel engine 1 installed in a vehicle. The injector 2 receives signals from an engine control unit (ECU) 20 serving as control means to control the injection timing and injection amount.
[0022] An intake throttle valve 4 is provided in an intake passage 3 of the engine 1 for varying the passage cross section. A driving portion 4 a of the intake throttle valve 4 receives signals from the ECU 20 to open/close control the intake throttle valve 4 .
[0023] An intake manifold 5 and an exhaust manifold 6 of the engine 1 are linked by an EGR passage 7 . An EGR valve 8 is provided in the EGR passage 7 for varying the passage cross section. A driving portion 8 a of the EGR valve 8 receives signals from the ECU 20 to open/close control the EGR valve 8 . An EGR cooler 9 is provided in the EGR passage 7 upstream of the EGR valve 8 (on the upstream side of the EGR gas flow direction) for cooling EGR gas which passes through the passage 7 .
[0024] An oxidation catalyst A and a catalyst-carrying filter B are provided in series on an exhaust passage 10 of the engine 1 . The oxidation catalyst A and catalyst-carrying filter B are accommodated in a storage case 11 interposed in the exhaust passage 10 . The oxidation catalyst A is disposed on the upstream side of the exhaust gas flow, and the catalyst-carrying filter B is disposed on the downstream side of the oxidation catalyst A at a predetermined remove therefrom. The interior of the storage case 11 is partitioned into an upstream chamber 11 a , an intermediate chamber 11 b , and a downstream chamber 11 c by the oxidation catalyst A and catalyst-carrying filter B.
[0025] The oxidation catalyst A is constituted by a block body composed entirely of an oxidation catalyst substance, and a plurality of pores connecting the upstream chamber 11 a to the intermediate chamber 11 b are provided in this block body. The oxidation catalyst A rises in temperature when supplied with unburned fuel components, thereby heating the exhaust gas which flows into the downstream side catalyst-carrying filter B. Thus the oxidation catalyst A functions to raise the temperature of the catalyst-carrying filter B. Note that the oxidation catalyst A assists in raising the temperature of the catalyst-carrying filter B, and therefore may be omitted, as will be described hereafter.
[0026] The catalyst-carrying filter B comprises a plurality of pores connecting the intermediate chamber 11 b to the downstream chamber 11 c . The upstream end and downstream end of adjacent pores are blocked alternately, and a catalyst is carried on the inner peripheral surface of each pore. The catalyst-carrying filter B traps the PM in the exhaust gas on the inner peripheral surface of the pores, and rises in temperature when supplied with unburned fuel components so that the trapped PM is burned. Thus the catalyst-carrying filter B regenerates.
[0027] The differential pressure between the upstream chamber 11 a and downstream chamber 11 c is detected by a differential pressure sensor 12 . More specifically, the upstream chamber 11 a and downstream chamber 11 c are connected by a pipe 13 , and the differential pressure sensor 12 is provided at a point on the pipe 13 for detecting the differential pressure between the left and right of the pipe 13 . The detection value of the differential pressure sensor 12 is outputted to the ECU 20 .
[0028] A catalyst inlet exhaust gas temperature sensor 14 is provided in the upstream chamber 11 a for detecting the temperature of the exhaust gas at the inlet to the oxidation catalyst A, and a filter inlet exhaust gas temperature sensor 15 is provided in the intermediate chamber 11 b for detecting the temperature of the exhaust gas at the inlet to the catalyst-carrying filter B. The detection values of these exhaust gas temperature sensors 14 , 15 are outputted to the ECU (electronic control unit) 20 .
[0029] In addition to the detection values of the differential pressure sensor 12 and exhaust gas temperature sensors 14 , 15 , signals from an accelerator position sensor 16 for detecting the opening of an accelerator pedal, signals from a rotation speed sensor 17 for detecting the engine rotation speed, and signals from a distance sensor 18 for detecting the traveled distance of the vehicle are also inputted respectively into the ECU 20 .
[0030] When the engine 1 is operative, the PM in the exhaust gas is trapped in the catalyst-carrying filter B, and the ECU 20 determines in the following manner whether or not to regenerate the catalyst-carrying filter B according to whether a fixed amount of PM has accumulated therein. More specifically, the distance traveled by the vehicle from the previous regeneration of the catalyst-carrying filter B to the present time is detected by the distance sensor 18 , and if the traveled distance has reached a predetermined distance, it is estimated that the fixed amount of PM has accumulated in the catalyst-carrying filter B and determined that the catalyst-carrying filter B should be regenerated.
[0031] However, depending on the traveling conditions of the vehicle, the fixed amount of PM may become trapped in the catalyst-carrying filter B before the traveled distance of the vehicle reaches the predetermined distance. Hence the differential pressure is detected by the differential pressure sensor 12 constantly or at predetermined time intervals, and when the differential pressure exceeds a predetermined differential pressure, it is estimated that the fixed amount of PM has accumulated in the catalyst-carrying filter B and determined that the catalyst-carrying filter B should be regenerated.
[0032] When it is determined that the catalyst-carrying filter B is not to be regenerated, the ECU 20 outputs a signal to the injector 2 to perform normal fuel injection on the basis of a signal from the accelerator position sensor 16 and a signal from the rotation speed sensor 17 . When it is determined that the catalyst-carrying filter B should be regenerated, regeneration is performed by switching between normal injection, multi-injection, and post-injection in the following manner in accordance with the detection values of the catalyst inlet exhaust gas temperature sensor 14 and filter inlet exhaust gas temperature sensor 15 . Multi-injection and post-injection are as described in the background art section.
[0033] Multi-injection and post-injection are performed when fuel injection is executed during normal traveling, idling, or the like, but are not performed when fuel injection is halted at times such as when the accelerator pedal is not depressed during downhill traveling and when the accelerator pedal is not depressed in order to reduce speed. Multi-injection and post-injection are performed as sub-injections following the main injection, and therefore are naturally not performed when the fuel supply is cut and the main injection is not performed.
[0034] When the temperature of the exhaust gas detected by the catalyst inlet exhaust gas temperature sensor 14 is lower than a first predetermined temperature (the activation temperature of the oxidation catalyst A, for example 250° C.), first a multi-injection is performed. As a result, waste heat that is not converted into motive power is supplied to the oxidation catalyst A, causing the temperature of the oxidation catalyst A to rise to its activation temperature.
[0035] A post-injection is then performed, whereby exhaust gas containing unburned components is supplied to the oxidation catalyst A and catalyst-carrying filter B. In so doing, the temperature of the exhaust gas is raised by the oxidation catalyst A to become high-temperature gas which is supplied to the catalyst-carrying filter B, and thus the temperature of the catalyst-carrying filter B is raised to its activation temperature (approximately 500 to 600° C.). As a result, the PM trapped in the catalyst-carrying filter B is burned, and the catalyst-carrying filter B is forcibly regenerated.
[0036] Note that multi-injection may be performed at the same time as post-injection. Moreover, post-injection may be performed after the detected temperature of the filter inlet exhaust gas temperature sensor 15 has reached a second predetermined temperature (approximately 300° C., for example).
[0037] When the catalyst-carrying filter B is regenerated by performing multi-injection and post-injection, the EGR valve 8 is closed by the ECU 20 , and hence exhaust gas recirculation to the intake side is halted. If the EGR valve 8 is open, the unburned components generated by the post-injection and multi-injection are recirculated to the intake side, where the unburned components turn into a tar-like substance which becomes adhered to the intake manifold 5 and so on. Therefore, the EGR valve 8 is closed to avoid such a situation.
[0038] Note, however, that even when the EGR valve 8 is closed, exhaust gas remains in the EGR passage 7 , EGR cooler 9 , and so on, which are disposed upstream of the closed EGR valve 8 in the EGR gas flow direction, and hence the unburned fuel turns into a tar-like substance and accumulates in these parts 7 , 9 .
[0039] Hence in this embodiment, when fuel is not injected from the injector 2 during regeneration of the catalyst-carrying filter B, for example when the accelerator pedal is not depressed in order to reduce the vehicle speed or the like, the EGR valve 8 , which has been closed up to this point, is opened by the ECU 20 .
[0040] In so doing, the injector 2 does not inject any fuel, and hence air (exhaust gas) that is not mixed with fuel is recirculated to the intake manifold 5 from the exhaust manifold 6 through the EGR passage 7 . Thus the residual unburned components in the EGR passage 7 and EGR cooler 9 can be scavenged in an appropriate manner by the air that is not mixed with fuel. As a result, unburned components can be prevented from accumulating in tar form in the EGR passage 7 and EGR cooler 9 .
[0041] More specifically, when fuel injection is performed during regeneration of the catalyst-carrying filter B, unburned components are supplied to the catalyst-carrying filter B by performing multi-injection and post-injection, and the EGR valve 8 basically remains fully closed to prevent the unburned components from adhering to and accumulating in the intake manifold 5 . Then, when fuel injection is not performed through the injector 2 at times such as when the accelerator pedal is not depressed, the EGR valve 8 is opened so that the EGR passage 7 and EGR cooler 9 can be scavenged by air that is not mixed with fuel, thereby removing the residual unburned components from the EGR passage 7 and EGR cooler 9 .
[0042] Further, the intake throttle valve 4 may be controlled by the ECU 20 to close (including a fully closed state) during regeneration of the catalyst-carrying filter B. Here, the intake throttle valve 4 being “fully closed” indicates that a little intake air may pass therethrough. In so doing, the amount of new intake air is reduced, and hence reductions in the temperature of the exhaust gas passing through the catalyst-carrying filter B can be suppressed. As a result, reductions in the temperature of the catalyst-carrying filter B are suppressed, and a deterioration in the regeneration capability thereof is prevented.
[0043] It is possible to execute this closing control of the intake throttle valve 4 only when the EGR valve 8 is closed (i.e. during multi-injection and post-injection). The reason for this is that the unburned fuel generated by the post-injection and multi-injection may be supplied to the catalyst-carrying filter B without reducing the concentration thereof by controlling the intake throttle valve 4 to close such that the amount of new intake air is reduced.
[0044] It is also possible to control the intake throttle valve 4 to close (including a fully closed state) and to control the EGR valve 8 to open when no fuel is injected during regeneration of the catalyst-carrying filter B. In so doing, the amount of new intake air is reduced by closing the intake throttle valve 4 , and hence reductions in the temperature of the catalyst-carrying filter B can be suppressed. Simultaneously, negative pressure inside the cylinder, which is generated when the intake throttle valve 4 is closed, can be reduced by opening the EGR valve 8 such that the intake manifold 5 and exhaust manifold 6 are connected, and hence oil loss via the piston rings and oil loss via the guides are suppressed within the cylinder.
[0045] More specifically, if the EGR valve 8 is maintained in a closed state when the intake throttle valve 4 is closed, the negative pressure inside the cylinder increases due to the closed state of the intake throttle valve 4 , causing oil loss via the piston rings and oil loss via the guides, which results in an increase in fuel consumption. By opening the EGR valve 8 at the same time as the intake throttle valve 4 is closed, the negative pressure inside the cylinder is reduced. As a result, oil loss via the piston rings and oil loss via the guides are suppressed, leading to a reduction in oil consumption.
[0046] Here, oil loss via the piston rings signifies that oil in the crank case passes between the cylinder and piston and moves into the combustion chamber above the piston, whereas oil loss via the guides indicates that oil in the cylinder head passes between the bulb stem, bulb guide, and so on, and moves into the combustion chamber.
[0047] Further, the EGR valve 8 is open when no fuel is injected through the injector 2 , and therefore by closing the intake throttle valve 4 and opening the EGR valve 8 when no fuel is injected during regeneration of the catalyst-carrying filter B, the residual unburned components in the EGR passage 7 and EGR cooler 9 can be scavenged by air that is not mixed with fuel.
[0048] The present invention is not limited to the embodiment described above.
[0049] For example, in the embodiment described above, the oxidation catalyst A and catalyst-carrying filter B are provided in the storage case 11 , but a constitution is also possible in which only the catalyst-carrying filter B is provided, and the oxidation catalyst A is omitted. It is also possible with this constitution to raise the temperature of the catalyst-carrying filter B to a regeneration temperature through multi-injection and/or post-injection.
[0050] A constitution is also possible in which the oxidation catalyst A is provided in the storage case 11 and a filter which does not carry a catalyst is provided downstream thereof. Likewise with this constitution, the temperature of the filter can be raised to a regeneration temperature by raising the temperature of the oxidation catalyst A through multi-injection and or post-injection.
[0051] Further, the injector 2 need not be a common rail-type injector. Also, instead of the differential pressure sensor 12 , pressure sensors may be provided in the upstream chamber Ha and downstream chamber 11 c respectively, and the difference between their output values may be used as the differential pressure.
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The present invention provides an engine exhaust gas purification device comprising a filter B provided in an exhaust passage ( 10 ) of an engine ( 1 ) for trapping particulate matter contained in the exhaust gas, a catalyst A for regenerating the filter B by burning the particulate matter trapped in the filter B, an EGR valve ( 8 ) provided in an EGR passage ( 7 ) linking the intake side and exhaust side of the engine 1 , an injector ( 2 ) for injecting fuel into a cylinder, and control unit ( 20 ) for controlling the injector ( 2 ) and EGR valve ( 8 ). During regeneration of the filter B, the control unit ( 20 ) close the EGR valve ( 8 ) when fuel injection from the injector ( 2 ) is controlled to supply unburned fuel components to the catalyst A, and open the EGR valve ( 8 ) when no fuel is injected from the injector ( 2 ) upon a request for speed reduction or the like. In so doing, residual unburned fuel components in the EGR passage ( 7 ) are scavenged by air.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method of treating a paper product to provide a moisture and/or oil resistant barrier to the material and a paper product treated by that method.
BACKGROUND OF THE INVENTION
[0002] The present invention will be described with particular reference to paper packaging products. However, it will be appreciated that the method of the present invention may be used to treat any desirable paper product so as to provide a water and/or oil resistant barrier.
[0003] In the present specification, the term “paper product” includes any material formed or otherwise derived from a cellulose pulp. Such material includes papers, containerboard, paperboard, corrugated containers, recycled paper products and the like.
[0004] It is well known to coat or laminate a paper product to provide a moisture resistant and/or oil and grease resistant barrier. Wax is a commonly used paper coating. Waxed paper cannot be recycled and used waxed paper is either disposed of as landfill or incinerated. These options are environmentally unacceptable.
[0005] Paper products are also laminated with plastic films such as polyethylene and polypropylene. Recycling of these materials requires separation of the plastic laminate from the paper. This adds to recycling costs, together with the additional burden of disposing or recycling the separated plastic. Further, not all paper recycling operations have this facility such that a considerable proportion of laminated paper products are not recycled.
[0006] It is clearly desirable to be able to provide an alternative to waxed coatings and/or plastic laminates and which coating is able to be recycled.
[0007] Lignin, together with cellulose and polysaccharides are the major components of the cell walls of woody plants.
[0008] It is an accepted view that phenylpropane (i.e., C 9 ) repeat units linked to each other by ether and carbon-carbon bonds comprises the majority of the composition of lignin.
[0000]
A Phenylpropane (C 9 Unit)
[0009] Woody plants synthesise lignin from trans-p-coumaryl alcohol, trans-coniferyl alcohol, and trans-sinapyl alcohol by an enzymatic dehydrogenation initiated, free radical crosslinking process. Parts of the phenylpropane units containing the aromatic ring and the aromatic substituents are called p-hydroxyphenyl (H), guaiacyl (G), and syringyl (S), respectively.
[0000]
The Lignin Precursors (i.e., Olignols)
[0010] Each class of plants, grasses, softwoods, and hardwoods produces a lignin rich in one type of the phenylpropane repeat unit. Sugarcane bagasse lignin (the preferred type of lignin used in the present invention), is a grass lignin and has a higher proportion of p-hydroxyphenyl lignin groups and lower methoxy content (i.e., vacant ortho and para sites on the aromatic groups) than softwood and hardwood.
[0011] Absorption of lignin onto cellulose fibres in solution has been studied. It was observed that a paper product having improved water resistance could be obtained by sequentially adding cationic starch and colloidal lignin to the pulp prior to forming the product. Use of the cationic starch negates the negative charge on the fibre surface which would under normal circumstances prevent the lignin from binding thereto.
[0012] It would be desirable to be able to treat a formed paper product to improve it's water resistance.
[0013] The present invention therefore relates to the use of lignin to treat a paper material so as to improve its water and/or oil resistance properties.
SUMMARY OF THE INVENTION
[0014] According to a first broad form of the invention there is provided a method of treating a paper product, the method comprising providing an aqueous lignin mixture having a pH of at least about 8 and comprising at least some soluble lignin and applying the mixture to the paper product.
[0015] The paper product may be treated in any suitable manner including dipping, soaking, spraying, rolling, painting or the like.
[0016] According to a further broad form of the invention, there is provided a method of treating a paper product, the method comprising;
[0000] providing a mixture comprising lignin in an aqueous solution at a concentration and pH such that substantially all the lignin is solubilised;
treating the paper product with a cationic polymer followed by treating the paper product with the lignin mixture.
[0017] The two treatment steps for the cationic starch and the lignin may be the same or different.
[0018] The present inventors have observed that when a formed paper product is treated with cationic starch followed by colloidal lignin that the contact angle is actually lowered to below the control, or other words wettability actually increased. This is contrary to the expectation of the earlier work discussed above. Whilst not wishing to be bound by theory, the present inventors believe that colloidal lignin particles are bound to the surface of the cellulose fibres such that the nonbound cellulose surface presents a charged hydrophilic surface, such that the net effect is hydrophilic. The present inventors have surprisingly and unexpectedly discovered that by ensuring that most of the lignin is in a soluble form that the wettability and/or oil resistance of the surface of the paper product may be improved. Whilst not wishing to be bound by theory, it is believed that soluble lignin is able to be absorbed into the pores of the cellulose fibres.
[0019] Lignin is insoluble in water but is soluble at higher pH. Lignin carries a negative charge at higher pH. An aqueous lignin mixture may contain lignin in soluble and/or colloidal form, with the soluble form predominating at higher pH's. The pH at which lignin becomes completely soluble depends upon a number of factors such as the type of lignin (for example it's source and extraction procedures), concentration and temperature. Methods of assessing whether lignin is in a soluble or colloidal form are known to those of skill in the art. Such methods include using a scanning electron microscope to determine the existence of any phase boundaries. Absence of a phase boundary is indicative of the presence of only soluble lignin. Another method is simply to filter the solution and ascertain the amount, if any residue is left remaining.
[0020] The term “substantially all of the lignin is solubilised” means that the at least about 80 wt % of the lignin is in a soluble form, preferably at least 90 wt % and most preferably close to 100% wt.
[0021] Typical pH's of the lignin solutions is above about 9. A preferred range is between about 9.5 to about 11. Typical lignin concentrations are between about 0.02 g.L −1 to about 20 g.L −1 preferably between about 0.02 g.L −1 to about 2 g.L −1
[0022] The lignin is preferably dissolved in an ammonium solution. The advantage of using an ammonium solution is that ammonia may be volatilized during drying and/or curing.
[0023] The cationic polymer may be any suitable polymer including homopolymers of trimethylaminoethylacrylate chloride (TMAEAC) and diallyldeimethylammonium chloride (DADMAC), co-polymers of TMAEAC—acrylamide. A preferred polymer is cationic starch, typically having a degree of hydrolysis of 10% to 30%. Typically the cationic polyelectrolyte is present in a range of between about 100 ppm to about 200 ppm, preferably between about 200 ppm to about 1000 ppm.
[0024] The lignin treatment step may be carried out at a temperature of up to about 65° C.
[0025] It is preferred that after treatment, the paper product is heated to a temperature of between about 80° C. to about 100° C. This drives off ammonia and cures the coating. Heating may be effected in any suitable manner and typically occurs in an oven.
[0026] The present inventors have also discovered that an effective barrier may be obtained by treating the paper product with lignin in the presence of a crosslinking agent.
[0027] According to a further preferred form of the invention there is provided a method of treating a paper product, the method comprising;
[0000] providing an aqueous lignin mixture having a lignin concentration and pH such that the lignin is present in both soluble and colloidal form;
adding a crosslinking agent to the lignin mixture;
treating the paper product with the mixture; and
allowing the mixture to cure.
[0028] A crosslinking agent refers to an agent having at least two functional groups, at least one of which is capable of forming a bond with hydroxy groups.
[0029] Typically the pH is from about 8 to about 10. The concentration of lignin is the mixture is typically between about 10 wt % to about 30 wt %, most preferably about 20 wt %. These concentrations are typically higher than that used in the first broad form of the invention. It will be appreciated that higher concentrations may be tolerated in view of the fact that a certain amount of colloidal lignin may be present. It is estimated that at about pH 10 the amount of colloidal lignin is about 10 wt %.
[0030] A preferred particle size of the colloidal material is between about 20 to about 50 nm, preferably about 30 nm. The present inventor has observed that dispersions containing lignin particles in this size range have the ability to penetrate surfaces, particularly those containing cellulose fibres, have the ability to form films and stable mixtures, and have adequate rheological and viscoelastic properties.
[0031] At higher concentrations, it may be desirable to add a plasticizer to the mixture to improve the melt flow characteristics and provide a workable coating mixture. Suitable plasticizers are polyols. Preferred polyols are those rated for use with food. Typical polyols include the ethoxylated sorbitan esters, for example polyoxyethylene sorbitan monooleate, polyoxyethylene sorbitan monolaurate, polyoxyethylene sorbitan mono-oleate, polyoxyethylene sorbitan monopalmitate, polyoxyethylene sorbitan monostearate and polyoxyethylene sorbitan tristearate. Another preferred polyol is polyethylene glycol having a molecular weight of between about 4000 to about 10000, preferably about 6000.
[0032] Preferred crosslinking agents are bifunctional compounds having a first functional group reactive with hydroxyl groups and a second functional group having a double bond. Whilst not wishing to be bound by theory, the present inventors believe that the hydroxyl reactive groups form an ester linkage with the cellulose and the double bond forms a bond with the lignin.
[0033] Examples of suitable compounds are compounds (1) to (4) below:
[0000]
[0000] wherein R 1 is a C 3 to C 24 branched or unbranched chain having at least one double bond and R 2 is H or lower alkyl having from 1 to 6 carbon atoms. Especially preferred compounds are those of formula 1 and 2 known as alkenyl succinic anhydrides and alkylketene dimmers respectively. Especially preferred are alkenyl succinic anhydrides such as dodecynyl succinic anhydride, hexadecynyl succinic anhydride, ocatadecynyl succinic anhydride or mixtures of any two or more thereof.
[0034] Typically the crosslinking agent is present in the mixture at levels of between about 0.1 wt % to about 4 wt %, preferably between about 0.1 wt % to about 1 wt %.
[0035] According to a further broad form of the invention there is provided a composition for treating a paper product, the composition comprising lignin mixed in an aqueous solution at a concentration and pH such that the lignin is present in both soluble and colloidal form and a crosslinking agent.
[0036] Preferably, the paper product is pre-treated with a cationic polymer prior to treatment with the lignin mixture in a manner as described above with respect to the first broad form of the invention.
[0037] After treatment, the mixture is allowed to cure. This is typically done at elevated temperatures, typically between about 80 and about 100° C.
[0038] The present inventors have also unexpectedly discovered that adding an amphiphlic polymer that is capable of temperature dependent self assembly to a lignin solution prior to treatment of the paper product will also provide an acceptable coating.
[0039] According to a further broad form of the present invention, there is provided a method of treating a paper product, the method comprising;
[0000] providing an aqueous mixture of lignin having a concentration and pH such that at least some of the lignin is present in a soluble form;
adding an amphiphilic polymer to the lignin mixture, the amphiphilic polymer being capable of temperature dependent self assembly such that it becomes more hydrophobic with an increase in temperature;
treating the paper product with the mixture; and
allowing the mixture to cure.
[0040] Amphiphiles have a hydrophilic portion and a hydrophobic portion. In aqueous solution, amphiphiles self assemble such that the hydrophilic portion contacts the water molecules. Temperature can affect the orientation of an amphiphilic molecule in solution or on a surface molecule
[0041] Preferred amphiphilic polymers are silicone polyols. The structure of the silicone polyols comprises defined hydrophobic and hydrophilic portions. The hydrophobic portion comprises one or more dihydrocarbylsiloxane units. The hydrophilic portion of the polyol may comprise one or more polar moieties including ionic groups such as sulfate, sulfonate, phosphonate, phosphate ester, carboxylate, carbonate, sulfosuccinate, taurate, phosphine oxide (as the free acid, a salt or an ester), betaine, betaine copolyol, or quaternary ammonium salt. Ionic hydrophilic moieties may also comprise ionically functionalized siloxane grafts, including polyelectrolytes. Siloxane surfactants containing such groups include, for example, polydimethylsiloxane-graft-(meth)acrylic acid salts, polydimethylsiloxane-graft-polyacrylate salts and polydimethylsiloxane grafted quaternary amines.
[0042] The polar moieties of the hydrophilic portion may comprise non-ionic groups formed by polyethers, such as polyethylene oxide (PEO), and mixed polyethylene oxide/polypropylene oxide polyethers (PEO/PPO); mono- and disaccharides; and water-soluble heterocycles such as pyrrolidinone. The ratio of ethylene oxide to propylene oxide (EO/PO) may be varied in mixed polyethylene oxide/polypropylene oxide polyethers, from about 10 wt. % EO to 100 wt. % EO.
[0043] The hydrophilic portion may also comprise combinations of ionic and nonionic moieties. Such moieties include, for example, ionically end-functionalized or randomly functionalized polyether or polyol.
[0044] The arrangement of the hydrophobic and hydrophilic portions may take the form of a diblock polymer (AB), triblock polymer (ABA), wherein the “B” represents the siloxane portion of the molecule, or multi-block polymer. The silicone polyol may alternatively comprise a graft polymer. The term “graft polymer” refers to a polymer comprising molecules with one or more species of polymeric functionality connected to the main polymer backbone as side chains, wherein the sidechains, or grafts, have structural or functional characteristics that differ from the characteristics of the main polymer backbone. Each graft of a polymeric functionality to the main polymer backbone is a “pendant” group. The structure of the graft may be linear, branched or cyclic.
[0045] A graft polymer useful in the practice of the invention may comprise a hydrophobic main polymer backbone of dihydrocarbylsiloxane units to which one or more hydrophilic grafts are bonded. One structure comprising multiple grafts onto a main polymer backbone is a “rake” type structure (also called “comb”). A rake-type structure is compared to an ABA structure, below.
[0000]
An especially preferred rake silicone polyol is one where the hydrophile has the formula C 3 H 6 O-(EO)m-(PO)n-R;
where EO is ethylene oxide —[CH 2 —CH 2 —O]m-; PO is propylene oxide —[CH 2 —CH(CH 3 )—O]n—, either, but not both, of m and n may be 0 and R is methyl, ethyl, butyl or propyl. X, y, m and/or n are selected such that the molecular weight of the polyol is between about 2000 to about 10000, typically between about 4000 and about 6000. Especially preferred are the rake silicone polyols available from Genesee.
A trisiloxane is an additional structure type, related to the rake-type structure. A representative trisiloxane structure is depicted below.
[0000]
[0000] The siloxane portion of the molecule may be polymeric or oligomeric with regard to the dihydrocarbylsiloxane unit. Siloxane portions of the surfactant molecule may comprise linear, branched or cyclic structures.
[0049] Another suitable amphiphatic polymer is a N-vinyl caprolactam copolymer. A suitable comonomer is vinyl acetate.
[0050] Typically the amphiphile is present in the mixture in an amount of between 0.5 to about 4%, preferably between about 1 to about 2%.
[0051] The mixture may include lignin in colloidal form. The preferred particle sizes and relative amounts of colloidal to soluble lignin are similar to that described above.
[0052] After treatment, the mixture is allowed to cure. This is typically done at elevated temperatures, typically between about 80° C. and about 100° C.
[0053] According to a further preferred from of the invention there is provided a composition for treating a paper product, the composition comprising lignin mixed in an aqueous solution at a concentration and pH such that the lignin is present in both soluble and colloidal form and an amphiphilic polymer that is capable of temperature dependent self assembly to the lignin mixture whereby the polymer becomes more hydrophobic with an increase in temperature.
[0054] A preferred lignin for use in each embodiment of the present invention is derived from a non-wood source. An especially preferred lignin is derived from sugarcane bagasse. It is also preferred that the lignin is separated from the cellulose component of the bagasse by the soda pulping or organosolv processes. The organosolv process uses an organic solvent such as aqueous ethanol to separate the lignin. The soda process uses caustic soda under pressure. Lignin obtained by these processes is believed to be particularly suitable for use in the methods and compositions of the present invention as it as it has a relatively low molecular weight and narrower molecular weight distribution that lignin fractionated by the conventional kraft process. These lignins also tend to be more hydrophobic.
DETAILED DESCRIPTION OF THE FIGURES
[0055] FIG. 1 is a photo of a paper product coated by a preferred method and composition of the present invention; and
[0056] FIG. 2 is a SEM micrograph of a paper product treated by a preferred method and composition of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Lignin Purification
[0057] Sugarcane bagasse was pulped with a solution of aqueous ethanol in a Parr reactor at 190° C., which produced black liquor and pulp. This liquor was then diluted and heated to recover the lignin. The lignin was obtained by filtration, air-dried and further dried overnight in a vacuum oven at 60° C. The crude lignin was then dissolved in 0.1 M caustic soda solution and the resulting solution heated to 40° C. with stirring for 30 min. The lignin was then re-precipitated by acidifying with sulfuric acid to a pH of 5.5-6. By purifying the lignin in this manner the amount of proteins, polysaccharides, lipids and ash impurities were reduced.
Substrate Preparation
[0058] The substrates were pre-treated by completely submerging them in beakers containing CS solutions at ˜23° C., 45° C. or 60° C. for ˜1 h. After this, they were removed and the excess solution allowed to drip, then lay flat to air-dry. This took ˜40 min. The pre-treated substrates were then either completely submerged in a beaker of lignin solution for 5 min, or a coating of the lignin solution was mechanically applied using a sponge roller. Like the starch solution, the lignin was applied at various temperatures, ranging from room temperature to 65° C. A hair-dryer was then used to dry the coated substrates before further drying in an oven at 100° C. overnight. The coated substrates were sandwiched between two panes of glass and clamped in an attempt to reverse the significant curling that occurred during oven drying. This provided a flat surface for contact angle measurements.
Contact Angle Measurements
[0059] A contact angle of a sample represents the angle at which a liquid/vapour interface of a liquid droplet meets a solid surface. This value is measured using a video contact angle device, which calculates the value using the Young-Laplace equation and incorporates a contact angle goniometer for visual analysis of the droplet.
[0060] The contact angle is specific for any given system and is determined by the interactions across the three interfaces (liquid, vapour and solid). On an extremely hydrophilic surface a water droplet will completely spread out, resulting in an effective contact angle of 0°. On a hydrophobic surface however, a large contact angle is observed and often falls in the range of 70° to 90°. Once a contact angle of 150° is obtained, the surface is deemed superhydrophobic and the water droplet effectively rests atop the surface, without wetting it to any significant extent.
[0061] In the present investigation, contact angle measurements were used to quantify the performance of the treated substrates. FIG. 1 shows a photograph of a water droplet on a lignin coated substrate.
[0062] The contact angle for each substrate prepared was taken at least 2 (and up to 5), different locations to ensure an average value was obtained. For the majority of the substrates the value obtained indicates a static value, as the contact angle was observed not to change with elapsed time. However, for those (less successful) substrates whose contact angle did decrease with time, a second value is indicated in parenthesis. This value describes the angle obtained once the droplet appeared to have ceased spreading, and was usually taken at 1-1.5 min after the initial impact.
Water Absorption Measurement
[0063] A qualitative measure of the relative water absorptive nature of the substrates was undertaken using a ‘5 min dunk test’. The substrates were submerged in a solution of ultra-pure water for 5 min. At the end of this the samples were removed from the solution and patted dry between two layers of paper toweling, to remove any excess surface moisture, before having their mass re-recorded. The difference in dry and wet mass of the substrate was then used to calculate its percentage increase in mass recorded due to water absorption.
Coating Thickness
[0064] In an attempt to measure the approximate thickness of the lignin/cationic starch coating, several coated samples and a control sample were analysed using scanning electron microscopy (SEM).
[0065] A razor blade was used to cut a small portion of the samples, such that a fresh, clean-cut vertical cross section could be observed. It was thought that this would produce a clearly visible phase boundary between the substrate and coating, allowing for the measurement of the coating thickness.
[0000] Preliminary Results with Cationic Starch
Solution Preparation
[0066] The Cationic Starch (CS) used for this study was WISPROFLOC P supplied by Swift and Co. Three concentrations of CS solutions were prepared 80 ppm, 250 ppm and 1,000 ppm. These solutions were heated to the desired temperature prior to use.
[0067] Three concentrations of lignin solutions in 0.1 M ammonia solution were prepared 0.2 g.L −1 , 2.0 g.L −1 and 200 g.L −1 . There were left to stir overnight. The beakers containing the lignin solutions were tightly covered, so as to prevent loss of ammonia. The pHs of the lignin solutions containing 0.2 g.L −1 and 2.0 g.L −1 were 10.2-10.8. However, for the 200 g.L −1 lignin solution the pH was raised just prior to application from 7.4 to 8, using the ammonia solution.
Results
Contact Angle and Water Absorption Results
[0068] The two lignin samples, one designated Dark/fine and the other designated Light/coarse were both obtained via aqueous ethanol extraction (see table 5.1). The samples differ only in the concentration of ethanol used in their extraction from the original bagasse as well as the pulping time.
[0000]
TABLE 1
Composition of lignin solutions
Solution
Type of
Lignin conc.
code
lignin
(g · L −1)
pH
S1
Dark/fine
0.2
10.8
S2
Dark/fine
2.0
10.4
S3
Light/coarse
0.2
not measured
S4
Dark/fine
200
7.4
(adjusted to 8.2)
[0069] The substrate codes used in table 5.2 identify the procedural variables involved in preparing the individual substrates. For example, substrate 250-R-60 was prepared using 250 ppm CS solution at room temperature (R), followed by treatment with a lignin solution at 60° C.
[0070] Table 2 includes the contact angles observed for all test specimens prepared, as well as that for the untreated sample)(91°), and for an untreated sample that was heated overnight in the oven at 100° C. (101°). The contact angles for the treated samples were in the range of 90°-118°. The contact angles of the substrates prepared with a lignin concentration of 200 g.L −1 were quite acceptable upon initial impact of the water droplet but decreased significantly over the course of a few minutes. This effect may be related to the pH of this solution which was ˜8.2 compared to a value of between 10.2 and 10.8 for the other lignin concentrations. At that pH and concentration, a significant portion of the lignin would be in colloidal form.
[0000]
TABLE 2
Contact angles for both treated and untreated substrates
Substrate
Dunked/
Contact angle (°)
code
Roller
S1
S2
S3
S4
80-R-R
D
110
108
—
—
R
111
100
—
—
80-R-40
D
103
111
—
—
R
112
95
—
—
80-45-R
D
108
109
—
—
R
90
104
—
—
80-45-40
D
101
109
—
—
R
104
104
—
—
80-60-R
D
101
110
—
—
R
93
99
—
—
80-60-40
D
97
109
—
—
R
93
100
—
—
250-R-R
D
108
114
109
110 (60)
R
105
102
108
—
250-R-40
D
103
114
108
—
R
101
109
107
—
250-R-60
D
—
116
116
—
R
—
106
111
—
250-45-R
D
107
118
107
—
R
105
104
99
—
250-45-40
D
103
114
110
—
R
104
105
96
—
250-45-60
D
—
115
112
—
R
—
109
105
—
250-60-R
D
105
111
102
—
R
103
105
104
—
250-60-40
D
103
116
107
—
R
105
106
102
—
250-60-60
D
—
115
109
—
R
—
107
104
—
1000-R-R
D
105
114
—
110 (55)
R
106
101
—
—
1000-R-40
D
113
114
—
—
R
105
105
—
—
1000-R-60
D
—
117
—
104 (70)
R
—
105
—
—
1000-45-R
D
109
112
—
—
R
105
98
—
—
1000-45-40
D
107
114
—
—
R
97
100
—
—
1000-45-60
D
—
116
—
—
R
—
102
—
—
1000-60-R
D
108
109
—
—
R
98
105
—
—
1000-60-40
D
111
112
—
—
R
101
99
—
—
1000-60-60
D
—
115
—
—
R
—
105
—
—
Uncoated substrate
91
Heat-treated (uncoated)
101
substrate
[0071] Table 3 gives the water absorption results for the untreated substrate and CS treated substrates. The increase in mass for the CS treated substrates ranged from 53%-69% slightly lower than the untreated substrate i.e., control.
[0000]
TABLE 3
Water absorption results for the untreated and CS treated
substrates
Increase in mass
Substrate code
(%)
Control
72
250-R
53
250-60
69
1000-R
55
1000-60
59
[0072] Table 4 gives the water absorption results for the lignin coated substrates. The increase in mass is between 52% and 64%, slightly lower than the untreated substrate.
[0000]
TABLE 4
Water absorption results for the lignin treated substrates
Increase in Mass (%)
Substrate code
Dunked/Roller
S1
S2
250-R-R
D
64
60
250-R-R
R
62
64
250-R-65
D
70
57
250-R-65
R
57
52
1000-R-R
D
57
60
1000-R-R
R
63
61
1000-R-65
D
62
63
1000-R-65
R
59
61
SEM Analysis
[0073] The use of SEM to determine the thickness of any coating proved unsuccessful as no obvious phase boundary was seen. This was probably because, at least for the dilute lignin solutions (0.2 g.L −1 and 2.0 g.L −1 ), the lignin macromolecules only occupied the pores and spaces between the fibres of the substrate. A SEM micrograph is shown in FIG. 2 .
FURTHER EXAMPLES
[0074] In each of the further examples, the coating was painted onto the substrate and cured at a temperature at 80° to 100° C. for a time sufficient to cure the formulation.
Example 1
[0075] A lignin solution was made by mixing lignin with ammonia solution such that the pH was 10. This solution was then made into a formulation consisting of components shown in table 1. The solution temperature was between 25° C. and 60° C.
Lignin/Silicon Polyol Coating Formulation
[0076]
[0000]
Component
Weight %
Lignin
20
Genesee 218
2
Ammonia solution
78
[0077] The contact angle of the coated substrates where taken after 1-2 min to take into account spreading of the water droplet and as such water penetration. The contact angle of the coated paper was 132° C.
Example 2
[0078] The lignin solution of Example 1 was incorporated into the formulation as shown below.
Lignin/Silicon Polyol Coating Formulation
[0079]
[0000]
Component
Weight %
Lignin
20
Genesee 218
4
Ammonia solution
78
[0080] The contact angle measurement of the coated paper taking after 1-2 min was 134°.
Example 3
[0081] The lignin solution of Example 1 was incorporated into the formulation as shown below.
Lignin/Silicon Polyol Coating Formulation
[0082]
[0000]
Component
Weight %
Lignin
20
Genesee 226
2
Ammonia solution
78
[0083] The contact angle measurement of the coated paper taking after 1-2 min was 115°.
Example 4
[0084] The lignin solution of Example 1 was incorporated into the formulation as shown in below.
Lignin/Polyol/ODSA Coating Formulation
[0085]
[0000]
Component
Weight %
Lignin
20
Polyethylene glycol,
2
6000
ODSA
0.3
Ammonia solution
77.7
[0086] The contact angle measurement of the coated paper taking after 1-2 min was 125°. Water adsorption 37%; control 51%. Kit test, 4. Water vapour transmission rate (WVTR) 468 gm 2 /24 hours.
Example 5
[0087] The lignin solution of Example 1 was incorporated into the formulation as shown below.
Lignin/Polyol/ODSA Coating Formulation
[0088]
[0000]
Component
Weight %
Lignin
20
Polyethylene glycol,
4
6000
ODSA
0.6
Ammonia solution
75.4
[0089] The contact angle measurement of the coated paper taking after 1-2 min was 115°. Water adsorption 31%; control 51%. Kit test, 4. WVTR 460 gm 2 /24 hours.
Example 6
[0090] The lignin solution of Example 1 was incorporated into the formulation as shown below.
Lignin/Cationic Starch Coating Formulation
[0091]
[0000]
Component
Weight %
Lignin
0.02
Ammonia solution
99.98
[0092] The paper substrate was contacted with ˜0.025 g.L −1 cationic starch (WISPROFLOC P).
[0093] The contact angle measurement of the coated paper taking after 1-2 min was 108°.
Example 7
[0094] The lignin solution of Example 1 was incorporated into the formulation as shown below.
Lignin/Cationic Starch Coating Formulation
[0095]
[0000]
Component
Weight %
Lignin
0.2
Ammonia solution
99.8
[0096] The paper substrate was contacted with ˜0.1 g.L −1 cationic starch (WISPROFLOC P).
[0097] The contact angle measurement of the coated paper taking after 1-2 min was 112°.
[0098] It may be seen that the methods and compositions of the present invention are able to increase the contact angle of the surface of a paperboard product. It may also be seen from the above examples that the treated paper products had an acceptable kit value. A kit value represents the ability of a surface to repel grease and oil.
[0099] Paper products treated by the present invention are able to be recycled and are also biodegradable. As the mixtures and solutions are aqueous, the use of the present invention avoids the use of organic solvents currently employed in the paper coating industry. Thus the present invention may be able to reduce the amount of volatile organic compounds and hazardous air pollutants being introduced into the environment.
[0100] In the specification and the claims the term “comprising” shall be understood to have a broad meaning similar to the term “including” and will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the term “comprising” such as “comprise” and “comprises”.
[0101] It will be appreciated that various changes and modifications may be made to the invention described and claimed herein without departing from the spirit and scope of the invention.
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A method is provided for treating a paper product, the method comprising; providing a mixture comprising lignin in an aqueous solution at a concentration and pH such that substantially all the lignin is solubilised; treating the paper product with a cationic polymer followed by treating the paper product with the lignin mixture.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Application No. 61/522,544, filed 11 Aug. 2011, and also claims benefit of U.S. Provisional Application No. 61/522,554, filed 11 Aug. 2011, and which applications are incorporated herein by reference. A claim of priority to all is made.
GOVERNMENT SUPPORT
[0002] This invention was made with government support under Grant No. CA122417 awarded by the National Institutes of Health. The Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] Diabetes mellitus is a complex metabolic disease that affects more than 340 million individuals in the world, including 25.8 million Americans. Diabetic patients have impaired ability to metabolize glucose, and the ensuing hyperglycemia results in many complications, which include damage to the vasculature and the inability to heal wounds. The vascular damage in diabetes results in ischemia as a contributing factor to the persistence of wounds, causing inflammation and triggering production of reactive oxygen species, which prevent wound closure by damaging the extracellular matrix (ECM). Matrix metalloproteinases (MMPs), a family of 26 zinc-dependent endopeptidases, normally restructure the ECM in an effort to repair the wound, but the ischemic condition in diabetic wounds presents an obstacle. As discussed herein, expression of MMPs in diabetic wounds is altered and contributes to the refractory nature of the wounds to heal.
[0004] MMPs are expressed as inactive zymogens (proMMPs), requiring proteolytic removal of the pro domain for their activation, which is mediated by other proteinases, including MMPs. MMPs are further regulated by complexation with tissue inhibitors of matrix metalloproteinases (TIMPs), which block access to the active site. Furthermore, MMPs are expressed at low levels in healthy tissues, but their expression increases during many diseases that involve remodeling of the ECM. This is known to be the case for chronic wounds, except the methods that have been employed do not differentiate among proMMPs and TIMP-complexed MMPs (both inactive as enzymes) and activated MMPs. It is the active MMPs that play roles in the physiology of wound healing and in the pathology of wounds refractory to healing.
[0005] Accordingly, there is a need for therapies that are effective for the treatment of chronic wounds. There is also a need for selective MMP inhibitors that are effective to enhance and accelerate the healing process.
SUMMARY
[0006] Selective matrix metalloproteinase (MMP) inhibitors have been found to facilitate healing of diabetic wounds. It has been discovered that a number of selective inhibitor compounds significantly accelerate the healing process of various chronic wounds. The evaluations described herein demonstrate that these compounds are indeed efficacious in accelerating the healing process in diabetic mammals. Notably, the therapy was effective in diabetic mice but not in non-diabetic mice. The non-diabetic mice treated with an MMP inhibitor failed to show any acceleration effect for their wound healing. These compounds are the first discovered for this type of therapy. There are no current clinical agents that can accelerate the wound healing process in diabetics, therefore the compounds, compositions, and methods described herein will be of significant importance to patients and practitioners in need of therapeutic methods for treating chronic wounds.
[0007] The invention thus provides methods of accelerating the healing process of a skin wound. The methods can include administering to a mammal afflicted with a skin wound an effective amount of an MMP inhibitor, or a pharmaceutically acceptable salt thereof, wherein the gelatinase inhibitor accelerates the healing process of the skin wound.
[0008] The invention also provides methods of inhibiting the progression of a skin wound associated disease state characterized by elevated levels of matrix metalloproteinases. The methods can include administering to a mammal afflicted with a skin wound an effective amount of a gelatinase inhibitor, or a pharmaceutically acceptable salt thereof, effective to inhibit the progression of the skin wound in the mammal.
[0009] The invention further provides a method for enhancing the rate of repair of a diabetic skin wound. The method can include administering to the skin wound an effective amount of a gelatinase inhibitor, or a pharmaceutically acceptable salt thereof, wherein the rate of repair of the skin wound is enhanced, for example, compared to the rate of repair of a skin wound not receiving administration of the gelatinase inhibitor.
[0010] The invention additionally provides a dressing or patch for a chronic skin wound. The dressing or patch can include an effective amount of a gelatinase inhibitor, or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable carrier, diluent, or excipient. For example, the active can be included in an ointment base, where the gelatinase inhibitor and the ointment base are combined and incorporated into a dressing. The dressing can a woven or non-woven fabric and can further include a backing and/or an adhesive.
[0011] The MMP inhibitor can be any suitable and effective gelatinase inhibitor or collagenase inhibitor. Examples of various gelatinase inhibitors and collagenase inhibitors are described, recited, illustrated, or referenced herein. The suitable compounds can include their salts, solvates, or prodrugs. Examples of effective inhibitors include SB-3CT, p-amino SB-3CT, p-hydroxy SB-3CT, and p-Arg SB-3CT.
[0012] In some embodiments, the effective amount of the gelatinase inhibitor can be, for example, about 0.01 to about 50 mg per day, about 0.1 to about 10 mg per day, about 0.5 to about 5 mg per day, or about 0.5 to about 2.5 mg per day. The effective amount of the gelatinase inhibitor can be applied, for example, topically, optionally in combination with other actives and/or carriers. The amount per day can be an amount in a composition applied, for example, topically or transdermally, or it can be an amount administered by another means, such as subdermally. For topical administration, the amount can also be about 0.01 to about 50 mg per day, about 0.1 to about 10 mg per day, about 0.5 to about 5 mg per day, or about 0.5 to about 2.5 mg per 100 cm 2 of wound on the surface of the patient being treated.
[0013] In some embodiments, the skin wound is a chronic skin wound. Subjects having wounds treatable by the methods described herein include mammals, such as humans. In some cases, the mammal can be suffering from diabetes, and the skin wound can be a chronic diabetic skin wound. The inhibitor can be delivered to the skin wound in a variety of forms, such as in an ointment, or the administration of the inhibitor can be intraperitoneal, such as intravenous administration.
[0014] The invention therefore provides therapeutic methods of treating skin wounds in a mammal. The methods can include administering to a mammal having a wound, such as a chronic skin wound, an effective amount of a compound or composition described herein. Mammals include primates, humans, rodents, canines, felines, bovines, ovines, equines, swine, caprines and the like.
[0015] The invention also provides compounds useful for treating wounds of the integument (e.g., skin ulcers and any break or damage to the integument) or wounds as a result of surgery, which can include systemic treatment to aid the healing of such internal wounds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The following drawings form part of the specification and are included to further demonstrate certain embodiments or various aspects of the invention. In some instances, embodiments of the invention can be best understood by referring to the accompanying drawings in combination with the detailed description presented herein. The description and accompanying drawings may highlight a certain specific example, or a certain aspect of the invention. However, one skilled in the art will understand that portions of the example or aspect may be used in combination with other examples or aspects of the invention.
[0017] FIG. 1A is a graph depicting the wound closure (percentage of original wound diameter) per day in female diabetic mice in Example 1. Wound closure was determined every day using the initial and final wound diameters, and the percentage wound closure calculated as [(initial−final)/initial]×100.
[0018] FIG. 1B is a graph depicting the wound closure (percentage of original wound diameter) per day in wild-type mice (top) and diabetic mice (bottom); the gelatinase inhibitor was p-amino SB-3CT.
[0019] FIG. 2A is a graph depicting the wound closure (percentage of original wound diameter) per day in female diabetic mice in Example 3. Wound closure was determined every day using the initial and final wound diameters, and the percentage wound closure calculated as [(initial−final)/initial]×100.
[0020] FIG. 2B is a photograph of the skin lesion of a representative mouse treated with p-amino SB-3CT at 0.25 mg/wound on day 13 of Example 3.
[0021] FIG. 2C is a photograph of the skin lesion of a representative mouse treated with saline (vehicle) at 50 μL/wound on day 13 of Example 3.
[0022] FIG. 2D depicts four images from in situ gelatin zymography of the wound tissue of diabetic mice after treatment with p-amino SB-3CT at 0.25 mg/wound (top images) and saline (vehicle) at 50 μL/wound (bottom images) on day 13 of Example 3. The wound tissue of mice treated with vehicle showed gelatinolytic activity (bottom images). Wound gelatinolytic activity is visualized using fluorescein isothiocyanate (FITC)-labeled substrate (right images), and 4′,6-diamidino-2-phenylindole (DAPI)-labeled substrate (left images). The wound tissue of mice treated with p-amino SB-3CT at 0.25 mg/wound showed significantly less gelatinolytic activity (top images) than the wounds of the mice treated with vehicle (bottom images).
[0023] FIGS. 3-16 illustrate various MMP inhibitors that can be used in the methods described herein for treating wounds, according to various embodiments. However, some of the MMP inhibitors are broad-spectrum inhibitors, therefore if they inhibit MMP-8 and/or they do not inhibit MMP-9, they will not be suitable inhibitors for use with the techniques described herein.
[0024] FIG. 3 . Collagen-based peptidomimetic hydroxamates.
[0025] FIG. 4 . Peptidomimetic hydroxamates and carboxylates.
[0026] FIG. 5 . Diaryl ether hydroxamates.
[0027] FIG. 6 . Peptidomimetic hydroxamates.
[0028] FIG. 7 . Peptidomimetic carboxylates.
[0029] FIG. 8 . Thiol-based MMP inhibitors.
[0030] FIG. 9 . Pyrimidine-based MMP inhibitors.
[0031] FIG. 10 . A pyrone MMP inhibitor.
[0032] FIG. 11 . Phosphine MMP inhibitors.
[0033] FIG. 12 . N-Sulfonyl aminophosphonate MMP Inhibitors.
[0034] FIG. 13 . A bisphosphonate MMP Inhibitor.
[0035] FIG. 14 . A chemically modified tetracycline MMP inhibitor.
[0036] FIG. 15 . Various competitive MMP inhibitors.
[0037] FIG. 16 . Phosphorus-based MMP Inhibitors.
[0038] FIG. 17 . Various mechanism-based MMP Inhibitors, including inhibitors selective for MMP-9.
[0039] FIG. 18 . Active MMP-8, MMP-9, and MMP-14 are found in diabetic wounds.
[0040] FIG. 19 . Identification and quantification of active MMPs in the course of diabetic wound-healing. Female diabetic (db/db) and wild-type mice received a single excisional 8-mm diameter wound in the dorsal region and were treated with 50 μL of saline once a day starting one day after wound infliction. (a) Broad-spectrum MMP inhibitor-tethered resin (compound 1). (b) Gelatin zymography of wound tissue extracts from db/db mice; proMMP-2, proMMP-9, and active MMP-2 are observed, however active MMP-9 is not detectable. The faint band below MMP-9 dimer on days 7, 10, and 14 might be the previously reported complex between MMP-8 and MMP-9. (c) Levels of active MMP-8 and MMP-9 in wound tissues quantified by the inhibitor-tethered resin coupled with nano UPLC with MRM detection. Data represent mean±SD, n=3; *p<0.05, #p<0.01. The increases in levels of active MMP-8 on day 10 were statistically significant in both wild-type and diabetic wounds, whereas active MMP-9 was upregulated only in diabetic wounds. These data indicate a detrimental role for MMP-9 and a possible beneficial role for MMP-8 in diabetic wound repair. Because active MMP-2 is not detected with the resin, the active MMP-2 band seen by gelatin zymography represents TIMP-inhibited MMP-2, a non-covalent complex. The SDS used in gelatin zymography denatures the TIMP-MMP complex, exposing the active site. Thus, detection of TIMP-inhibited gelatinases is a major drawback of gelatin zymography.
[0041] FIG. 20 . ND-322 accelerates wound healing by re-epithelialization and abrogates MMP-9 activity in db/db wounds. Female db/db and wild-type mice received a single excisional 8-mm diameter wound in the dorsal region and were treated with ND-322 (50 μL of 5.0 mg/mL ND-322 in saline, equivalent to 0.25 mg/wound/day) or saline.
[0042] FIG. 20( a ) Chemical structure of inhibitor 2 (also known as ND-322).
[0043] FIG. 20( b ) Wound closure in db/db and wild-type mice as determined by taking photographs at the indicated time points. Wound area was calculated at each time point using photographs taken at a fixed distance above the wound and ImageJ software and expressed as percentage of wound area relative to that at day 0. Data given as mean±SD; n=35 on day 1, n=28 on day 3, n=21 on day 7, n=14 on day 10, and n=7 on day 14; *p<0.05, *p<0.01 indicate statistically significant differences in wound closure between ND-322-treated and vehicle-treated db/db mice. Differences in average wound closures in ND-322-treated and vehicle-treated wild-type mice are not statistically significant (p>0.25) on days 1, 3, 7, 10, 14. Enlargement of wounds on day 1 are due to wound retraction.
[0044] FIG. 20( c ) and ( d ). Representative wound images in (c) wild-type and (d) db/db mice. A photo of the wound in each panel is given to the left (all to the same scale) and H&E staining to the right for day 14 after wound infliction. Wounds of vehicle-treated wild-type, ND-322-treated wild-type, and ND-322-treated db/db mice were completely re-epithelialized (indicated by dotted line) with hair growth, while those of vehicle-treated db/db mice showed partial re-epithelialization (dotted line) with no hair growth. Scale bars in panels c and d are 100 μm.
[0045] FIG. 20( e ). In situ gelatin zymography with MMP fluorogenic substrate DQ-gel (green in left panels) merged with nuclear DNA staining by DAPI (blue). The extracellular MMP-9 activity (green) surrounds the nucleus. ND-322 significantly reduced gelatinolytic activity in db/db wounds compared to vehicle-treated control. Scale bars, 25 μm.
DETAILED DESCRIPTION
[0046] Chronic wounds affect millions of individuals in the US every year. Chronic wounds include diabetic foot ulcers, pressure ulcers, and venous ulcers. These wounds do not follow a normal, predictable course of healing and can take an extended time to heal. Ischemia is an important factor contributing to the formation and persistence of wounds, causing tissue inflammation and releasing chemokines, leukotrienes, and complement factors that recruit leukocytes. Leukocytes migrate into tissue, where they express proinflammatory cytokines and produce reactive oxygen species (ROS). ROS damages cells and prevent wound closure by damaging the extracellular matrix (ECM) and cytokines that accelerate healing.
[0047] The ECM is a complex network of proteins and proteoglycans that surrounds cells and provides physical support of cells in tissue. Collagen is a major component of the ECM. A family of 26 zinc-dependent endopeptidases are responsible for the turnover and degradation of the ECM, including its collagen. These endopeptidases are also known as matrix metalloproteinases (MMPs). Gelatinases A (MMP-2) and B (MMP-9) are able to break down collagen more effectively than other MMPs. They also cleave collagen type IV, the major constituent of the basement membrane. In addition, MMP-2 has been shown to play an important role in the reorganization of collagen lattices. These enzymes are inhibited by tissue inhibitors of MMP (TIMP) and are believed to be responsible for the increased destruction of the ECM observed in chronic wounds. Fluids from chronic human wounds have elevated levels of pro-inflammatory cytokines, including tumor necrosis factor-alpha and interleukin-1b, and elevated levels of MMPs and serine proteases.
[0048] Marked upregulation of MMP-2 and MMP-9 is found in chronic wounds. Higher levels of MMP-9 in chronic wound fluid correlate with clinically more severe wounds. Reduced levels of TIMP are also found in chronic wounds. As described herein, it has now been determined that selective gelatinase inhibitors can be effective in the treatment of chronic wounds.
[0049] The discovery and synthesis of 2-(((4-phenoxyphenyl)sulfonyl)methyl)thiirane (SB-3CT; compound (1)), the first prototype mechanism-based inhibitor for MMPs (K i 14±1 nM and 600±200 nM for human MMP-2 and MMP-9, respectively), was reported in 2000 (Brown et al., J. Am. Chem. Soc. 2000, 122, 6799-6800; Toth et al., J. Biol. Chem. 2000, 275, 41415-23). SB-3CT has been found to be effective in animal models of prostate cancer metastasis to the bone, breast cancer metastasis to the lungs, T-cell lymphoma metastasis to the liver, ischemic stroke, subarachnoid hemorrhage, spinal cord injury, traumatic brain injury, and testosterone-induced neurogenesis.
DEFINITIONS
[0050] As used herein, the recited terms have the following meanings. All other terms and phrases used in this specification have their ordinary meanings as one of skill in the art would understand. Such ordinary meanings may be obtained by reference to technical dictionaries, such as Hawley's Condensed Chemical Dictionary 14 th Edition, by R. J. Lewis, John Wiley & Sons, New York, N.Y., 2001 ; Mosby's Medical Dictionary, 8 th Edition, 2009, Elsevier; and The American Heritage Medical Dictionary, 2007, Houghton Mifflin Company.
[0051] References in the specification to “one embodiment”, “an embodiment”, etc., indicate that the embodiment described may include a particular aspect, feature, structure, moiety, or characteristic, but not every embodiment necessarily includes that aspect, feature, structure, moiety, or characteristic. Moreover, such phrases may, but do not necessarily, refer to the same embodiment referred to in other portions of the specification. Further, when a particular aspect, feature, structure, moiety, or characteristic is described in connection with an embodiment, it is within the knowledge of one skilled in the art to affect or connect such aspect, feature, structure, moiety, or characteristic with other embodiments, whether or not explicitly described.
[0052] The singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “a compound” includes a plurality of such compounds, so that a compound X includes a plurality of compounds X. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for the use of exclusive terminology, such as “solely,” “only,” and the like, in connection with the recitation of claim elements or use of a “negative” limitation.
[0053] The term “and/or” means any one of the items, any combination of the items, or all of the items with which this term is associated. The phrase “one or more” is readily understood by one of skill in the art, particularly when read in context of its usage. For example, one or more substituents on a phenyl ring refers to one to five, or one to four, for example if the phenyl ring is disubstituted.
[0054] The term “about” can refer to a variation of ±5%, ±10%, ±20%, or ±25% of the value specified. For example, “about 50” percent can in some embodiments carry a variation from 45 to 55 percent. For integer ranges, the term “about” can include one or two integers greater than and/or less than a recited integer at each end of the range. Unless indicated otherwise herein, the term “about” is intended to include values, e.g., weight percents, proximate to the recited range that are equivalent in terms of the functionality of the individual ingredient, the composition, or the embodiment.
[0055] As will be understood by the skilled artisan, all numbers, including those expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth, are approximations and are understood as being optionally modified in all instances by the term “about.” These values can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings of the descriptions herein. It is also understood that such values inherently contain variability necessarily resulting from the standard deviations found in their respective testing measurements.
[0056] As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges recited herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof, as well as the individual values making up the range, particularly integer values. A recited range (e.g., weight percents or carbon groups) includes each specific value, integer, decimal, or identity within the range. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, or tenths. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art, all language such as “up to”, “at least”, “greater than”, “less than”, “more than”, “or more”, and the like, include the number recited and such terms refer to ranges that can be subsequently broken down into sub-ranges as discussed above. In the same manner, all ratios recited herein also include all sub-ratios falling within the broader ratio. Accordingly, specific values recited for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for radicals and substituents.
[0057] One skilled in the art will also readily recognize that where members are grouped together in a common manner, such as in a Markush group, the invention encompasses not only the entire group listed as a whole, but each member of the group individually and all possible subgroups of the main group. Additionally, for all purposes, the invention encompasses not only the main group, but also the main group absent one or more of the group members. The invention therefore envisages the explicit exclusion of any one or more of members of a recited group. Accordingly, provisos may apply to any of the disclosed categories or embodiments whereby any one or more of the recited elements, species, or embodiments, may be excluded from such categories or embodiments, for example, as used in an explicit negative limitation.
[0058] Specific values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
[0059] The term “alkyl” refers to a branched, unbranched, or cyclic hydrocarbon having, for example, from 1-20 carbon atoms, and often 1-12, 1-10, 1-8, 1-6, or 1-4 carbon atoms. Examples include, but are not limited to, methyl, ethyl, 1-propyl, 2-propyl (iso-propyl), 1-butyl, 2-methyl-1-propyl (isobutyl), 2-butyl (sec-butyl), 2-methyl-2-propyl (t-butyl), 1-pentyl, 2-pentyl, 3-pentyl, 2-methyl-2-butyl, 3-methyl-2-butyl, 3-methyl-1-butyl, 2-methyl-1-butyl, 1-hexyl, 2-hexyl, 3-hexyl, 2-methyl-2-pentyl, 3-methyl-2-pentyl, 4-methyl-2-pentyl, 3-methyl-3-pentyl, 2-methyl-3-pentyl, 2,3-dimethyl-2-butyl, 3,3-dimethyl-2-butyl, hexyl, octyl, decyl, dodecyl, and the like. The alkyl can be unsubstituted or substituted, for example, with a substituent described below. The alkyl can also be optionally partially or fully unsaturated. As such, the recitation of an alkyl group includes both alkenyl and alkynyl groups. The alkyl can be a monovalent hydrocarbon radical, as described and exemplified above, or it can be a divalent hydrocarbon radical (i.e., an alkylene).
[0060] The term “cycloalkyl” refers to cyclic alkyl groups of, for example, from 3 to 10 carbon atoms having a single cyclic ring or multiple condensed rings. Cycloalkyl groups include, by way of example, single ring structures such as cyclopropyl, cyclobutyl, cyclopentyl, cyclooctyl, and the like, or multiple ring structures such as adamantyl, and the like. The cycloalkyl can be unsubstituted or substituted. The cycloalkyl group can be monovalent or divalent, and can be optionally substituted as described for alkyl groups. The cycloalkyl group can optionally include one or more cites of unsaturation, for example, the cycloalkyl group can include one or more carbon-carbon double bonds, such as, for example, 1-cyclopent-1-enyl, 1-cyclopent-2-enyl, 1-cyclopent-3-enyl, cyclohexyl, 1-cyclohex-1-enyl, 1-cyclohex-2-enyl, 1-cyclohex-3-enyl, and the like.
[0061] The term “aryl” refers to an aromatic hydrocarbon group derived from the removal of at least one hydrogen atom from a single carbon atom of a parent aromatic ring system. The radical attachment site can be at a saturated or unsaturated carbon atom of the parent ring system. The aryl group can have from 6 to 30 carbon atoms, for example, about 6-10 carbon atoms. The aryl group can have a single ring (e.g., phenyl) or multiple condensed (fused) rings, wherein at least one ring is aromatic (e.g., naphthyl, dihydrophenanthrenyl, fluorenyl, or anthryl). Typical aryl groups include, but are not limited to, radicals derived from benzene, naphthalene, anthracene, biphenyl, and the like. The aryl can be unsubstituted or optionally substituted, as described for alkyl groups.
[0062] The term “heteroaryl” refers to a monocyclic, bicyclic, or tricyclic ring system containing one, two, or three aromatic rings and containing at least one nitrogen, oxygen, or sulfur atom in an aromatic ring, and that can be unsubstituted or substituted, for example, with one or more, and in particular one to three, substituents, as described in the definition of “substituted”. Typical heteroaryl groups contain 2-20 carbon atoms in addition to the one or more hetoeroatoms. Examples of heteroaryl groups include, but are not limited to, 2H-pyrrolyl, 3H-indolyl, 4H-quinolizinyl, acridinyl, benzo[b]thienyl, benzothiazolyl, β-carbolinyl, carbazolyl, chromenyl, cinnolinyl, dibenzo[b,d]furanyl, furazanyl, furyl, imidazolyl, imidizolyl, indazolyl, indolisinyl, indolyl, isobenzofuranyl, isoindolyl, isoquinolyl, isothiazolyl, isoxazolyl, naphthyridinyl, oxazolyl, perimidinyl, phenanthridinyl, phenanthrolinyl, phenarsazinyl, phenazinyl, phenothiazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, pteridinyl, purinyl, pyranyl, pyrazinyl, pyrazolyl, pyridazinyl, pyridyl, pyrimidinyl, pyrimidinyl, pyrrolyl, quinazolinyl, quinolyl, quinoxalinyl, thiadiazolyl, thianthrenyl, thiazolyl, thienyl, triazolyl, tetrazolyl, and xanthenyl. In one embodiment the term “heteroaryl” denotes a monocyclic aromatic ring containing five or six ring atoms containing carbon and 1, 2, 3, or 4 heteroatoms independently selected from non-peroxide oxygen, sulfur, and N(Z) wherein Z is absent or is H, O, alkyl, aryl, or —(C 1 -C 6 )alkylaryl. In some embodiments, heteroaryl denotes an ortho-fused bicyclic heterocycle of about eight to ten ring atoms derived therefrom, particularly a benz-derivative or one derived by fusing a propylene, trimethylene, or tetramethylene diradical thereto.
[0063] The term “heterocycle” refers to a saturated or partially unsaturated ring system, containing at least one heteroatom selected from the group oxygen, nitrogen, silicon, and sulfur, and optionally substituted with one or more groups as defined for the term “substituted”. A heterocycle can be a monocyclic, bicyclic, or tricyclic group. A heterocycle group also can contain an oxo group (═O) or a thioxo (═S) group attached to the ring. Non-limiting examples of heterocycle groups include 1,3-dihydrobenzofuran, 1,3-dioxolane, 1,4-dioxane, 1,4-dithiane, 2H-pyran, 2-pyrazoline, 4H-pyran, chromanyl, imidazolidinyl, imidazolinyl, indolinyl, isochromanyl, isoindolinyl, morpholinyl, piperazinyl, piperidinyl, pyrazolidinyl, pyrazolinyl, pyrrolidine, pyrroline, quinuclidine, tetrahydrofuranyl, and thiomorpholine.
[0064] The term “substituted” indicates that one or more hydrogen atoms on the group indicated in the expression using “substituted” is replaced with a “substituent”, such as for a substituted alkyl, aryl, or amino group. The number referred to by ‘one or more’ can be apparent from the moiety one which the substituents reside. For example, one or more can refer to, e.g., 1, 2, 3, 4, 5, or 6; in some embodiments 1, 2, or 3; and in other embodiments 1 or 2. The substituent can be one of a selection of indicated groups, or it can be a suitable group known to those of skill in the art, provided that the substituted atom's normal valency is not exceeded, and that the substitution results in a stable compound. Suitable substituent groups include, e.g., alkyl, alkenyl, alkynyl, alkoxy, halo, haloalkyl, hydroxy, hydroxyalkyl, aryl, aroyl, (aryl)alkyl (e.g., benzyl or phenylethyl), heteroaryl, heterocycle, cycloalkyl, alkanoyl, alkoxycarbonyl, amino, alkylamino, dialkylamino, trifluoromethyl, trifluoromethoxy, trifluoromethylthio, difluoromethyl, acylamino, nitro, carboxy, carboxyalkyl, keto, thioxo, alkylthio, alkylsulfinyl, alkylsulfonyl, arylsulfinyl, arylsulfonyl, heteroarylsulfinyl, heteroarylsulfonyl, heterocyclesulfinyl, heterocyclesulfonyl, phosphate, sulfate, hydroxylamine, hydroxyl (alkyl)amine, and cyano. Additionally, suitable substituent groups can be, e.g., —X, —R, —O − , —OR, —SR, —S − , —NR 2 , —NR 3 , ═NR, —CX 3 , —CN, —OCN, —SCN, —N═C═O, —NCS, —NO, —NO 2 , ═N 2 , —N 3 , —NC(═O)R, —C(═O)R, —C(═O)NRR, —S(═O) 2 O − , —S(═O) 2 OH, —S(═O) 2 R, —OS(═O) 2 OR, —S(═O) 2 NR, —S(═O)R, —OP(═O)O 2 RR, —P(═O)O 2 RR, —P(═O)(O − ) 2 , —P(═O)(OH) 2 , —C(═O)R, —C(═O)X, —C(S)R, —C(O)OR, —C(O)O − , —C(S)OR, —C(O)SR, —C(S)SR, —C(O)NRR, —C(S)NRR, or —C(NR)NRR, where each X is independently a halogen (“halo”): F, Cl, Br, or I; and each R is independently H, alkyl, aryl, (aryl)alkyl (e.g., benzyl), heteroaryl, (heteroaryl)alkyl, heterocycle, heterocycle(alkyl), or a protecting group. As would be readily understood by one skilled in the art, when a substituent is keto (═O) or thioxo (═S), or the like, then two hydrogen atoms on the substituted atom are replaced. In some embodiments, one or more of the substituents above are excluded from the group of potential values for substituents on the substituted group.
[0065] The term “interrupted” indicates that another group is inserted between two adjacent carbon atoms (and the hydrogen atoms to which they are attached (e.g., methyl (CH 3 ), methylene (CH 2 ) or methine (CH))) of a particular carbon chain being referred to in the expression using the term “interrupted, provided that each of the indicated atoms' normal valency is not exceeded, and that the interruption results in a stable compound. Suitable groups that can interrupt a carbon chain include, e.g., with one or more non-peroxide oxy (—O—), thio (—S—), imino (—N(H)—), methylene dioxy (—OCH 2 O—), carbonyl (—C(═O)—), carboxy (—C(═O)O—), carbonyldioxy (—OC(═O)O—), carboxylato (—OC(═O)—), imine (C═NH), sulfinyl (SO) and sulfonyl (SO 2 ). Alkyl groups can be interrupted by one or more (e.g., 1, 2, 3, 4, 5, or about 6) of the aforementioned suitable groups. The site of interruption can also be between a carbon atom of an alkyl group and a carbon atom to which the alkyl group is attached.
[0066] Selected substituents within the compounds described herein may be present to a recursive degree. In this context, “recursive substituent” means that a substituent may recite another instance of itself. Because of the recursive nature of such substituents, theoretically, a large number may be present in any given claim. One of ordinary skill in the art of medicinal chemistry and organic chemistry understands that the total number of such substituents is reasonably limited by the desired properties of the compound intended. Such properties include, by of example and not limitation, physical properties such as molecular weight, solubility or log P, application properties such as activity against the intended target, and practical properties such as ease of synthesis. In some embodiments, the substitution will result in a compound having a molecular weight of less than about 1200 Da, less than about 1000 Da, less than about 900 Da, less than about 800 Da, less than about 750 Da, less than about 700 Da, less than about 650 Da, less than about 600 Da, less than about 500 Da, or less than about 400 Da.
[0067] Recursive substituents are an intended aspect of the invention. One of ordinary skill in the art of medicinal and organic chemistry understands the versatility of such substituents. To the degree that recursive substituents are present in an embodiment, the total number will be determined as set forth above.
[0068] The term “amino acid” refers to a natural amino acid residue (e.g. Ala, Arg, Asn, Asp, Cys, Glu, Gln, Gly, His, Hyl, Hyp, Be, Leu, Lys, Met, Phe, Pro, Ser, Thr, Trp, Tyr, and Val) in D or L form, as well as unnatural amino acid (e.g. phosphoserine; phosphothreonine; phosphotyrosine; hydroxyproline; gamma-carboxyglutamate; hippuric acid; octahydroindole-2-carboxylic acid; statine; 1,2,3,4-tetrahydroisoquinoline-3-carboxylic acid; penicillamine; ornithine; citruline; a-methyl-alanine; para-benzoylphenylalanine; phenylglycine; propargylglycine; sarcosine; and tert-butylglycine) residue having one or more open valences. The term also comprises natural and unnatural amino acids bearing amino protecting groups (e.g. acetyl, acyl, trifluoroacetyl, or benzyloxycarbonyl), as well as natural and unnatural amino acids protected at carboxy with protecting groups (e.g. as a (C 1 -C 6 )alkyl, phenyl or benzyl ester or amide). Other suitable amino and carboxy protecting groups are known to those skilled in the art (see for example, T. W. Greene, Protecting Groups In Organic Synthesis ; Wiley: New York, Third Edition, 1999, and references cited therein; D. Voet, Biochemistry, Wiley: New York, 1990; L. Stryer, Biochemistry , (3rd Ed.), W.H. Freeman and Co.: New York, 1975; J. March, Advanced Organic Chemistry, Reactions, Mechanisms and Structure, (2nd Ed.), McGraw Hill: New York, 1977; F. Carey and R. Sundberg, Advanced Organic Chemistry, Part B: Reactions and Synthesis , (2nd Ed.), Plenum: New York, 1977; and references cited therein).
[0069] The term “contacting” refers to the act of touching, making contact, or of bringing to immediate or close proximity, including at the cellular or molecular level, for example, to bring about a physiological reaction, a chemical reaction, or a physical change, e.g., in a solution, in a reaction mixture, in vitro, or in vivo.
[0070] An “effective amount” refers to an amount effective to treat a disease, disorder, and/or condition, or to bring about a recited effect. For example, an amount effective can be an amount effective to reduce the progression or severity of the condition or symptoms being treated. Determination of a therapeutically effective amount is well within the capacity of persons skilled in the art. The term “effective amount” is intended to include an amount of a compound described herein, or an amount of a combination of compounds described herein, e.g., that is effective to treat or prevent a disease or disorder, or to treat the symptoms of the disease or disorder, in a host. Thus, an “effective amount” generally means an amount that provides the desired effect.
[0071] The terms “treating”, “treat” and “treatment” include (i) preventing a disease, pathologic or medical condition from occurring (e.g., prophylaxis); (ii) inhibiting the disease, pathologic or medical condition or arresting its development; (iii) relieving the disease, pathologic or medical condition; and/or (iv) diminishing symptoms associated with the disease, pathologic or medical condition. Thus, the terms “treat”, “treatment”, and “treating” extend to prophylaxis and include prevent, prevention, preventing, lowering, stopping or reversing the progression or severity of the condition or symptoms being treated. As such, the term “treatment” includes both medical, therapeutic, and/or prophylactic administration, as appropriate.
[0072] The terms “inhibit”, “inhibiting”, and “inhibition” refer to the slowing, halting, or reversing the growth or progression of a disease, infection, condition, or group of cells. The inhibition can be greater than about 20%, 40%, 60%, 80%, 90%, 95%, or 99%, for example, compared to the growth or progression that occurs in the absence of the treatment or contacting.
[0073] The compositions and methods described herein can be used for aiding wound management. The term “wound management” refers to therapeutic methods that induce and/or promote repair of a wound including, but not limited to, arresting tissue damage such as necrotization, promoting tissue growth and repair, reduction or elimination of an established microbial infection of the wound and prevention of new or additional microbial infection or colonization. The term can further include reducing or eliminating the sensation of pain attributable to a wound.
[0074] The therapeutic compositions for use in methods of wound management can include a surfactant that can useful in cleaning a wound or contributing to bactericidal activity of the administered compositions. Suitable surfactants include, but are not limited to, phospholipids such as lecithin, including soy lecithin and detergents. The surfactant selected for application to a wound or skin surface will typically be mild and will not lead to extensive irritation or promote further tissue damage to the patient.
[0075] Suitable nonionic surfactants that can be used include, for example, fatty alcohol ethoxylates (alkylpolyethylene glycols); alkylphenol polyethylene glycols; alkyl mercaptan polyethylene glycols; fatty amine ethoxylates (alkylaminopolyethylene glycols); fatty acid ethoxylates (acylpolyethylene glycols); polypropylene glycol ethoxylates (Pluronics); fatty acid alkylolamides (fatty acid amide polyethylene glycols); alkyl polyglycosides, N-alkyl-, N-alkoxypolyhydroxy fatty acid amide, in particular N-methyl-fatty acid glucamide, sucrose esters; sorbitol esters, and esters of sorbitol polyglycol ethers. One specific surfactant is polypropylene glycol ethoxylates, for example, with a concentration of about 5 wt % and about 25 wt %, including, for example, the poloxymer Pluronic F-127 (Poloxamer 407). In other embodiments, the surfactant can include lecithin with or without the addition of Pluronic F-127, the Pluronic F-127 being about 2 and about 20 wt % for increasing the viscosity or gelling of the compositions.
[0076] A “wound” refers to an injury to the body, including but not limited to an injury from trauma, violence, accident, or surgery. A wound may occur due to laceration or breaking of a membrane (such as the skin) and usually damage to underlying tissues. A wound may occur in a topical location or internally. Chronic wounds may be caused by diseases, including but not limited to diabetes; diseases of internal organs, including but not limited to diseases of the liver, kidneys or lungs; cancer; or any other condition that slows the healing process.
[0077] Natural healing occurs in clearly defined stages. Skin wounds of acute nature may heal in 1-3 weeks in a biological process that restores the integrity and function of the skin and the underlying tissue. Such wounds may be the result of a scrape, abrasion, cut, graze, incision, tear, or bruise to the skin. If a wound does not heal in 4-12 weeks, it may be considered chronic. In the chase of chronic wounds, the wound may be attenuated at one of the stages of healing or fail to progress through the normal stages of healing. A chronic wound may have been present for a brief period of time, such as a month, or it may have been present for several years.
[0078] The phrase “chronic skin wound” includes, but is not limited to, skin ulcers, bed sores, pressure sores, diabetic ulcers and sores, and other skin disorders. Chronic skin wounds can be any size, shape or depth, and may appear discolored as compared to normal, healthy skin pigment. Chronic skin wounds can bleed, swell, seep pus or purulent discharge or other fluid, cause pain or cause movement of the affected area to be difficult or painful. Chronic skin wounds can become infected, producing elevated body temperatures, as well as pus or discharge that is milky, yellow, green, or brown in color, and is odorless or has a pungent odor. If infected, chronic skin wounds may be red, tender, or warm to the touch.
[0079] Chronic skin wounds can be caused by diabetes, poor blood supply, low blood oxygen, by conditions where blood flow is decreased due to low blood pressure, or by conditions characterized by occluded, blocked or narrowed blood vessels. A low oxygen supply can be caused by certain blood, heart, and lung diseases, and/or by smoking cigarettes. Chronic skin wounds can also be the result of repeated trauma to the skin, such as swelling or increased pressure in the tissues, or constant pressure on the wound area. Chronic skin wounds can be caused by a weakened or compromised immune system. A weakened or compromised immune system can be caused by increasing age, radiation, poor nutrition, and/or medications, such as anti-cancer medicines or steroids. Chronic skin wounds can also be cause by bacterial, viral or fungal infections, or the presence of foreign objects.
[0080] The term “diabetes” refers to any of several metabolic conditions characterized by the excessive excretion of urine and persistent thirst. The excess of urine can be caused by a deficiency of antidiuretic hormone, as in diabetes insipidus, or it can be the polyuria resulting from the hyperglycemia that occurs in diabetes mellitus.
[0081] The phrase “type 1 diabetes mellitus” refers to the first of the two major types of diabetes mellitus, characterized by abrupt onset of symptoms (often in early adolescence), insulinopenia, and dependence on exogenous insulin. It results from a lack of insulin production by the pancreatic beta cells. With inadequate control, hyperglycemia, protein wasting, and ketone body production occur. The hyperglycemia leads to overflow glycosuria, osmotic diuresis, hyperosmolarity, dehydration, and diabetic ketoacidosis, which can progress to nausea and vomiting, stupor, and potentially fatal hyperosmolar coma. The associated angiopathy of blood vessels (particularly microangiopathy) affects the retinas, kidneys, and arteriolar basement membranes. Polyuria, polydipsia, polyphagia, weight loss, paresthesias, blurred vision, and irritability can also occur.
[0082] The phrase “type 2 diabetes mellitus” refers to the second of the two major types of diabetes mellitus, peaking in onset between 50 and 60 years of age, characterized by gradual onset with few symptoms of metabolic disturbance (glycosuria and its consequences) and control by diet, with or without oral hypoglycemics but without exogenous insulin required. Basal insulin secretion is maintained at normal or reduced levels, but insulin release in response to a glucose load is delayed or reduced. Defective glucose receptors on the pancreatic beta cells may be involved. It is often accompanied by disease of blood vessels, particularly the large ones, leading to premature atherosclerosis with myocardial infarction or stroke syndrome.
[0083] Patients suffering from diabetes can develop chronic wounds of the skin, internal wounds from surgery, or other medical conditions that are not able to fully heal without the aid of the treatments methods described herein.
[0084] A “matrix metalloproteinase inhibitor” is a compound that inhibits one or more isoforms of an enzyme of the class of matrix metalloproteinases. Suitable and effective MMP inhibitors for the compositions and methods described herein can be collagenase inhibitors or gelatinase inhibitors. In some embodiments, the inhibitor inhibits MMP-9. In some embodiments, the inhibitor does not inhibit MMP-8. In further embodiments, the inhibitor selectively inhibits MMP-9 but not MMP-8. In various embodiments, the structure of the MMP inhibitor comprises a thiirane group, such as a methyl thiirane moiety. Examples of matrix metalloproteinase inhibitors (MMPi's) include SB-3CT (1) and substituted derivatives thereof, such as compounds 2-5.
[0000]
[0000] When substituted, the substituent on the phenoxy group can be ortho, meta, or para with respect to the oxygen linking the two phenyl groups. Specific examples can include SB-3CT, p-amino SB-3CT, p-hydroxy SB-3CT, or p-Arg SB-3CT. Thus, in some embodiments, the gelatinase inhibitor is a compound of Formula I:
[0000]
[0000] wherein R is H, OH, NH 2 , NH-amino acid, or —X—(C═O)—R′ where X is O or NH, and R′ is alkyl, aryl, alkylaryl, amino, or alkoxy, where any alkyl, aryl, or amino is optionally substituted. In one specific embodiment, the amino acid can be arginine. Additional examples of suitable MMP inhibitors include the compounds disclosed in U.S. Pat. Nos. 6,703,415 (Mobashery et al.) and 7,928,127 (Lee et al.), and PCT Publication No. WO 2011/026107 (Mobashery et al.). Additional examples of MMP inhibitors are illustrated in FIGS. 3-17 .
Pharmaceutical Formulations
[0085] The compounds recited, illustrated, described, or referenced herein can be used to prepare therapeutic pharmaceutical compositions. The compounds may be added to the compositions in the form of a salt or solvate. For example, in cases where compounds are sufficiently basic or acidic to form stable nontoxic acid or base salts, administration of the compounds as salts may be appropriate. Examples of pharmaceutically acceptable salts are organic acid addition salts formed with acids which form a physiological acceptable anion, for example, tosylate, methanesulfonate, acetate, citrate, malonate, tartrate, succinate, benzoate, ascorbate, a-ketoglutarate, and a-glycerophosphate. Suitable inorganic salts may also be formed, including hydrochloride, halide, sulfate, nitrate, bicarbonate, and carbonate salts.
[0086] Pharmaceutically acceptable salts may be obtained using standard procedures well known in the art, for example by reacting a sufficiently basic compound such as an amine with a suitable acid to provide a physiologically acceptable ionic compound. Alkali metal (for example, sodium, potassium or lithium) or alkaline earth metal (for example, calcium) salts of carboxylic acids can also be prepared by analogous methods.
[0087] The compounds of the formulas described herein can be formulated as pharmaceutical compositions and administered to a mammalian host, such as a human patient, in a variety of forms. The forms can be specifically adapted to a chosen route of administration, e.g., oral or parenteral administration, by intravenous, intramuscular, topical or subcutaneous routes.
[0088] The compounds described herein may be systemically administered in combination with a pharmaceutically acceptable vehicle, such as an inert diluent or an assimilable edible carrier. For oral administration, compounds can be enclosed in hard or soft shell gelatin capsules, compressed into tablets, or incorporated directly into the food of a patient's diet. Compounds may also be combined with one or more excipients and used in the form of ingestible tablets, buccal tablets, troches, capsules, elixirs, suspensions, syrups, wafers, and the like. Such compositions and preparations typically contain at least 0.1% of active compound. The percentage of the compositions and preparations can vary and may conveniently be from about 2% to about 60% of the weight of a given unit dosage form. The amount of active compound in such therapeutically useful compositions is such that an effective dosage level can be obtained.
[0089] The tablets, troches, pills, capsules, and the like may also contain one or more of the following: binders such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; and a lubricant such as magnesium stearate. A sweetening agent such as sucrose, fructose, lactose or aspartame; or a flavoring agent such as peppermint, oil of wintergreen, or cherry flavoring, may be added. When the unit dosage form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier, such as a vegetable oil or a polyethylene glycol. Various other materials may be present as coatings or to otherwise modify the physical form of the solid unit dosage form. For instance, tablets, pills, or capsules may be coated with gelatin, wax, shellac or sugar and the like. A syrup or elixir may contain the active compound, sucrose or fructose as a sweetening agent, methyl and propyl parabens as preservatives, a dye and flavoring such as cherry or orange flavor. Any material used in preparing any unit dosage form should be pharmaceutically acceptable and substantially non-toxic in the amounts employed. In addition, the active compound may be incorporated into sustained-release preparations and devices.
[0090] The active compound may be administered intravenously or intraperitoneally or subcutaneously by infusion or injection. Solutions of the active compound or its salts can be prepared in water, optionally mixed with a nontoxic surfactant. Dispersions can be prepared in glycerol, liquid polyethylene glycols, triacetin, or mixtures thereof, or in a pharmaceutically acceptable oil. Under ordinary conditions of storage and use, preparations may contain a preservative to prevent the growth of microorganisms.
[0091] Pharmaceutical dosage forms suitable for injection or infusion can include sterile aqueous solutions, dispersions, or sterile powders comprising the active ingredient adapted for the extemporaneous preparation of sterile injectable or infusible solutions or dispersions, optionally encapsulated in liposomes. The ultimate dosage form should be sterile, fluid and stable under the conditions of manufacture and storage. The liquid carrier or vehicle can be a solvent or liquid dispersion medium comprising, for example, water, ethanol, a polyol (for example, glycerol, propylene glycol, liquid polyethylene glycols, and the like), vegetable oils, nontoxic glyceryl esters, and suitable mixtures thereof. The proper fluidity can be maintained, for example, by the formation of liposomes, by the maintenance of the required particle size in the case of dispersions, or by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, thiomersal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars, buffers, or sodium chloride. Prolonged absorption of the injectable compositions can be brought about by agents delaying absorption, for example, aluminum monostearate and/or gelatin.
[0092] Sterile injectable solutions can be prepared by incorporating the active compound in the required amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filter sterilization. In the case of sterile powders for the preparation of sterile injectable solutions, methods of preparation can include vacuum drying and freeze drying techniques, which yield a powder of the active ingredient plus any additional desired ingredient present in the previously sterile-filtered solutions.
[0093] For topical administration, compounds may be applied in pure form, e.g., when they are liquids. However, it will generally be desirable to administer the active agent to the skin as a composition or formulation, for example, in combination with a dermatologically acceptable carrier, which may be a solid or a liquid.
[0094] Useful solid carriers include finely divided solids such as talc, clay, microcrystalline cellulose, silica, alumina, and the like. Useful liquid carriers include water, dimethyl sulfoxide (DMSO), alcohols, glycols, or water-alcohol/glycol blends, in which a compound can be dissolved or dispersed at effective levels, optionally with the aid of non-toxic surfactants. Adjuvants such as fragrances and additional antimicrobial agents can be added to optimize the properties for a given use. The resultant liquid compositions can be applied from absorbent pads, used to impregnate bandages and other dressings, or sprayed onto the affected area using a pump-type or aerosol sprayer.
[0095] Thickeners such as synthetic polymers, fatty acids, fatty acid salts and esters, fatty alcohols, modified celluloses, or modified mineral materials can also be employed with liquid carriers to form spreadable pastes, gels, ointments, soaps, and the like, for application directly to the skin of the user.
[0096] Ointments are semisolid preparations that are typically based on petrolatum or other petroleum derivatives. The specific ointment base to be used, as will be appreciated by those skilled in the art, can be one that will provide for optimum active ingredients delivery and can provide for other desired characteristics such as emolliency or the like. As with other carriers or vehicles, an ointment base should be relatively inert, stable, nonirritating and nonsensitizing. As explained in Remington: The Science and Practice of Pharmacy, 19th Ed. (Easton, Pa.: Mack Publishing Co., 1995), at pages 1399-1404, ointment bases may be grouped in four classes: oleaginous bases; emulsifiable bases; emulsion bases; and water-soluble bases. Oleaginous ointment bases include, for example, vegetable oils, fats obtained from animals, and semisolid hydrocarbons obtained from petroleum. Emulsifiable ointment bases, also known as absorbent ointment bases, contain little or no water and include, for example, hydroxystearin sulfate, anhydrous lanolin and hydrophilic petrolatum. Emulsion ointment bases are either water-in-oil (W/O) emulsions or oil-in-water (O/W) emulsions, and include, for example, cetyl alcohol, glyceryl monostearate, lanolin and stearic acid. Some water-soluble ointment bases are prepared from polyethylene glycols of varying molecular weight; again, reference may be made to Remington: The Science and Practice of Pharmacy for further information.
[0097] Examples of dermatological compositions for delivering active agents to the skin are known to the art; for example, see U.S. Pat. Nos. 4,992,478 (Geria), 4,820,508 (Wortzman), 4,608,392 (Jacquet et al.), and 4,559,157 (Smith et al.). Such dermatological compositions can be used in combinations with the compounds described herein.
[0098] Useful dosages of the compounds and compositions described herein can be determined by comparing their in vitro activity, and in vivo activity in animal models. Methods for the extrapolation of effective dosages in mice, and other animals, to humans are known to the art; for example, see U.S. Pat. No. 4,938,949 (Borch et al.). The amount of a compound, or an active salt or derivative thereof, required for use in treatment will vary not only with the particular compound or salt selected but also with the route of administration, the nature of the condition being treated, and the age and condition of the patient, and will be ultimately at the discretion of an attendant physician, practitioner, or clinician.
[0099] The compound can be conveniently administered in a unit dosage form, for example, containing 5 to 1000 m g/m 2 , conveniently 10 to 750 mg/m 2 , most conveniently, 50 to 500 mg/m 2 of active ingredient per unit dosage form. The desired dose may conveniently be presented in a single dose or as divided doses administered at appropriate intervals, for example, as two, three, four or more sub-doses per day. The sub-dose itself may be further divided, e.g., into a number of discrete loosely spaced administrations.
[0100] The ability of a compound of the invention to treat skin wounds may be determined by using assays well known to the art. For example, the design of treatment protocols, analysis of wound tissue or fluid, toxicity evaluation, data analysis, and quantification of wound characteristics are known. In addition, the ability of a compound to treat wounds in diabetic mammals may be determined using the Tests as described below.
[0101] Medical dressings suitable for use in methods for contacting a wound with the therapeutic compositions can be any material that is biologically acceptable and suitable for placing over a chronic wound. In some embodiments, the support can be a woven or non-woven fabric of synthetic or non-synthetic fibers, or any combination thereof. The dressing can also include a support, such as a polymer foam, a natural or man-made sponge, a gel or a membrane that can absorb or have disposed thereon, a therapeutic composition. One gel suitable for use as a support for the composition is sodium carboxymethylcellulose 7H 4F.
[0102] In some embodiments, the formulation can include a permeation enhancer, such as transcutol, (diethylene glycol monoethyl ether), propylene glycol, dimethylsulfoxide (DMSO), menthol, 1-dodecylazepan-2-one (Azone), 2-nonyl-1,3-dioxolane (SEPA 009), sorbitan monolaurate (Span20), or dodecyl-2-dimethylaminopropanoate (DDAIP), which can be provided at a weight/weight concentration of about 0.1% to about 10%, usually from about 2.5% to about 7.5%, often about 5%.
[0103] The following Examples are intended to illustrate the above invention and should not be construed as to narrow its scope. One skilled in the art will readily recognize that the Examples suggest many other ways in which the invention could be practiced. It should be understood that numerous variations and modifications may be made while remaining within the scope of the invention.
EXAMPLES
Example 1
Evaluation of SB-3CT in a Chronic Wound Model
[0104] Female diabetic mice (db/db mice, 9-10 weeks old, Jackson Laboratory, Bar Harbour, Me.) (n=10 per group) were prepared for aseptic surgery by clipping the hair on the dorsal thorax and scrubbing the skin with betadine followed by alcohol. Each mouse received two 6-mm skin punch biopsy lesions on the dorsal thorax, as described by Sullivan et al ( Plast. Reconstr. Surg. 2004, 113, 953-960), under isoflurane anesthesia. Each wound was covered with an occlusive dressing following biopsy. The mice recovered on a cage with clean bedding on a heating pad. Mice received buprenorphine subcutaneously (1.5-2.5 mg/kg) at the conclusion of surgery and again 3-5 hours later. Mice were administered 0.5 mL of warm sterile saline intraperitoneally at the conclusion of surgery. The mice were treated topically with SB-3CT at a dose equivalent to 0.25 mg/wound, SB-3CT at a dose equivalent to 1.25 mg/wound, or vehicle (DMSO) at 50 μL/wound daily once per day for 23 days. Wound closure was determined every day for each animal using the initial and final wound diameters, with the percentage wound closure calculated as [(initial−final)/initial]×100.
[0105] On day 12, half of the mice (n=10) were sacrificed and the wounds of each animal excised. The remaining mice continued treatment at the dosages provided above once a day until day 23, when they were sacrificed On the day of sacrifice, the wounds of each mouse were excised, and analyzed by histology, gelatin zymography and Western blot, and in situ gelatin zymography. Specifically, one wound from each sacrificed animal was analyzed by in situ gelatin zymography, and one wound from each sacrificed animal was analyzed by gelatin zymography, followed by Western blot.
[0106] Significant differences (p<0.05) between the vehicle and SB-3CT-treated mice were observed starting on day 2 ( FIG. 1 ). On day 6, wound closure was 49.6±14.0%, 50.0±7.4%, and 21.6±10.6% in mice receiving SB-3CT at 0.25 mg/wound per day, SB-3CT at 1.25 mg/wound per day, and vehicle (DMSO) at 50 μL/wound per day, respectively. At 13-14 days, the SB-3CT-treated mice achieved >90% wound closure. Mice given vehicle achieved >90% wound closure by day 23.
Example 2
Evaluation of p-Amino SB-3CT and p-Arg SB-3CT in Chronic Wound Model
[0107] Female diabetic mice (db/db mice; 9-10 weeks old, Jackson Laboratory, Bar Harbour, Me.) (n=10 per group) were prepared for aseptic surgery by clipping the hair on the dorsal thorax and scrubbing the skin with betadine followed by alcohol. Each mouse received two 6-mm skin punch biopsy lesions on the dorsal thorax, as described by Sullivan et al ( Plast. Reconstr. Surg. 2004, 113, 953-960), under isoflurane anesthesia. Each wound was covered with an occlusive dressing following biopsy. The mice recovered on a cage with clean bedding on a heating pad. Mice received buprenorphine subcutaneously (1.5-2.5 mg/kg) at the conclusion of surgery and again 3-5 hours later. Mice were administered 0.5 mL of warm sterile saline intraperitoneally at the conclusion of surgery. The mice were treated topically with p-amino SB-3CT (at a dose equivalent to 0.25 mg/wound), p-Arg (at a dose equivalent to 0.25 mg/wound) or vehicle (saline) (50 μL/wound) once per day for 6 days. Wound closure was determined every day for each animal using the initial and final wound diameters, with the percentage wound closure calculated as [(initial−final)/initial]×100.
[0108] On day 6, mice treated with p-amino SB-3CT showed 37.0±9.5% wound closure; mice treated with p-Arg showed 34.7±13.2% wound closure; and mice treated with vehicle (saline) showed 21.6±10.6% wound closure. Both experimental compounds showed efficacy in this example.
Example 3
Evaluation of p-Amino SB-3CT in Chronic Wound Model
[0109] Female diabetic mice (db/db mice) (n=10 mice per group, n=2 wounds per mouse, 9-10 weeks old, Jackson Laboratory, Bar Harbour, Me.) were prepared for aseptic surgery by clipping the hair on the dorsal thorax and scrubbing the skin with betadine followed by alcohol. Each mouse received two 6-mm skin punch biopsy lesions on the dorsal thorax, as described by Sullivan et al ( Plast. Reconstr. Surg. 2004, 113, 953-960), under isoflurane anesthesia. Each wound was covered with an occlusive dressing following biopsy. The mice recovered on a cage with clean bedding on a heating pad. Mice received buprenorphine subcutaneously (1.5-2.5 mg/kg) at the conclusion of surgery and again 3-5 hours later. Mice were administered 0.5 mL of warm sterile saline intraperitoneally at the conclusion of surgery. The mice were treated topically with p-amino SB-3CT (at a dose equivalent to 0.25 mg/wound) or vehicle (saline) at 50 μL/wound daily once per day 13 days. Wound closure was determined every day for each animal using the initial and final wound diameters, with the percentage wound closure calculated as [(initial−final)/initial]×100.
[0110] On day 7, half of the mice (n=10) were sacrificed and the wounds of each animal excised. The remaining mice continued treatment with vehicle or p-amino SB-3CT once a day until day 13, when the mice were sacrificed. On the day of sacrifice, the wounds of each mouse were excised, and analyzed by histology, gelatin zymography and Western blot, and in situ gelatin zymography. Specifically, one wound from each sacrificed animal was analyzed by in situ gelatin zymography, and one wound from each sacrificed animal was analyzed by gelatin zymography, followed by Western blot.
[0111] Significant differences in wound healing were observed between the treated and vehicle groups ( FIGS. 2(A) , 2 (B), 2 (C) and 2 (D)). FIG. 2(A) is a graph of the wound closure measurements, determined every day of the study as [(initial−final)/initial]×100. FIG. 2(B) is a photograph of a representative skin lesion of a mouse treated with p-amino SB-3CT on day 13. FIG. 2(C) is a photograph of a representative skin lesion of a mouse treated with saline on day 13. FIG. 2(D) shows four images of in situ gelatin zymography of the wound tissue of diabetic mice after treatment with p-amino SB-3CT at 0.25 mg/wound (top images) and saline (vehicle) at 50 μL/wound (bottom images) on day 13. Wound gelatinolytic activity is visualized using fluorescein isothiocyanate (FITC)-labeled substrate (right images), and 4′,6-diamidino-2-phenylindole (DAPI)-labeled substrate (left images). The wound tissue of mice treated with vehicle showed gelatinolytic activity (bottom images). The wound tissue of mice treated with p-amino SB-3CT at 0.25 mg/wound showed suppression of gelatinolytic activity (top images), as compared to the wounds of the mice treated with vehicle (bottom images). Thus, gelatinolytic activity was suppressed in the gelatinase inhibitor-treated group ( FIG. 2 (D)).
Example 4
Diabetic Wound Healing
[0112] Using a broad-spectrum MMP-tethered resin coupled with tandem mass spectrometry, the active MMPs present in wound tissues of diabetic mice can be identified. These studies confirm the importance of MMPs in wound healing in diabetic mice and open the doors to effective therapies for the management of wounds in diabetes.
[0113] Prodrugs 5 (Scheme 4-1), where the base compounds are derivatized with a lipophilic group, are amenable to formulation as a depot prodrug in ointment or oil. Topical treatment with a depot formulation that includes an MMP prodrug is one method to increase the duration of action of a drug. The ointment or oil formulation can serve as a drug reservoir at the site of the wounds. After application to a wound, a long duration of action occurs as a result of the slow release of the drug from the reservoir. The prodrugs 5 can slowly hydrolyze to the active gelatinase inhibitor 6 within the wound tissue to exert their efficacy.
[0000]
[0000] where each R and R′ group is independently H, alkyl, aryl, alkylaryl, heteroaryl, alkylheteroaryl, heterocycle, alkylheterocycle, cycloalkyl, or alkylcycloalkyl, each optionally substituted, and optionally linked to compound 5 through a tether or linking group.
[0114] The alkyl groups of Scheme 4-1 can each independently be, for example, (C 1 -C 24 )alkyl, wherein the alkyl is optionally substituted, optionally unsaturated, and optionally interrupted at carbon with one or more oxygen or nitrogen atoms, and/or one or more ester, amide, or carbamate groups.
[0115] The variable substituent on compounds 5 and 6 can be ortho, meta, or para with respect to the phenyl ether. Additional examples of suitable inhibitors include the compounds described in U.S. Pat. Nos. 6,703,415 (Mobashery et al.) and 7,928,127 (Lee et al.), and PCT Publication No. WO 2011/026107 (Mobashery et al.), each of which is incorporated herein by reference. Further examples of MMP inhibitors that can be used in therapeutic methods described herein are illustrated in FIGS. 3-17 , which can also be converted into prodrugs for use in the therapeutic methods described herein.
Example 5
Selective Inhibition of MMP-9 Accelerates Healing of Diabetic Wounds
[0116] Chronic wounds are a complication of diabetes. With the use of a novel affinity resin that binds only the active forms of matrix metalloproteinases (MMPs), MMP-8 and MMP-9 were identified in a mouse diabetic wound model. The activity of MMP-9 makes diabetic wounds refractory to healing. Pharmacological intervention with a selective MMP-9 inhibitor led to acceleration of wound healing, accompanied by re-epithelialization.
[0117] In addressing what active MMPs might play roles in disease, we have devised a resin that has been covalently tethered to a broad-spectrum MMP inhibitor ( FIG. 19 a , compound 1), based on the structure of batimastat. The resin binds only to active MMPs, to the exclusion of MMP zymogens and TIMP-inhibited MMPs. Bound active MMPs were detected and quantified by mass spectrometry with a limit of detection at the single-digit femtomole (10 −15 mole) level (Hesek et al., Chem. Biol. 13 (4), 379-386 (2006)). An excision wound-healing model was used in diabetic mice, which produces wounds that undergo re-epithelialization rather than contraction as they heal, hence it is relevant to wounds in diabetic patients.
[0118] Incubation with the resin, followed by reduction of disulfide bonds in the bound proteins, alkylation to prevent disulfide linkages from recurring, digestion with trypsin, and analysis by nano ultra performance liquid chromatography (UPLC) coupled to tandem mass spectrometry identified active MMP-8 and MMP-9, and trace amounts of active MMP-14, MMP-19, ADAMS, ADAMS, ADAM 10, and ADAM 17 in wound tissues of diabetic mice (ADAMs are zinc proteases closely related to MMPs). The tissues were also analyzed by zymography, a method of choice in the field for detection of MMPs.
[0119] Zymography showed the presence of proMMP-2, active MMP-2, and proMMP-9 ( FIG. 19 b ), whereas active MMP-9 was conspicuously not detectable by this method. A faint band of slightly lower molecular mass than the MMP-9 dimer might represent the known complex between MMP-8 and MMP-9. While MMP-2 and MMP-9 have been proposed to exist in diabetic wounds, active MMP-2 was not found in diabetic wounds with our resin. Because the resin binds only to active MMP(s), the active MMP-2 band observed by gelatin zymography ( FIG. 19 b ) was determined to be TIMP-inhibited, resulting in an inactive form of the enzyme. In contrast, active MMP-9 is not detectable by gelatin zymography ( FIG. 19 b ), however it is the major active MMP determined by the resin method ( FIG. 19 c ). Analyses here revealed the inadequacy of the widely used zymography assay for the purpose of identifying culprit MMPs in diseased tissues.
[0120] Methods for quantification of active MMP-8 and MMP-9 were developed using multiple-reaction monitoring (MRM), as described below. Data is shown in Table 5-1.
[0000]
TABLE 5-1
Peptides and internal standard selected for MRM.
Protein
Peptide Sequence
Precursor Ion
Product Ions
MMP-8
CGVPDSGDFLLTPGSPK
873.92 [M + 2H] 2+
935.36 [M + H] + ,
1074.58 [M + H] + ,
959.56 [M + H] +
MMP-9
AFAVWGEVAPLTFTR
832.94 [M + 2H] 2+
1033.57 [M + H] + ,
1090.59 [M + H] + ,
734.42 [M + H] +
555.63 [M + 3H] 3+
1090.59 [M + H] + ,
1033.57 [M + H] + ,
734.42 [M + H] +
Yeast
NVNDVIAPAFVK
643.86 [M + 2H] 2+
632.38 [M + H] + ,
enolase
844.53 [M + H] + ,
561.34 [M + H] +
[0121] It is noted that active MMP-8 and MMP-9 are present in the wounds of both wild-type and diabetic mice, except that MMP-9 is elevated at statistically significant levels only in diabetic wounds ( FIG. 19 c and Table 5-2).
[0000]
TABLE 5-2
Concentrations of active MMP-8 and MMP-9 in wound tissues.
Active MMP-8
Active MMP-9
(fmole/mg tissue)
(fmole/mg tissue)
Day
wild-type
db/db
wild-type
db/db
0
17.6 ± 0.1
19.5 ± 1.5
0
0
1
18.3 ± 0.6
18.2 ± 0.6
17.9 ± 0.3
13.4 ± 4.5
3
17.8 ± 0.1
21.6 ± 3.4
18.1 ± 0.4
25.6 ± 6.5
7
17.8 ± 0.3
25.4 ± 0.7
20.4 ± 0.7
39.4 ± 13.7
10
21.1 ± 1.8
26.1 ± 3.1
26.3 ± 6.2
29.3 ± 2.3
14
17.9 ± 0.4
20.0 ± 2.3
19.2 ± 1.8
26.9 ± 9.1
[0122] Apoptosis is essential for normal wound repair. It regulates the removal of inflammatory cells and the conversion of granulation tissue into scar tissue. However, apoptosis is increased in diabetic wounds, which is likely to be instigated by the elevated levels of active MMP-9. This deregulated apoptosis leads to delayed wound healing in diabetes. Gutiérrrez-Fernandez et al. reported that MMP-8 is involved in healing of skin wounds ( FASEB J 21 (10), 2580-2591 (2007)). Detection of active MMP-8 in the wounds of both wild-type and diabetic mice is likely a reflection of the effort by the tissue in healing.
[0123] It was determined that MMP-9 plays a detrimental effect on diabetic wound healing. The inventors have worked on a class of selective thiirane MMP inhibitors, which are distinct from the commonly used broad-spectrum hydroxamate inhibitors, of which a library of a few hundred compounds has been prepared (Lee et al., ACS Med. Chem. Lett. 3 (6), 490-495 (2012)). This inhibitor class shows selectivity in targeting MMPs because of its unique mechanism of action, which involves ring-opening of the thiirane ring and generation of a thiolate at the active site. The effect of inhibitor 2 (also known as ND-322, FIG. 20 a ) was assessed. ND-322 exhibits selectivity in inhibition toward MMP-2, MMP-9, and MMP-14, on wound healing as a function of time as percentage of the initial wound area ( FIG. 20 b ). Therefore, ND-322 inhibits selectively active MMP-9 found upregulated in diabetic wounds, while sparing MMP-8. The activity of MMP-9 is an impediment to healing of diabetic wounds and MMP-8 is necessary for wound repair, accordingly treatment with ND-322 can accelerate wound healing.
[0124] Differences in wound closure in diabetic and wild-type mice treated with vehicle were statistically significant on days 7, 10, and 14 (day 7: 35±21% vs. 65±15%, p<0.00001; day 10: 53±19% vs. 83±9%, p<0.0005; day 14: 74±12% vs. 98±1%, p<0.005). Wounds in wild-type mice were essentially healed on day 14 ( FIG. 20 c , top left), while those in diabetic mice lagged behind significantly ( FIG. 20 d , top left). Hematoxylin-eosin (H&E) staining revealed that wild-type mice showed complete re-epithelialization on day 14 ( FIG. 20 c , top right), whereas diabetic mice treated with vehicle had partial re-epithelialization ( FIG. 20 d , top right).
[0125] Topical treatment with ND-322 ( FIG. 20 a ) of wounds in wild-type mice did not accelerate healing, compared to vehicle-treatment (day 7: 62±19% vs. 65±15%, n=21; day 10: 82±11% vs. 83±9%, n=14; day 14: 96±4% vs. 98±1%, n=7; p>0.25, FIG. 20 b ). Because active MMP-9 is not up-regulated in wounds of wild-type mice, treatment with an MMP-9 inhibitor does not appear to have any beneficial effect on wound healing in wild-type animals.
[0126] In contrast, topical treatment with ND-322 of wounds in diabetic mice accelerated wound healing ( FIG. 20 b ). On days 1, 3, and 7, wound closures in ND-322-treated and vehicle-treated diabetic mice were not statistically significant (p>0.2, n=35, 28, and 21 on days 1, 3, and 7, respectively). On days 10 and 14, wound closure was significantly greater in ND-322-treated diabetic mice than in vehicle-treated diabetic mice (day 10: 70±16% vs. 53±19%, p<0.05, n=14; day 14: 92±4% vs. 74±12%, p<0.01, n=7). Remarkably, the extent of wound healing of diabetic mice treated with ND-322 on day 14 was comparable to that of wild-type mice (92±4% vs. 96±4%, p>0.14, n=7). Not only was wound healing in ND-322-treated diabetic mice more rapid, it also entailed complete re-epithelialization ( FIG. 20 d , bottom right); as is true for wild-type vehicle-treated wounds ( FIG. 20 c , top right) and wild-type ND-322-treated wounds ( FIG. 20 c , bottom right).
[0127] In-situ zymography, a technique that detects active MMPs localized in tissues and that is limited by the scarcity of substrates, showed considerable gelatinase activity in wound tissues of diabetic mice treated with vehicle ( FIG. 20 e , top left), which was significantly decreased on treatment with ND-322 ( FIG. 20 e , bottom left). Nuclei, as visualized with DAPI in vehicle-treated mice, were comparable to those in ND-322-treated animals ( FIG. 20 e , top right and bottom right).
[0128] In the present study, a novel resin was used for identification of active MMP-8 and MMP-9 in both diabetic and non-diabetic wounds, except the levels of the latter were elevated at statistically significant levels only in diabetic wounds. Identifying that MMP-9 was detrimental to healing of diabetic wounds, but that MMP-8 likely played a beneficial effect, MMP-9 was selectively inhibited by the use of ND-322. The diabetic wounds healed more rapidly in a process that involved re-epithelialization of the wounds, as is the case for the non-diabetic wounds in wild-type mice.
[0129] This example reveals the beneficial effect of selective inhibition of MMP-9 in healing of diabetic wounds, an enzyme that is upregulated. Other related examples and techniques include those described in U.S. Patent Application No. 61/522,554 filed Aug. 11, 2011. Whereas the use of the selective inhibitor ND-322 does not show any effect on non-diabetic wounds, neither detrimental nor beneficial, it is intriguing that the use of the broad-spectrum MMP inhibitor illomastat (also known as GM-6001) in non-diabetic wounds in rats, pigs, and humans exhibited significant deleterious effects, such as delayed wound closure and diminished epithelialization (Mirastschijski et al., Exp. Cell Res. 299 (2), 465-475 (2004); Agren, Arch. Dermatol. Res. 291 (11), 583-590 (1999); Agren et al., Exp. Dermatol. 10 (5), 337-348 (2001)). These findings reveal that broad inhibition of the “good” and the “bad” MMPs at once does not bode well for the healing process. Clinical management of diabetic wounds presently involves merely debridement of the wound and attempts at keeping it clean and free of infection. Disclosed herein is the first pharmacological intervention in treatment of diabetic wounds. The treatment of diabetic wounds with a selective MMP-9 inhibitor therefore provides significant new therapies for intervention of this disease.
[0130] Synthesis and Formulation of ND-322.
[0131] ND-322 was synthesized as reported previously (Gooyit et al., J. Med. Chem. 54 (19), 6676-6690 (2011)) and was dissolved in saline at a concentration of 5.0 mg/mL. The dosing solution and the vehicle (saline) were sterilized by filtration through an Acrodisc syringe filter (Pall Life Sciences, Ann Arbor, Mich., USA, 0.2 μm, 13 mm diameter, PTFE membrane).
[0132] Animals.
[0133] Female diabetic db/db mice (n=70, BKS.Cg-Dock7 m +/+Lepr db /J, 6-8 weeks old, 38-40 g body weight, Jackson Laboratory, Bar Harbor, Me., USA) and female wild-type mice (n=70, C57BL/6J, 6-8 weeks old, 18-20 g body weight, Jackson Laboratory, Bar Harbor, Me., USA) were used. All procedures were performed in accordance with the University of Notre Dame Institutional Animal Care and Use Committee. Mice were provided with Laboratory 5001 Rodent Diet (PMI, Richmond, Ind., USA) and water ad libitum. Animals were maintained in polycarbonate shoebox cages with hardwood bedding in a room under a 12:12 h light/dark cycle and at 72±2° F.
[0134] Excisional Diabetic Wound Model.
[0135] Single excisional wounds 8-mm in diameter were made with a biopsy punch (Miltex, York, Pa., USA) using aseptic technique in the shaved dorsal regions of female diabetic db/db mice and female wild-type mice under isoflurane anesthesia. The diabetic and wild-type mice were each divided into two groups (35 per group): one group was treated with 50 μL of ND-322 in saline (equivalent to 0.25 mg per wound) and the other group with 50 μL of saline (vehicle). Wounds were photographed and immediately covered with a sterile dressing (3M Tegaderm™ Transparent Dressing, Butler Schein Animal Health, Inc., Dublin, Ohio). Cellulose acetate collars were made in-house from expired films and mounted on the wild-type mice to prevent them from disturbing the wounds on their back. Topical treatment with either ND-322 or vehicle commenced one day after wounding and continued for 14 days. On days 1, 3, 7, 10, and 14, digital photographs of wounds were taken while animals were under isoflurane anesthesia. On the same days, 14 mice (n=7 treated with ND-322 and n=7 vehicle) were sacrificed for wound-tissue sampling. The wounds with minimal surrounding healthy tissue were excised and either flash-frozen in liquid nitrogen for protein expression profiling or embedded in optimal cutting temperature (OCT) compound (Tissue-Tek, Torrance, Calif., USA) followed by cryosectioning for histological assessment.
[0136] Digital images were analyzed for wound areas using the NIH ImageJ version 1.45 software. Photographs of each wound were taken using a digital camera (Olympus SP-800UZ, Center Valley, Pa., USA), which was statically mounted on a tripod at a fixed distance above the mouse wound. A ruler was included in the photographic frame to allow ImageJ calibration. The wound outline was defined from the photographic image and the ImageJ software calculated the wound area. Wound closure was expressed as the change in wound area relative to that from day 0.
[0137] Statistical Analysis.
[0138] Wound closures are expressed as mean±SD (n=35 on day 1; n=28 on day 3; n=21 on day 7; n=14 on day 10; n=7 on day 14). Wound closures and levels of MMP-8 and MMP-9 were analyzed using a paired Student t-test; p<0.05 was considered statistically significant.
[0139] Synthesis of MMP Inhibitor-Tethered Resin.
[0140] The resin ( FIG. 19 compound 1) was synthesized in our laboratories in twelve synthetic steps according to previously reported procedures (Hesek et al., J. Org. Chem. 71 (16), 5848-5854 (2006)).
[0141] Gelatin Zymography.
[0142] To assess gelatinolytic activity, aliquots of the tissue extracts, containing 0.4 mg of protein, were subjected to affinity precipitation with gelatin-agarose beads. The bound gelatinases were released from the beads in 2% SDS, and the samples were analyzed by electrophoresis in a 10% gelatin zymogram gel, as previously described (Toth and Fridman, Methods Mol. Med. 57, 163-174 (2001)).
[0143] Histological Evaluation and In-Situ Gelatin Zymography.
[0144] Fresh wound tissue was cut, embedded in OCT compound, and cryosectioned at a thickness of 12-μm in preparation for hematoxylin-eosin (H&E) staining. Morphological assessment of re-epithelialization was performed on a Nikon Eclipse 90i Fluorescent Microscope (Nikon Instruments Inc., Melville, N.Y., USA) (Tkalcevic et al., Toxicol. Pathol. 37 (2), 183-192 (2009)). In situ gelatin zymography was performed as described (Oh et al., J. Neurosci. 19 (19), 8464-8475 (1999)). Briefly, unfixed cryostat sections (12-μm-thick) of wound tissues were incubated in a reaction buffer (50 mM TBS pH 7.6) containing DQ-gelatin conjugate (Molecular Probes, Eugene, Oreg., USA) at 37° C. for 6 h. After fixation in 4% paraformaldehyde in PBS, cells were counterstained with DAPI (Molecular Probes, Eugene, Oreg., USA) and the images were visualized by fluorescence microscopy.
[0145] MMP-Expression Profiling.
[0146] Wound tissues (10 mg) were weighed and homogenized in 100 μL of cold lysis buffer (25 mM Tris-HCl pH 7.5, 100 mM NaCl, lie; Nonidet P-40 and protease inhibitors, with the exception of metalloproteinase inhibitors). The tissue extracts were diluted with CB buffer and were analyzed for protein concentration by the BCA protein assay. To the tissue extracts, 100 μL of inhibitor-tethered resin 1 ( FIG. 19 a ) was mixed at 4° C. for 18 hours. After centrifugation (15000 g, 1 min), the supernatant was removed, the resin beads were thoroughly washed with CB buffer and water, and the resin bound proteins were subjected to trypsin-digest.
[0147] The procedure for on-resin reduction, alkylation, and tryptic digestion was adapted from the Pierce In - Solution Tryptic Digestion Kit (Thermo Scientific, Rockford, Ill., USA). Briefly, proteins bound to the resin were treated with 100 mM dithiothreitol in HPLC grade water. To the sample tube containing the resin-bound proteins was added a volume of the dithiothreitol solution sufficient to cover completely the resin. The tube was incubated at 65° C. for 20 min, then allowed to cool to room temperature. Samples were then alkylated by adding 3 μL of 100 mM iodoacetamide in HPLC-grade water to the cooled tubes, followed by incubation in the dark at room temperature for 20 min. Samples were then enzymatically digested overnight at 37° C. with trypsin (2 μL of 0.1 μg/μL in 50 mM ammonium bicarbonate). Following trypsin digestion, samples were desalted using Millipore ZipTip® C18 (EMD Millipore Corp., Billerica. MA), as described in the User Guide for Reversed-Phase ZipTip Pipette Tips for Sample Preparation. Briefly, each ZipTip® was wetted with HPLC-grade acetonitrile, equilibrated with 0.1% trifluoroacetic acid (TFA) in HPLC-grade water, loaded with 4 μL of digested sample, washed with 0.1% TFA in water, and eluted with 0.1% TFA in 50:50 (v:v) acetonitrile:water. This procedure was repeated until ˜20 μL of the eluted solution had been collected in an autosampler vial.
[0148] A 2-μL aliquot of the ZipTip® cleaned peptide mixtures were then analyzed on a reversed phase Waters nanoACQUITY column (1.7 μm, BEH130 C18, 100 μm i.d.×100 μm, Waters Corp., Milford, Mass.) coupled to a Thermo-Finnegan LTQ Velos Orbitrap tandem mass spectrometer (Thermo Fisher Scientific, Waltham, Mass., USA). Samples were eluted at a flow of 1.2 μL/min with the following gradient program: t=0-5 min 99% A/1% B, t=5.1 min 85% A/15% B, t=50 min 40% A/60% B, t=55 min 15% A/85% B, t=55.1-65 min 99% A/1% B where A=97% water/3% acetonitrile with 0.1% formic acid and B=0.1% formic acid in acetonitrile. Peptides were ionized via a nanoelectrospray ionization source, and their mass spectra and collisionally induced dissociation fragmentation mass spectra were recorded using a linear ion trap mass analyzer (LTQ Velos). High resolution (60,000 resolving power), accurate mass spectra were recorded between m/z 395-2,000 in ˜1.2 sec on the orbitrap mass analyzer. While the next high-resolution mass spectrum was being acquired on the orbitrap, the LTQ Velos linear ion trap independently recorded CID fragmentation mass spectra of the 8 most abundant ions present in the previous orbitrap mass spectrum. During the course of a 60-min nanoUPLC/MS/MS run, this approach typically generated ˜3,000 high-resolution mass spectra and between 12,000-15,000 CID MS/MS spectra.
[0149] Thermo-Finnegan Proteome Discoverer 2.0 software (Thermo Fisher Scientific, Waltham, Mass., USA) was used to interface with the Mascot (Matrix Science, Boston, Mass., USA) protein database search engine. MS/MS spectral information was used by Mascot to search the SwissProt Protein database, and a decoy search was employed to establish a false discovery rate. Standard solutions of MMPs that had been digested and analyzed using the approach described herein then served as references by which all results from the tissue-derived samples would be directly compared.
[0150] Quantification of MMPs/ADAMs in Wound Tissues.
[0151] The ZipTip® samples were concentrated to dryness on a miVac concentrator (Genevac Ltd., Suffolk, UK) and the residue was resuspended in 12 μL of water containing 1% formic acid and internal standard (yeast enolase at a final concentration of 150 fmole/mg tissue) was added. A 2-1 μL aliquot of the sample was injected directly onto a nanoACQUITY UPLC C18 column (1.8 μm, 100 μm i.d.×100 mm, Waters Corp., Milford, Mass.). The mobile phase consisted of 12-min elution at 600 mL/min with 2% acetonitrile/0.1% formic acid/water, followed by a 60-min linear gradient to 35% acetonitrile/0.1% formic acid/water. Samples were analyzed on a ABSciex QTrap 5500 mass spectrometer (ABSciex, Framingham, Mass., USA) running in ion trap IDA mode coupled to a two-dimensional Eksignet Ultra NanoUPLC system, consisting of a nanoLC ultra 2D pump and a nanoLC AS-2 autosampler (Eksignet, Dublin, Calif., USA).
[0152] The mass spectrometer was operated in the positive electrospray ionization (ESI) mode. The following conditions were used: curtain gas: curtain gas 20 psi, ion spray voltage 2350 V, ion source gas 1 10 psi, declustering potential 100V, entrance potential 10V, collision cell exit potential 40V. Acquisition parameters were as described previously (Llarrull et al, J. Biol. Chem. 286, 38148-58 (2011)). MRM transitions were determined through the use of empirical MS/MS data obtained from the bottom-up proteomics analysis and through the use of in silico prediction, as described previously (Llarrull et al, J Biol Chem 286, 38148-58 (2011)). MMP-8 and MMP-9 were quantified using three product-ion transitions per peptide, with one as the ‘quantifier’ and two as the ‘qualifier’ transitions (Table 5-1). The quantifier MMP-8 specific tryptic peptide [CAm]CGVPDSGDFLLTPGSPK was observed and quantified for the transition m/z 873.92 (M+2H) 2+ →product ion m/z 935.36 (M+H) + corresponding to the b10 ion. The MMP-9 specific tryptic peptide AFAVWGEVAPLTFTR observed at m/z 832.94 (M+2H) 2+ →product ion m/z 1033.57 (M+H) + (y9) was used. Quantification of MMP-8 and MMP-9 was relative to the yeast enolase (internal standard) peptide NVNDVIAPAFVK at m/z 643.86 (M+2H) 2+ →product ion m/z 632.38 (M+H) + (y6). Standard calibration curves of MMP-8 and MMP-9 were prepared in control mouse skin tissue at concentrations of 0.6, 6.0, 15, 30, 60, 150, 300, and 600 fmole/mg tissue. Concentrations in unknown samples were determined using peak area ratios relative to the internal standard and regression parameters calculated from the calibration curve standards. Levels of MMP-8 and MMP-9 are expressed as mean±SD (n=3) and analyzed for statistical significance with a Student t-test; p<0.05 was considered statistically significant.
Example 6
Pharmaceutical Dosage Forms
[0153] The following formulations illustrate representative pharmaceutical dosage forms that can be used for the therapeutic or prophylactic administration of a compound described herein, a compound specifically disclosed herein, a composition thereof (e.g., one containing an MMP inhibitor), or a pharmaceutically acceptable salt or solvate thereof (hereinafter referred to as ‘Compound X’):
[0000]
(i) Tablet 1
mg/tablet
‘Compound X’
100.0
Lactose
77.5
Povidone
15.0
Croscarmellose sodium
12.0
Microcrystalline cellulose
92.5
Magnesium stearate
3.0
300.0
[0000]
(ii) Tablet 2
mg/tablet
‘Compound X’
20.0
Microcrystalline cellulose
410.0
Starch
50.0
Sodium starch glycolate
15.0
Magnesium stearate
5.0
500.0
[0000]
(iii) Capsule
mg/capsule
‘Compound X’
10.0
Colloidal silicon dioxide
1.5
Lactose
465.5
Pregelatinized starch
120.0
Magnesium stearate
3.0
600.0
[0000]
(iv) Injection 1 (1 mg/mL)
mg/mL
‘Compound X’ (free acid form)
1.0
Dibasic sodium phosphate
12.0
Monobasic sodium phosphate
0.7
Sodium chloride
4.5
1.0N Sodium hydroxide solution
q.s.
(pH adjustment to 7.0-7.5)
Water for injection
q.s. ad 1 mL
[0000]
(v) Injection 2 (10 mg/mL)
mg/mL
‘Compound X’ (free acid form)
10.0
Monobasic sodium phosphate
0.3
Dibasic sodium phosphate
1.1
Polyethylene glycol 400
200.0
0.1N Sodium hydroxide solution
q.s.
(pH adjustment to 7.0-7.5)
Water for injection
q.s. ad 1 mL
[0000]
(vi) Aerosol
mg/can
‘Compound X’
20
Oleic acid
10
Trichloromonofluoromethane
5,000
Dichlorodifluoromethane
10,000
Dichlorotetrafluoroethane
5,000
[0000]
(vii) Topical Gel 1
wt. %
‘Compound X’
5%
Carbomer 934
1.25%
Triethanolamine
q.s.
(pH adjustment to 5-7)
Methyl paraben
0.2%
Purified water
q.s. to 100 g
[0000]
(viii) Topical Gel 2
wt. %
‘Compound X’
5%
Methylcellulose
2%
Methyl paraben
0.2%
Propyl paraben
0.02%
Purified water
q.s. to 100 g
[0000]
(ix) Topical Ointment
wt. %
‘Compound X’
5%
Propylene glycol
1%
Anhydrous ointment base
40%
Polysorbate 80
2%
Methyl paraben
0.2%
Purified water
q.s. to 100 g
[0000]
(x) Topical Cream 1
wt. %
‘Compound X’
5%
White bees wax
10%
Liquid paraffin
30%
Benzyl alcohol
5%
Purified water
q.s. to 100 g
[0000]
(xi) Topical Cream 2
wt. %
‘Compound X’
5%
Stearic acid
10%
Glyceryl monostearate
3%
Polyoxyethylene stearyl ether
3%
Sorbitol
5%
Isopropyl palmitate
2%
Methyl Paraban
0.2%
Purified water
q.s. to 100 g
[0154] These formulations may be prepared by conventional procedures well known in the pharmaceutical art. It will be appreciated that the above pharmaceutical compositions may be varied according to well-known pharmaceutical techniques to accommodate differing amounts and types of active ingredient ‘Compound X’. Aerosol formulation (vi) may be used in conjunction with a standard, metered dose aerosol dispenser. Additionally, the specific ingredients and proportions are for illustrative purposes. Ingredients may be exchanged for suitable equivalents and proportions may be varied, according to the desired properties of the dosage form of interest.
[0155] While specific embodiments have been described above with reference to the disclosed embodiments and examples, such embodiments are only illustrative and do not limit the scope of the invention. Changes and modifications can be made in accordance with ordinary skill in the art without departing from the invention in its broader aspects as defined in the following claims.
[0156] All publications, patents, and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.
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The invention provides a method of accelerating the healing process of a skin or subdermal wound. The method can include administering to a mammal afflicted with a skin or subdermal wound an effective amount of a gelatinase inhibitor, or a pharmaceutically acceptable salt thereof, wherein the gelatinase inhibitor is effective to accelerate the healing process of the skin wound. The method is particularly effective when the mammal is suffering from diabetes. The gelatinase inhibitor can be topically administered, for example, in the form of a cream, gel, lotion, ointment, salve, or solution.
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